Connector for insulated conductors

Claim 2

An electrical connection of conductors having insulation thereon comprising: a. a generally channel-shaped metal member having a web and opposed spaced apart walls extending therefrom; b. rows of conductor engaging protuberances on said spaced walls with said rows arranged transversely thereof; c. conductors having insulation thereon with portions positioned between said walls; d. said rows of protuberances each having a plurality of said protuberances with a spacing between adjacent protuberances receiving said conductor therebetween with the adjacent edges of the protuberances being spaced less than the width of said conductor and engaging same; e. an imperforate cover sheet of electrical non-conductive material on outer surfaces of said web and walls in covering relation thereto; and f. said conductors being clamped between the walls of said channel-shaped member and said protuberance edge penetrating into the insulation of said conductors therebetween and said protuberances curving away from an adjacent end of the channelshaped member to hold said conductor and make electrical contact therewith.

Claim 3

An electrical connection as set forth in claim 1 wherein the rows of protuberances in one wall are offset from the rows in the other wall with a row of protuberances in one wall being substantially between adjacent rows of protuberances in the other wall.

Claim 4

An electrical connection as set forth in claim 2 wherein: a. the rows of protuberances are in pairs struck inwardly from the spaced walls; and b. said protuberances of each pair of rows being inclined toward the opposed wall and away from the adjacent end of the channel-shaped member.

Claim 5

An electrical connection as set forth in claim 3 wherein: a. each opposed wall of the channel-shaped member has a plurality of rows of protuberances with protuberances of rows in one end portion inclined toward the protuberances of rowS in the other end portion; and b. each row having a plurality of protuberances and a plurality of spaces therebetween receiving at least two of said conductors extending from an adjacent end of the connector with each of said conductors being engaged by edges of two adjacent protuberances in the respective rows.

Claim 6

An electrical connection as set forth in claim 4 wherein the channel-shaped member having the web connecting the walls at one side crushed to crimp the channel-shaped member to hold the protuberances in conductor engaging position.

Claim 7

An electrical connection as set forth in claim 1 and including: a. said rows of protuberances being formed in said metal member with openings between certain adjacent rows; b. said imperforate cover sheet having an entrance opening therethrough communicating with the area having the conductor therein through an opening between rows of protuberances in the metal member; and c. a setable semi-solid filler inserted through said entrance opening and surrounding all electrical connections between said metal member and the electrical conductors to encapsulate same.

Claim 8

An electrical connection as set forth in claim 1 wherein said web has a line of weakness extending longitudinal thereof and crushing of the channel-shaped member along said line of weakness bends the web on said line and the wall portions adjacent said line are in substantially face-to-face contact.

Claim 9

An electrical connection as set forth in claim 7 wherein the line of weakness is a plurality of longitudinally aligned slots extending through the metal member.

Claim 10

An electrical connection as set forth in claim 7 wherein: a. said channel-shaped metal member has side and end edges with said side edges defining a side opening at the other side of the web of said member; and b. said imperforate cover sheet has marginal portions extending outwardly beyond the end and side edges of said metal member and forming an overhanging insulating protector from circuit interferring contact of said metal member and conductors with foreign objects.

Claim 11

An electrical connection as set forth in claim 9 wherein: a. said spaced apart walls having portions adjacent said side edges being bent one toward the other whereby the marginal portions extending beyond said side edges are engaged and close and form an insulating closure for said side opening.

Claim 12

An electrical connector as set forth in claim 10 and including: a. a filling of setable material in the metal member encapsulating the areas of electrical engagement and protecting same against moisture and air, said setable material being introduced after completion of the connection of the connector metal member with the conductors.

Claim 13

An electrical connection as set forth in claim 1 wherein: a. said imperforate cover sheet has marginal portions extending outwardly beyond side and end edges of said channel-shaped metal member and form an insulating protector of said metal member from circuit interfacing contact with foreign objects.

Claim 14

An electrical connection as set forth in claim 1 wherein: a. said channel-shaped metal member has side and end edges with said side edges defining a side opening; b. said imperforate cover sheet has marginal portions extending outwardly beyond said side edges; c. said spaced apart walls of said channel-shaped metal member having portions adjacent said side edges being bent one toward the other and the marginal portions of said cover sheet being engaged to close said side opening and form an insulating protector from circuit interferring contacts.

