Clamping cage for an edge connector

Abstract

A connector module for connecting the bare end of an insulated electrical conductor with an electrical device, including a hollow generally-rectangular terminal cage body formed from a bent conductive first metal sheet to form at least one vertical generally rectangular side wall and a pair of end walls, one of the cage walls having a horizontal lower surface defining a first cage sealing surface, and a vertical interior wall surface defining a second cage sealing surface; a horizontal bus bar formed from a conductive second metal sheet and having a relatively broad horizontal top surface defining a horizontal first bus bar sealing surface, and a relatively narrow side surface defining a vertical second bus bar sealing surface; and a securing seam for securing one of the bus bar first and second sealing surfaces with the corresponding one of the cage first and second sealing surfaces.

Claims

1. A connector module for connecting a bare end of an insulated electrical conductor with an electrical device, comprising: (a) a hollow generally-rectangular terminal cage body formed from a bent conductive first metal sheet, said cage body having a longitudinal conductor entry axis and including: (1) at least one vertical generally rectangular side wall; and (2) a pair of parallel spaced generally-rectangular longitudinally-extending end walls connected with said side wall, one of said cage walls having: (a) a horizontal lower surface defining a bottom surface of said cage body; (b) a vertical interior wall surface; and (b) a horizontal bus bar formed from a conductive second metal sheet having a rectangular cross section, including: (1) a relatively broad horizontal top surface defining a horizontal bus bar surface, and (2) a relatively narrow side surface, said bus bar being connected with said terminal cage body by securing said horizontal bus bar surface with said cage body bottom surface.

2. A connector module as defined in claim 1, wherein said cage end walls are orthogonally arranged relative to said cage side wall.

3. A connector module as defined in claim 2, wherein said cage body includes four walls and has a generally square transverse cross-sectional configuration.

4. A connector module as defined in claim 2, wherein said cage body includes three walls and has a generally U-shaped transverse cross-sectional configuration.

5. A connector module as defined in claim 1, wherein said bus bar is connected with said terminal cage body by a linear welded seam.

6. A connector module as defined in claim 1, wherein said conductor entry axis is vertical.

7. A connector module as defined in claim 6, wherein said at least one side wall of said cage body includes a downwardly extending tongue portion having a horizontal bottom edge defining said cage body bottom surface.

8. A connector module as defined in claim 1, wherein said conductor entry axis is horizontal.

9. A connector module for connecting a bare end of an insulated electrical conductor with an electrical device, comprising: (a) a hollow generally-rectangular terminal cage body formed from a bent conductive metal sheet, including: (1) at least one vertical relatively-wide generally rectangular side wall; and (2) a pair of parallel spaced vertical relatively-narrow generally-rectangular end walls orthogonally connected with said side wall, said side wall having a horizontal lower edge, and a coplanar tongue portion extending downwardly from said side wall lower edge, said tongue portion having: (a) a horizontal tongue portion lower edge defining a horizontal first cage surface; and (b) a vertical interior wall surface defining a vertical second cage surface; and (b) a horizontal bus bar formed from a conductive metal sheet and having a rectangular cross section including: (1) a relatively broad horizontal top surface defining a first bus bar surface, and (2) a relatively narrow vertical side surface defining a second bus bar surface, said bus bar being connected with said terminal edge body by securing one of said first and second bus bar surfaces with the corresponding one of said first and second cage surfaces.

10. A connector module as defined in claim 9, and further comprising: (d) a resilient generally inverted V-shaped spring contact mounted between said cage end walls, said spring contact having a stationary first leg adapted to react with an inner surface of a first cage end wall, and a second leg biased away from said first leg to displace the conductor bare end toward electrical engagement with an inner surface of the other can end wall.

11. A connector module as defined in claim 10, and further comprising a spring release member operable to displace said second spring leg toward said first spring leg, thereby to permit insertion and removal of the conductor relative to said cage body.

12. A connector module as defined in claim 10, and further comprising: (e) a housing formed of insulating material and containing: (1) a chamber in which said cage body is mounted; and (2) an inlet opening for introducing the conductor bare end into said housing chamber.

