DESC:
FIELD OF THE INVENTION

[001] The present invention relates generally to electrical connectors and more particularly to plug socket type electrical connectors.

BACKGROUND OF THE INVENTION

[002] An electrical connector is an electro-mechanical device used to join electric conductors mechanically and electrically to other conductors and to the terminals of equipment to form an electrical circuit. Electrical connectors are commonly utilized for interconnecting two groups of wires rather than separately joining together individual pairs of wires. The term ‘electrical connector’ covers a wide range of devices designed to connect small conductors employed in communication circuits, or large cables and bus-bars. The connection may be temporary or permanent as per the needs of the connection.

[003] Electrical connectors are installed on conductors in many different ways. Soldered connectors have a tube or hole of approximately the same diameter as the conductor. The conductor and connector are heated, the conductor inserted, and solder flowed into the joint until it is filled. Another method is by clamping the conductor in a bolted assembly or by staking or crimping under great mechanical force. Terminal lugs join the conductor to a drilled tongue for bolting to a busbar.

[004] Separable connectors consist of matched plugs and receptacles, which may be readily separated to disconnect a conductor from the circuit. Separable connectors are commonly used for the connection of portable appliances and equipment to an electric wiring system.

[005] However most of the connectors have disadvantage such as loose connection, problems during installation and servicing, they are prone to electrical shock and mechanical failure and also lead to I2R losses, heat dissipation and lack of reliability.

[006] In view of the limitations inherent in the available electrical connectors, there exists a need for an improved electrical connector which overcomes the disadvantages of the prior art and which can be manufactured in a cost effective, reliable, secure and environmental friendly manner.

[007] The present invention fulfils this need and provides further advantages as described.

SUMMARY OF THE INVENTION

[008] In view of the foregoing disadvantages inherent in the prior art, the general purpose of the present invention is to provide an improved combination of convenience and utility, to include the advantages of the prior art, and to overcome the drawbacks inherent therein.

[009] A primary objective of the present invention is to provide an electrical connector for connecting a flat conductor with a circular conductor which is simple and cost effective.

[0010] In one aspect, the present invention provides an electrical connector for connecting a flat conductor with a circular conductor. The connector comprises a socket having a flat conductor connecting portion and a plug connecting portion, a plug having a circular conductor connecting portion and a socket connecting portion and a connecting means for connecting the socket connecting portion with the plug connecting portion.

[0011] In another aspect of the present invention, the flat conductor is a busbar and the circular conductor is a conductor wire.

[0012] In yet another aspect of the present invention, the flat conductor connecting portion includes at least two parallel flanges with a plurality of holes to receive the flat conductor between the flanges and mount the socket on the flat conductor.

[0013] In one aspect of the present invention, the flat conductor includes a plurality of holes corresponding to the plurality of holes on the flanges adapted to be connected using a nut and a bolt.

[0014] In another aspect of the present invention, the circular conductor connecting portion includes a cavity to receive the circular conductor and adapted to be crimped to hold the circular conductor.

[0015] In a further aspect of the present invention, the connecting means includes a socket cavity box and a hollow receptacle in the plug connecting portion, the hollow receptacle is located at the centre of the socket cavity box, a plug cavity box with a pillar at the centre of the plug cavity box, such that the plug cavity box is adapted to be received inside the socket cavity box and the pillar is adapted to be received in the hollow receptacle.

[0016] In another aspect of the present invention, the connecting means further comprises a plurality of serration on the inner surface of the socket cavity box and the hollow receptacle and a plurality of spring strips on the periphery of the plug cavity box such that it engages with the plurality of serration to lock the socket with the plug.
[0017] In yet another aspect of the present invention, the connecting means includes a socket cavity box and a socket pillar in the plug connecting portion, the socket pillar is located at the centre of the socket cavity box, a plug cavity box, such that the plug cavity box is adapted to be received inside the socket cavity box is adapted to fit over the socket pillar and inside the socket cavity box.

[0018] In another aspect of the present invention, the connecting means further comprises a plurality of strips which extend vertically along the axis of the plug and bend towards its centre to form a conical shape, such that the conical shape at an open end forms a circle which is adapted to fit over the socket pillar.

[0019] These together with other aspects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the description annexed hereto and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The advantages and features of the present invention will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawings in which:

[0021] FIG.1 illustrates a schematic diagram of an electrical connector, according to one embodiment of the present invention;

[0022] FIG. 2 illustrates a schematic diagram of the socket, according to one embodiment of the present invention;

[0023] FIG. 3 illustrates a schematic diagram of the plug, according to one embodiment of the present invention;

[0024] FIG. 4 illustrates a schematic diagram of alternate design of the socket, according to another embodiment of the present invention; and

[0025] FIG. 5 illustrates a schematic diagram of alternate design of the plug, according to another embodiment of the present invention.

[0026] Like reference names refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE DRAWINGS

[0027] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details.

[0028] As used herein, the term ‘plurality’ refers to the presence of more than one of the referenced item and the terms ‘a’, ‘an’, and ‘at least’ do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

[0029] Reference herein to “one embodiment” or “another embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the diagrams representing one or more embodiments of the invention do not inherently indicate any particular order nor imply any limitations in the invention.