Claim 15

An electrical connection of insulated electrical conductors comprising, a generally channel-shaped metal member having a web and opposed spaced apart walls extending therefrom, rows of conductor engaging edges on said spaced walls with said rows arranged transversely thereof, said rows of edges on one wall being offset with respect to the rows of edges on the other wall with a row of said edges on one wall being substantially between adjacent rows of edges on the other wall, insulated conductors positioned between said walls and extending longitudinally of said channel-shaped member and from an end thereof, said conductors being engaged by certain of said rows of edges, each of said rows being inclined at an acute angel with respect to its respective wall and away from the end of the channel-shaped member from which the respective conductors engaged thereby extends, an imperforate cover sheet of electrical non-conductive material on outer surfaces of said web and walls in covering relationship thereto, said insulated conductors being clamped between said walls of the channel-shaped members with said edges penetrating into the insulation of the conductors and into engagement with the conductor and said edges curving away from an adjacent end of the said channel-shaped member from which the respective engaged conductor extends to hold said conductor and make electrical contact therewith.

Claim 16

An electrical connection of insulated electrical conductors comprising, a generally channel-shaped metal member having a web and opposed spaced apart walls extending therefrom, rows of conductor engaging edges on said spaced walls with said rows arranged transversely thereof, said rows of edges on one wall being offset with respect to the rows of edges on the other wall with a row of said edges on one wall being substantially between adjacent rows of edges on the other wall, insulated conductors positioned between said walls and extending longitudinally of said channel-shaped member and from an end thereof, said conductors being engaged by certain of said rows of edges, each of said rows being inclined at an acute angel with respect to its respective wall and away from the end of the channel-shaped member from which the respective conductors engaged thereby extends, an imperforate cover sheet of electrical non-conductive material on outer surfaces of said web and walls in covering relationship thereto, said insulated conductors being clamped between said walls of the channel-shaped members with said edges penetrating into the insulation of the conductors and into engagement with the conductor and said edges curving away from an adjacent end of the said channel-shaped member from which the respective engaged conductor extends to hold said conductor and make electrical contact therewith.

Claim 17

An electrical connection of conductors having insulation thereon comprising: a. a generally channel-shaped metal member having a web and opposed spaced apart walls extending therefrom; b. rows of conductor engaging protuberances on said spaced walls with said rows arranged transversely thereof; c. conductors having insulation thereon with portions positioned between said walls, said conductors extending longitudinally of said channel-shaped member and from an end thereof; d. said rows of protuberances each having a plurality of said protuberances with a spacing between adjacent protuberances receiving said conductors therebetween with adjacent edges of the protuberances being spaced less than the width of the conductor and engaging same; e. the rows of protuberances are in pairs struck inwardly from the spaced walls; f. said protuberances of each pair of rows being inclined toward the opposed wall and away from the adjacent end of the channel-shaped member; g. an imperforate cover sheet of electrical non-conductive material on outer surfaces of said web and walls in covering relation thereto; h. the channel-shaped member has said web portion connecting the opposed walls at one side thereof; i. said conductors being clamped between the walls of said channel-shaped member and adjacent protuberance edges penetrating into the insulation of said conductors therebetween and said protuberances curving away from an adjacent end of the channel-shaped member to hold the conductor and make electrical contact therewith; and j. said web being further crushed and bent beyond the elastic limit of the material to hold the walls and the protuberances thereon in conductor connecting position.

Claim 18

An electrical connection of conductors having insulation thereon comprising: a. a generally channel-shaped metal member having a web and opposed spaced apart walls extending therefrom; b. rows of conductor engaging protuberances on said spaced walls with said rows arranged transversely thereof; c. conductors having insulation thereon with portions positioned between said walls, said conductors extending longitudinally of said channel-shaped member and from an end thereof; d. said rows of protuberances each having a plurality of said protuberances with a spacing between adjacent protuberances receiving said conductors therebetween with adjacent edges of the protuberances being spaced less than the width of the conductor and engaging same; e. the rows of protuberances are in pairs struck inwardly from the spaced walls; f. said protuberances of each pair of rows being inclined toward the opposed wall and away from the adjacent end of the channel-shaped member; g. an imperforate cover sheet of electrical non-conductive material on outer surfaces of said web and walls in covering relation thereto; h. the channel-shaped member has said web portion connecting the opposed walls at one side thereof; i. said conductors being clamped between the walls of said channel-shaped member and adjacent protuberance edges penetrating into the insulation of said conductors therebetween and said protuberances curving away from an adjacent end of the channel-shaped member to hold the conductor and make electrical contact therewith; and j. said web being further crushed and bent beyond the elastic limit of the material to hold the walls and the protuberances thereon in conductor connecting position.

Claim 19

An electrical connection as set forth in claim 15 wherein said web has a plurality of longitudinally aligned slots extending through the metal member and defining a line of weakness substantially midway between the spaced walls and the crushing and bend of the web is along said line with adjacent wall portions in substantially face-to-face contact.