13. A connector module as defined in claim 10, wherein a plurality of said modules are secured in spaced relation on said bus bar.

14. A connector module as defined in claim 13, wherein the spacing distance between some of said modules is less than the width of one of said cage body end walls.

15. The method for forming a connector module, comprising the steps of: (a) bending a first conductive metal sheet to define a cage body having a longitudinal entry axis and including: (1) at least one vertical generally rectangular side wall; and (2) a pair of parallel spaced generally-rectangular longitudinally-extending end walls connected with said side wall, one of said cage walls having: (a) a horizontal lower surface defining a horizontal first cage surface at a bottom of said cage body; and (b) a vertical interior wall surface defining a vertical second cage surface; (b) forming a horizontal bus bar from a second conductive metal sheet having a rectangular cross section, including: (1) a relatively broad horizontal top surface defining a horizontal first bus bar surface, and (2) a relatively narrow side surface defining a vertical second bus bar surface; and (c) connecting said bus bar with said cage body by securing one of said bus bar first and second surfaces with the corresponding one of said cage first and second surfaces, respectively.

16. The method for forming a connector module as defined in claim 15, and further comprising the step of: (d) mounting a resilient generally inverted V-shaped spring contact between said cage end walls, said spring contact having a stationary first leg adapted to react with an inner surface of a first end wall, and a second leg biased away from said first leg to displace the conductor bare end toward electrical engagement with an inner surface of the other cage end wall.

17. The method for forming a connector module as defined in claim 16, and further comprising the step of: (e) mounting the cage body in a chamber contained in a housing formed of insulating material.

18. The method for forming a connector module as defined in claim 15, wherein said connecting step comprises welding one of said bus bar first and second surfaces with the corresponding one of said cage first and second surfaces, respectively, along a linear seam.

19. A connector module for connecting a bare end of an insulated electrical conductor with an electrical device, comprising: (a) a hollow generally-rectangular terminal cage body formed from a bent conductive first metal sheet, said cage body having a longitudinal conductor entry axis and including: (1) at least one vertical generally rectangular side wall; and (2) a pair of parallel spaced generally-rectangular longitudinally-extending end walls connected with said side wall, one of said cage walls having: (a) a horizontal lower surface defining a bottom surface of said cage body; (b) a vertical interior wall surface defining a vertical cage surface; and (b) a horizontal bus bar formed from a conductive second metal sheet having a rectangular cross section, including: (1) a relatively broad horizontal top surface, and (2) a relatively narrow side surface defining a vertical bus bar surface, said bus bar being connected with said terminal cage body by securing said vertical bus bar surface with said vertical cage surface.

20. A connector module as defined in claim 19, wherein said cage end walls are orthogonally arranged relative to said cage side wall.

21. A connector module as defined in claim 20, wherein said cage body includes four walls and has a generally square transverse cross-sectional configuration.

22. A connector module as defined in claim 20, wherein said cage body includes three walls and has a generally U-shaped transverse cross-sectional configuration.

23. A connector module as defined in claim 19, wherein said bus bar is connected with said terminal cage body by a linear welded seam.

24. A connector module as defined in claim 19, wherein said conductor entry axis is vertical.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other objects and advantages of the invention will become apparent from a study of the following specification, when viewed in the light of the accompanying drawing, in which:

(2) FIG. 1a is an explodeed perspective view of a plug in terminal block including a first connector module embodiment, and FIG. 1b is a perspective view of a second connector module embodiment;

(3) FIGS. 1c and 1d are perspective views of the conductive sheets from which the bus bar and the cage body are formed, respectively;

(4) FIG. 1e is an end view of a cage body formed by bending the sheet of FIG. 1d;

(5) FIGS. 1f and 1g are cross sectional views of three-sided and four-sided embodiments of the invention, respectively;

(6) FIGS. 2 and 3 are side views of embodiments of the invention wherein the conductor entry directions are vertical and horizontal, respectively, relative to a horizontally arranged bus bar;

(7) FIGS. 4a-4d are perspective views illustrating embodiments having a plurality of connector modules mounted on a common bus bar;

(8) FIG. 5a is a perspective view illustrating the connector module arrangement of FIG. 4b mounted in a terminal block housing; and

(9) FIG. 5b is a perspective view of the connector module arrangement of FIG. 4c mounted in a terminal block housing.

