US5140746A — Method and device for making electrical connector

Claim 1

Independent Claim 121 words

A device for protecting an electrical contact and wire combination comprising: (i) a gel which; (a) has been preformed apart from the wire to be protected to have an elastic modulus of less than 10 6 dynes/cm 2 and ultimate elongation of at least 200%; and (b) is capable of undergoing elastic deformation around the electrical contact and wire combination; (ii) a support member for said gel, said support member assisting in containing said gel and protecting the electrical contact and wire combination; and (iii) means, operatively associated with said support member, for deforming said gel into close, conforming, and direct contact with the electrical contact and wire combination, at least part of said deformation of said gel being elastic deformation.

Claim 2

Independent Claim 121 words

A device for protecting an electrical contact and wire combination comprising: (i) a gel which; (a) has been preformed apart from the wire to be protected to have an elastic modulus of less than 10 6 dynes/cm 2 and ultimate elongation of at least 200%; and (b) is capable of undergoing elastic deformation around the electrical contact and wire combination; (ii) a support member for said gel, said support member assisting in containing said gel and protecting the electrical contact and wire combination; and (iii) means, operatively associated with said support member, for deforming said gel into close, conforming, and direct contact with the electrical contact and wire combination, at least part of said deformation of said gel being elastic deformation.

Claim 3

Dependent Claim 37 words

The device according to claim 1 wherein said means for deforming exerts sufficient pressure on said gel in combination with said support member to seal the electrical contact and wire combination within said gel from the environment.

Claim 4

Dependent Claim 21 words

The device according to claim 2 wherein the elastic modulus of said gel is less than 10 5 dyne/cm 2 .

Claim 5

Dependent Claim 37 words

The device according to claim 2 wherein said support member includes an electrical contact and said gel, said gel having an adhesive strength to the wire to be sealed which is less than the gel's cohesive strength.

Claim 6

Dependent Claim 26 words

The device according to claim 1 wherein the elastic modulus of said gel is less than 10 5 dynes/cm 2 and said support member is deformable.

Claim 7

Dependent Claim 32 words

The device according to claim 1 wherein said gel is initially formed in contact with said support member and said gel has a cone penetration of 150 to 350 (10 -1 mm).

Claim 8

Dependent Claim 52 words

The device according to claim 1 wherein said support member includes an electrical contact associated with said support member, and where at least part of said means for deforming includes a bolt member and said means for deforming is in combination with said support member and associated with such an electrical contact.

Claim 9

Dependent Claim 20 words

The device according to claim 7 wherein said gel has a cone penetration of 150 to 350 (10 -1 mm).

Claim 10

Dependent Claim 18 words

The device according to claim 1 further including an insulation displacement electrical contact contained within said support member.

Claim 11

Dependent Claim 24 words

The device according to claim 9 wherein said gel an oil-extended polyurethane and has a cone penetration of 150 to 350 (10 -1 mm).

Claim 12

Dependent Claim 55 words

The device according to claim 9 wherein said gel is initially formed in contact with said support member and electrical contact and said gel has an adhesive strength to the wire to be protected which is less than the gel's adhesive strength to said support member and electrical contact, and also the gel's cohesive strength.

Claim 13

Dependent Claim 56 words

The device according to claim 11 wherein said means for deforming includes a force member for maintaining said gel in compressive contact with the electrical contact and wire combination and said force member is selected to include a member from the group consisting of a nut, a bolt, a slip retaining nut member and combinations thereof.

Claim 14

Dependent Claim 51 words

The device according to claim 12 wherein said support member is composed of an organic polymeric material and said gel is an aliphatic polyurethane composition selected from the group consisting of a plasticized polyurethane, an oil-extended polyurethane, said gel has a cone penetration value of 150 to 350 (10 -1 mm).

Claim 15

Dependent Claim 26 words

The device according to claim 11 wherein said gel is a silicone gel and has a cone penetration value of 150 to 350 (10 -1 mm).

Claim 16

Dependent Claim 35 words

The device according to claim 1 wherein the properties of said gel are such that a plane of weakness is formed therein when deformed about the wire by the operation of said means for deforming.

Claim 17

Dependent Claim 41 words

The device according to claim 1 wherein said gel is selected from the group consisting of gels substantially inert towards the wire; hydrolytically stable moisture insensitive and electrically insulating gels; tacky gels; non-tacky gels; and gels with combinations of properties thereof.

Claim 18

Independent Claim 105 words

A device for protecting an electrical contact and wire combination, comprising: (1) a gel which has been preformed in the absence of the wire to be protected to have an elastic modulus of less than 10 6 dynes/cm 2 and an ultimate elongation of at least 200%; (2) a support member for said gel; and (3) force means to act in operative association with said support member for maintaining said gel in close, conforming and direct contact with the electrical contact and wire combination, at least part of said gel which is in direct contact with the electrical contact and wire combination being elastically deformed.

