Insulation-penetrating slotted beam contact element

Claim 2

A slotted beam contact element (10,110) for electrically terminating an insulated conductor (220) comprised of a conductor (202) surrounded by a jacket of insulation (224), where the contact element is a substantially planar conductive structure comprising a base portion (12), a bifurcated beam (14) with substantially parallel furcations (16,116) extending from the base portion where the furcations define between them a substantially V-shaped wire-guiding entrance (18,118) near the free ends (17,117) of the furcations, and a wire-gripping slot (20,120) formed with facing furcation sidewalls (30,126) where the sidewalls at their ends adjacent the entrance form a mouth (32,128) to the slot, the contact element being characterized by: means for removing outer-insulation portions (228) from the insulation of the insulated conductor as the insulated conductor is guided toward the wire-gripping slot, the outer-insulation removing means being disposed at a predetermined location remote from the mouth and along the entrance, said outer-insulation removing means comprising a cutting edge on each furcation (16,116) substantially normal to the plane of the contact element, the cutting edge being defined by an intersection of a ledge (34,134) formed from a first coined region (11,130) on a first face (13,132) of the contact element with its associated entrance sidewall (26,124).

Claim 3

The contact element (10, 110) pursuant to claim 1 where on each furcation (16, 116), each entrance sidewall (26, 124) undergoes a gradual transition defined by a gentle radius to be continuous with its associated sidewall (30, 126).

Claim 4

The contact element (10) pursuant to claim 1 further comprising: means for penetrating the remaining insulation on the insulated conductor (220) to establish electrical contact between the conductor (202) and the contact element.

Claim 5

The contact element (10, 110) pursuant to claim 1 where the wire-gripping slot (20, 120) in the unstressed state is tapered with the narrowest width in the region of the mouth (32, 128).

Claim 6

The contact element (10, 110) pursuant to claim 1 with a second identically configured beam (14, 114) extended from the base portion (12, 112).

Claim 7

The contact element (110) pursuant to claim 1 where each ledge (134) faces away from the wire-gripping slot (120) to cause its associated cutting edge (136) to cut into the insulation (224) with a positive rake angle (α').

Claim 8

The contact element (110) pursuant to claim 1 where each ledge (134) slopes sufficiently in a region adjacent its cutting edge (136) to receive a force from its associated outer-insulation portion (229) directed toward the wire-gripping slot (120).

Claim 9

The contact element (110) pursuant to claim 1 further comprising: means for (146) crushing insulation.

Claim 10

The contact element (110) pursuant to claim 8 where the crushing means (146) includes a crushing edge (146) on each furcation (116) remote from the mouth (128) and along the entrance (118).

Claim 11

The contact element (110) pursuant to claim 9 where the crushing edge (146) on each furcation (116) is defined by the entrance sidewall (124) intersecting with a sidewall (144) adjacent a second coined region (142) on a second face (140) of the contact element.

Claim 12

The contact element (110) pursuant to claim 1 where each furcation (116) has a coined region (142) of reduced thickness on a second face (140) of the contact element in the area of the wire-gripping slot (120) so that the sidewalls (126) can apply sufficient bearing pressure on the wire 220 to penetrate the remaining insulation.

Claim 13

The contact element (110) pursuant to claim 11 where each sidewall (126) is in substantial collinear alignment with its associated cutting edge (136) along an axis normal to the plane of the contact element.

Claim 14

The contact element (110) pursuant to claim 11 where each coined region (142) is bounded by a sidewall (144) which terminates beyond the mouth (128) and slopes inward toward the center of the wire-guiding entrance (118) to intersect with its associated entrance sidewall (124).