DETAILED DESCRIPTION OF THE INVENTION

(10) Referring first to FIGS. 1a and 1b, a terminal block connector 10 includes a housing 12 formed of electrically insulating material, which housing contains a chamber 13 in which is mounted a connector module 1, and a first conductor inlet opening 11 for introducing the bare end 81 of an insulated conductor into the chamber along a longitudinal entry axis 80. As best shown in FIG. 1b, the connector module 1 includes a cage body 2 that is formed by bending a planar sheet 200 (FIG. 1d) of conductive metal, thereby to define at least one side wall 221, and a pair of orthogonally arranged end walls 222, 223. One end of a horizontal bus bar 3 is introduced into housing chamber 13 via a second inlet opening 11a. As shown in FIG. 1c, the bus bar 3 is formed from a conductive metal strip 300 having a rectangular cross section to define a pair of relatively wide horizontal top and bottom wall surfaces 320, and a pair of relatively narrow vertical side wall surfaces 310.

(11) Also mounted in the chamber 13 on a fixed support pin 14 is an inverted V-shaped spring 4 having a first leg 42 in engagement with one end wall 223 of the cage body 2 of the connector module 1, and a second leg 41 biased toward the other end wall 222 of the cage body. A manually operable release member 5 is vertically slideably mounted in the housing 12 for displacing the spring leg 41 toward the spring leg 42, thereby to permit insertion and removal of the conductor bare end into the chamber 13. Consequently, when the release member 5 is in the released condition of FIG. 1b, the spring leg 41 biases the conductor bare end 81 toward electrical engagement with the end wall 222 of cage body 2.

(12) As will be explained in greater detail below, in the embodiment of FIGS. 1b and 1e, the bus bar 3 vertical side wall 310 (FIG. 1c) is permanently welded to the inside vertical surface of the cage tongue portion 27 that extends downwardly from the lower edge 281 (FIGS. 1b and 1d) from the cage side wall 221. The cage tongue portion 27 terminates at its lower end in a horizontal lower edge 21. The bus bar is welded to the tongue portion flush with this lower horizontal edge 21 so that a spacing distance A (FIG. 1e) is provided between the upper surface 320 of the bus bar and the lower edges 281 of the end walls.

(13) The terminal cage body 2 and the bus bar 3 are produced independently of one another and are then fastened permanently to one another. The terminal cage body extends in a longitudinal direction 60 which is here opposite the conductor entry direction 80. The bus bar 3 in this embodiment is arranged on the terminal cage body 2 in such a way that it extends transversely to the conductor entry direction 80.

(14) For pivoting the first spring arm 41 in the pivoting direction 141 (FIG. 1a), the pressure member 5 can be actuated manually, in particular with a tool such as the tip of a screwdriver (not shown). Here, the first spring arm 41 is actuated by actuating the pressure piece 5 in a conductor entry direction 80 so that a clamping site (not shown), which is arranged in the interior space 24 of the terminal cage 2, opens. In this state, an electrical conductor 8 can be introduced into the clamping site. By releasing the pressure piece 5, the first spring arm 41 is pivoted back due to the restoring force of the spring 4 against the pivoting direction 141, and the electrical conductor 8 introduced into the clamping site is clamped between the spring 4 and the terminal cage 2. Therefore, the terminal cage body 2 is provided here for providing the clamping site.

(15) The insulated electrical conductor 8 is represented diagrammatically in FIG. 1a. It has a bare conductor end 81 by means of which it can be introduced into the clamping site. In FIG. 1b, the spring 4 and the pressure piece 5 are arranged in the position relative to the connection module 1 in which they are arranged in the connector terminal block 10.

(16) FIG. 1c shows the flat strip 300 from which the bus bar 3 is produced. The flat strip 300 extends in an unrolling direction 330, wherein the narrow vertical sides 310 extend transversely to and along the unrolling direction 330. The flat strip 300 has a constant thickness D3 which corresponds to the height H3 of the narrow sides 310.