Claim 19

Independent Claim 105 words

A device for protecting an electrical contact and wire combination, comprising: (1) a gel which has been preformed in the absence of the wire to be protected to have an elastic modulus of less than 10 6 dynes/cm 2 and an ultimate elongation of at least 200%; (2) a support member for said gel; and (3) force means to act in operative association with said support member for maintaining said gel in close, conforming and direct contact with the electrical contact and wire combination, at least part of said gel which is in direct contact with the electrical contact and wire combination being elastically deformed.

Claim 20

Dependent Claim 18 words

The device according to claim 17 wherein said gel is initially formed in contact with said support member.

Claim 21

Dependent Claim 38 words

The device according to claim 18 wherein said gel a cone penetration value of 150-350 (10 -1 mm), said gel having an adhesive strength to the wire to be sealed which is less than the gel's cohesive strength.

Claim 22

Dependent Claim 29 words

The device according to claim 17 wherein said support member includes an electrical contact and said gel is initially formed in contact with said support member and electrical contact.

Claim 23

Dependent Claim 27 words

The device according to claim 20 wherein said gel has an adhesive strength to the wire to be sealed which is less than the gel's cohesive strength.

Claim 24

Dependent Claim 17 words

The device according to claim 21 wherein said gel a cone penetration of 150-350 (10 -1 mm).

Claim 25

Dependent Claim 51 words

The device according to claim 17 wherein with said support member includes an insulation displacement electrical contact and said gel, said gel having an adhesive strength the wire to be sealed which is less than the gel's cohesive strength and an elastic modulus of less than 10 5 dynes/cm 2 .

Claim 26

Dependent Claim 19 words

The device according to claim 23 wherein said gel has a cone penetration value of 150-350 (10 -1 mm).

Claim 27

Dependent Claim 105 words

In combination, a substrate wherein the substrate comprises at least an electrical contact and wire combination, an electrically insulating gel associated with said substrate, said gel having an elastic modulus of less than 10 6 dynes/cm 2 and an ultimate elongation of at least 200%, said gel preformed in the absence of the wire to be protected, wherein said gel undergoes elastic deformation at least at the interface between the combination and said gel directly in contact therewith when compressed thereon, and a member operatively acting in conjunction with said substrate for deforming and compressing said gel into close and conforming contact with the combination.

Claim 28

Dependent Claim 105 words

In combination, a substrate wherein the substrate comprises at least an electrical contact and wire combination, an electrically insulating gel associated with said substrate, said gel having an elastic modulus of less than 10 6 dynes/cm 2 and an ultimate elongation of at least 200%, said gel preformed in the absence of the wire to be protected, wherein said gel undergoes elastic deformation at least at the interface between the combination and said gel directly in contact therewith when compressed thereon, and a member operatively acting in conjunction with said substrate for deforming and compressing said gel into close and conforming contact with the combination.

Claim 29

Dependent Claim 43 words

The device according to claim 25 wherein said gel has an adhesive strength to the combination which is less than the gel's cohesive strength and an elastic modulus of less than 10 5 dynes/cm 2 , and said substrate includes a support member.

Claim 30

Dependent Claim 38 words

The device according to claim 26 wherein said gel has a maximum tensile strength of less than 20 psi and a cone penetration value of 150-350 (10 -1 mm) and the electrical contact is an insulation displacement contact.

Claim 31

Dependent Claim 100 words

A process for environmentally protecting a combined electrical contact and wire substrate comprising the steps of: (a) placing a device into contact with the electrical contact and wire substrate, the device comprising a support member and a gel which, prior to coming into contact with the electrical contact and wire substrate to be protected, is elastic and adherent to said support member and which has an elastic modulus of less than 10 6 dyne/cm 2 and an ultimate elongation of at least 200%; and (b) compressing said gel directly contacting the electrical contact and wire substrate into sealing contact therewith.

Claim 32

Dependent Claim 100 words

A process for environmentally protecting a combined electrical contact and wire substrate comprising the steps of: (a) placing a device into contact with the electrical contact and wire substrate, the device comprising a support member and a gel which, prior to coming into contact with the electrical contact and wire substrate to be protected, is elastic and adherent to said support member and which has an elastic modulus of less than 10 6 dyne/cm 2 and an ultimate elongation of at least 200%; and (b) compressing said gel directly contacting the electrical contact and wire substrate into sealing contact therewith.

Claim 33

Dependent Claim 48 words

The process according to claim 28 which protects the wires in the articles selected from the group consisting of a telephone circuit wire connector, a telephone termination block, and a telephone splice connector and said gel has an elastic modulus of less than 10 5 dynes/cm 2 .

Claim 34

Dependent Claim 59 words

The process according to claim 29 wherein said gel has an adhesive strength to the electrical contact and wire substrate which is less than the gel's cohesive strength and said device includes said electrical contact and the compressing is created by a force which is selected from the group of forces which is substantially non-varying in time or dynamic.

Claim 35

Dependent Claim 32 words

The process according to claim 30 wherein said gel has a cone penetration value of 150-350 (10 -1 mm) and wherein said compressing is achieved by the rotation of a bolt head.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1995-08-25	1996-02-24	1996-08-25	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1999-08-25	2000-02-24	2000-08-25	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2003-08-25	2004-02-24	2004-08-25	$7700.00	Window Closed / Lapsed

Method and device for making electrical connector

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