Claim 15

A slotted beam contact element (10) for electrically terminating an insulated conductor (220) comprising a conductor (202) surrounded by a jacket of insulation (224) where the contact element is a substantially planar conductive structure comprising: a base portion (12); a beam (14) bifurcated to form substantially parallel furcations (16) extending from the base portion, the furcations defining between them a substantially V-shaped entrance (18) near the free ends (17) of the furcations and a wire-gripping slot (20), where the entrance is substantially defined by a first sidewall (24) and a second sidewall (26) on each furcation; an indentation (28) on each furcation, each indentation defined by a surface means (29) connecting the first and second sidewalls on each furcation, the surface means intersecting with the second sidewall (26) on each furcation to define a cutting edge (44) such that the cutting edges (44) on both furcations are capable of cutting away outer portions (228) of the insulation (224); a third substantially planar sidewall (30) on each furcation (16), the third sidewalls defining the wire-gripping slot (20), and at their end adjacent the entrance (18) defining a mouth (32) to the wire-gripping slot, each second sidewall (26) in the region of the mouth being defined by a curved surface which is continuous with the surface on its associated third planar sidewall; and an abrupt transition in the thickness in each of the third sidewalls (30) below the mouth (32) to the wire-gripping slot (20) to form below the abrupt transition a conductor-holding region (58), the conductor-holding region of the third sidewalls being somewhat thicker than the third sidewalls in the region of the mouth, the abrupt transition forming a ledge (34) substantially facing the free ends (17) of the beams, each ledge intersecting its associated third sidewall (30) to define a cutting edge (36).

Claim 16

A slotted beam contact element (10) for electrically terminating an insulated conductor (220) comprising a conductor (202) surrounded by a jacket of insulation (224) where the contact element is a substantially planar conductive structure comprising: a base portion (12); a beam (14) bifurcated to form substantially parallel furcations (16) extending from the base portion, the furcations defining between them a substantially V-shaped entrance (18) near the free ends (17) of the furcations and a wire-gripping slot (20), where the entrance is substantially defined by a first sidewall (24) and a second sidewall (26) on each furcation; an indentation (28) on each furcation, each indentation defined by a surface means (29) connecting the first and second sidewalls on each furcation, the surface means intersecting with the second sidewall (26) on each furcation to define a cutting edge (44) such that the cutting edges (44) on both furcations are capable of cutting away outer portions (228) of the insulation (224); a third substantially planar sidewall (30) on each furcation (16), the third sidewalls defining the wire-gripping slot (20), and at their end adjacent the entrance (18) defining a mouth (32) to the wire-gripping slot, each second sidewall (26) in the region of the mouth being defined by a curved surface which is continuous with the surface on its associated third planar sidewall; and an abrupt transition in the thickness in each of the third sidewalls (30) below the mouth (32) to the wire-gripping slot (20) to form below the abrupt transition a conductor-holding region (58), the conductor-holding region of the third sidewalls being somewhat thicker than the third sidewalls in the region of the mouth, the abrupt transition forming a ledge (34) substantially facing the free ends (17) of the beams, each ledge intersecting its associated third sidewall (30) to define a cutting edge (36).

Claim 17

The slotted beam contact element (10) pursuant to claim 14 further comprising: means for penetrating the remaining insulation on the insulated conductor (220) to establish electrical contact between the conductor (202) and the contact element.

Claim 18

The slotted beam contact element (10) pursuant to claim 14 where the surface means (29) comprises a substantially concave surface (29) connecting the first (24) and second (26) sidewalls on each furcation (16).

Claim 19

The slotted beam contact element (10) pursuant to claim 14 where each surface means (29) has adjacent its associated cutting edge (44), a region (42) facing sufficiently away from the wire-gripping slot (20) to form a positive rake angle (α) with respect to the insertion direction (52) of the insulated conductor (220).

Claim 20

The slotted beam contact element (10) pursuant to claim 14 where each surface means (29) has adjacent its associated cutting edge (44), a region (42) facing sufficiently away from the wire-gripping slot (20) so as to receive from the outer-insulation portions (228), a force (54) having a force component directed toward the wire-gripping slot.

Claim 21

The slotted beam contact (10) pursuant to claim 14 where on each furcation (16), the first sidewall (24) is set back with respect to its associated second sidewall (26) to enhance contact of the snagging surface means (29) and the cutting edge (44) with the insulated conductor (220) inserted.