(17) In order to produce a bus bar 3 for the connection module 1 of FIG. 1b from this flat strip 300, the flat strip 300 is merely cut to length. Therefore, the bus bar 3 is preferably produced as a punched part. Therefore, the narrow sides 310 of the flat strip 300 are the narrow sides 31 of the bus bar 3. Moreover, the broad sides 320 of the flat strip 300 are also the broad sides 32 of the bus bar 3.

(18) Similarly, the terminal cage 2 is produced from a flat strip 200 unrolled in the unrolling direction 230. Here, the shape of the broad sides 220 is adapted, for example, by punching or sawing. Subsequently, the flat strip 200 is folded to form the terminal cage body 2. Therefore, the terminal cage body 2 is produced as a punched and folded part. The narrow sides 210 of the flat strip 200 which has been adapted and folded in this way are the narrow sides 210 of the terminal cage 2. They have a height H2 which corresponds to the thickness D2 of the flat strip 200. FIG. 1d shows the unrolled view of the terminal cage body 2.

(19) The terminal cage body 2 of FIGS. 1b and 1e is designed so that it has a square cross section. Therefore, it has either four walls 221, 221a, 222, 223 (FIG. 1g), or three walls 221, 222, 223 (FIG. 1f). The walls 221-223 are arranged at an approximately right angle relative to one another. They in each case have an extension component 602 in the longitudinal direction 60 as well as an extension component 601 transversely to the longitudinal direction 60 of the terminal cage 2. Here as well, the longitudinal direction 60 extends opposite the conductor entry direction 80. The walls 221-223 are therefore provided parallel to the conductor entry direction 80.

(20) In order to be able to produce the smallest possible direct plug-in terminal 10 with the connection module 1, the terminal cage 2 has two walls 222, 223 facing one another which have a width B.sub.W, which here corresponds to a width B.sub.S of the bus bar 3 plus the height H2 of the narrow sides 21 of the terminal cage 2. The end walls 222, 223 facing one another are also referred to as narrow walls.

(21) The spring 4 is supported on a first of the two narrow walls 223. The clamping site is arranged between the spring 4 and a second of the two narrow walls 222.

(22) The narrow walls 222, 223 are connected to one another by a connecting wall 221. The connecting wall 221 has a larger width B.sub.V, as determined by the spring and a clamping angle 41 of the spring 4, than the narrow walls 222, 223.

(23) Here, a first wall 221 of the terminal cage body 2 is extended relative to its other walls 222, 223, so that this wall 221 has an extension 27 designed as a rectangular tongue. The terms extension 27 and tongue are used synonymously below. The tongue 27 therefore extends over a lower edge 281 of the terminal cage 2, viewed in the conductor entry direction 80.

(24) In the represented embodiment example of FIGS. 1b and 1e, the bus bar 3 is fastened on the extension 27 on the terminal cage 2. In particular, it is fastened with one of its narrow sides 31 on the extension 27 on the terminal cage 2. Here, it is provided flush with an edge 271 of the extension 27. As a result, it is at a distance from the lower edge 281. The distance A is represented in FIG. 1e.

(25) The fastening occurs preferably in a firmly bonded manner, preferably by welding. As a result, a connection seam 7, along which the bus bar 3 is arranged on the terminal cage body 2, has a linear design. By laser welding or resistance welding, a very precise and accurate production of the connection seam 7 is possible.

(26) FIGS. 2 and 3 show two additional embodiments of connector modules 1 according to the invention. In both embodiments, in contrast to the embodiment of FIGS. 1b and 1e, the bus bar 3 is arranged on a narrow side 21 of the terminal cage body 2.

(27) Here, the bus bar 3 of FIG. 2 extends transversely to the longitudinal direction 60 of the terminal cage body 2, that is to say parallel to the end faces 25, 26 of the terminal cage 2, and, in FIG. 3, in the longitudinal direction 60, that is to say transversely to the end faces 25, 26 of the terminal cage body 2. As a result, the terminal cage 2 of FIG. 2 is accessible from outside from one of the end faces 25, and the terminal cage body 2 of FIG. 3 is accessible from both end faces 25, 26.

(28) In both embodiments, the first side wall 221 is extended. In the embodiment of FIG. 2, the first side wall 221 is extended so that, when viewed in the conductor entry direction 80, it projects relative to a lower edge 281 of a wall 222, 223 of the terminal cage 2. The bus bar 3 is here provided flush with an edge 271 of the extension 27. Therefore, it is separated in this embodiment from the lower edge 281 by the distance A.

(29) On the other hand, in the embodiment of FIG. 3, the first wall 221 is extended so that, viewed in the conductor entry direction 80, it projects over a side edge 282 of the terminal cage 2. Therefore, in this embodiment, the bus bar 3 is at a distance A from the side edge 282.

(30) The connection modules 1 produced in this manner have the advantage, compared to the connection modules known to date (not shown), that, in their production, a considerable material savings of approximately 15%-25% is possible.

(31) FIGS. 4a to 4d show, in each case, a series connection device 100 with at least two such connection modules 1 each without a housing 12. The connection modules 1 in each case have a common bus bar 3 as well as at least two or more terminal cage bodies 2. In the embodiments of FIGS. 4a-4c, the terminal cage body 2 is welded in each case on the narrow side 31 of the bus bar 3. In the embodiment of FIG. 4d, on the other hand, it is welded with its narrow side 21 on the bus bar 3. In both cases, the terminal cage 2 is connected at its tongue 27 to the bus bar 3.

(32) In the embodiment of FIG. 4a, two connection modules 1 are provided. The terminal cage bodies 2 of the two connection modules 1 are arranged on the common bus bar 3. Between the terminal cages 2, the bus bar 3 has a bend 32, so that the conductor entry directions 80 of an electrical conductor into the terminal cages 2 are arranged with respect to one another at an angle (not marked) determined by the bend 32.

(33) Moreover, the two terminal cages 2 here are in a mirror symmetrical arrangement with respect to an axis of symmetry 9. As a result, they are oriented opposite one another. Their conductor entry openings 11 are arranged, therefore, on the side facing away from their adjacent terminal cage 2.

(34) In the series connection device 100 of FIG. 4b, in each case two connection modules 1 oriented in the same direction are arranged grouped with respect to one another at the smallest possible distance apart A1. The series connection device 100 has two such groups of connection modules 1, wherein the connection modules 1 of the two groups are in a mirror symmetrical arrangement with respect to the axis of symmetry 9. The terminal cages 2 of the two groups are, therefore, oriented opposite one another.

(35) In comparison to a single-part production of a series connection device (not shown), in which a distance between two adjacent connection modules (not shown) is determined by a width of the adjacent terminal cages (not shown), in particular of their narrow walls, the series connection arrangement 100 according to the invention allows a very tight placement of the terminal cages 2 on the bus bar 3, because the production of the bus bar 3 and the production of the terminal cages 2 occur independently of one another. The distance A1 between adjacent 2 terminal cages can therefore be selected to be very small. It can be selected to be smaller than the sum of the widths B of the narrow walls 223, 222 of the adjacent terminal cages 2.

(36) In the series connection device 100 of FIG. 4c, four connection modules 1 oriented in the same direction are arranged grouped with respect to one another at the smallest possible distance apart A1. The distance A1 is smaller than the sum of the widths B of the narrow walls 2222, 223 of the adjacent terminal cages 2. In addition, the series connection device 100 has a connection module 1 oriented in the opposite direction, which is farther apart from the four grouped connection modules 1.

(37) The series connection device 100 of FIG. 4d has two connection modules 1 in a mirror symmetrical arrangement with respect to the axis of symmetry 9, which are arranged a large distance apart from one another.

(38) FIG. 5a shows the series connection device 100 of FIG. 4c, and in FIG. 5b, the series connection devices 100 of FIG. 4b, each with housing 12. Both series connection devices 100 have snap-in mounting feet 101, by means of which they can be arranged on a hat-shaped mounting rail (not shown), as is known in the art. As a result, several such series connection devices 100 can be arranged in a row next to one another on the same mounting rail.

(39) While in accordance with the provisions of the Patent Statutes the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that changes may be made without deviating from the invention described above.