[0030] Referring to FIG. 1 that illustrates a schematic diagram of an electrical connector 10 for connecting a flat conductor with a circular conductor. The electrical connector 10 comprises a socket 12 and a plug 14 which are attached to each other by connecting means 16 forming the electrical connection between a flat conductor and a circular conductor. In one embodiment of the present invention, the flat conductor is a busbar and the circular conductor is a conductor wire. The socket 12 has to be connected with the busbar at one end and the plug 14 is connected to the conductor for making the electrical connection between the busbar and the conductor.

[0031] Now referring to FIG. 2 that illustrates a schematic diagram of the socket 12, according to one embodiment of the present invention. The socket 12 is a rectangular block type structure which includes a flat conductor connecting portion 18 at one end and a plug connecting portion 20 at another end. In one embodiment of the present invention, the flat conductor connecting portion 18 includes at least two parallel flanges with a plurality of holes 22 to receive the flat conductor between the flanges and mount the socket 12 on the flat conductor.The flat conductor such as busbar also includes a plurality of holes corresponding to the plurality of holes 22 on the flanges adapted to be connected using a nut and a bolt. The bus bar is received between the flanges such that the plurality of holes of the busbar are aligned with the plurality of holes 22 of the flat conductor connecting portion 18. Now nuts and bolts may be used to fasten the busbar with the socket 12. The dimension of the flanges 18 and the gap between the flanges corresponds with the shape and thickness of the busbar where the connector 10 needs to be connected.

[0032] In another embodiment of the present invention, the socket 12 may include more than two flanges to connect with multiple busbars arranged parallel to each other. The flanges 18 shown are flat in shape, however in another embodiment the flanges may be curved to connect with a curved busbar. The through holes 22 in the flanges are used to mount the socket 12 on the busbar which has similar holes by using nuts and bolts. The diameter of through holes 22 on the socket is made as per the diameter of the through holes on the busbar. The number of through holes is also dependent on the requirement.

[0033] Referring to FIG.3, that illustrates a schematic diagram of the plug 14, according to one embodiment of the present invention. The plug includes a socket connecting portion 24 and a circular conductor connecting portion 26. The socket connecting portion 24 mates with the plug connecting portion 20 of socket to form the connector 10. In one embodiment of the present invention, the circular conductor connecting portion 26 is a hollow cylinder to receive the circular conductor and adapted to be crimped to hold the circular conductor. The conductor is inserted in the hollow portion and the outer surface of the plug 14 is crimped to hold the conductor tightly thereby making the connection. In another embodiment of the present invention, the plug 14 may include more than one conductor connection portions to connect a plurality of conductors to the busbar.

[0034] In one embodiment of the present invention, the connecting means 16 includes a socket cavity box 30 and a hollow receptacle 32 in the plug connecting portion 20 of the socket 12 as shown in FIG. 2 and a plug cavity box 34 and a pillar 36 in the socket connecting portion 24 of the plug 14 as shown in FIG.3.

[0035] . The hollow receptacle 32 is located at the centre of the socket cavity box 30 and the pillar 36 is located at the centre of the plug cavity box 34, such that the plug cavity box 34 is adapted to be received inside the socket cavity box 30 and the pillar 36 is adapted to be received in the hollow receptacle 32 respectively for engaging the plug 14 with the socket 12. In one preferred embodiment of the present invention, the connecting means 16 further comprises a plurality of serrations 40 on the inner surface of the socket cavity box 30 and the hollow receptacle 32 and a plurality of spring strips 42 on the periphery of the plug cavity box 34 such that it engages with the plurality of serrations 40 to lock the plug 14 with the socket 12.

[0036] The socket cavity box 30 is shaped as a hollow cavity of square cross section with its inner walls having serrations 40. The hollow receptacle 32 is a hollow cylinder, which is fixed along the axis of the socket cavity box 30 and is contained within it. The inner surface of the hollow receptacle 32 also includes serrations 40. The length of the hollow receptacle 32 is equal to the depth of the socket cavity box 30.

[0037] The shape and dimensions of the plug cavity box 34 are designed such that the socket connecting portion 24 fits snugly within the socket cavity box 30. The plurality of spring strips 42 on the periphery of the plug cavity box 34 are mounted on the box along the axial direction of the plug 14. The strips 42 are mounted between two edges of the plug cavity box 34 box, such that they are bent to forms a convex shape on outside. A plurality of slots may be made on the outer surface of the box 34 to mount the strips 42, thereby forming the connecting means 16. The plug cavity box 34 when inserted in the plug connecting portion 20 of the socket, gets engaged due to the spring effect of the strips 42 and the serrations 40 provided on inner surface of the socket cavity box 30.

[0038] The pillar 36 is solid cylinder and is adapted to contain within the hollow receptacle 32 of the socket for making the connection. The diameter and length of the pillar 36 is such that it snugly fits in the hollow receptacle 32. The cross sectional shape of the pillar 36 shown is circular since it has to fit in the hollow receptacle 32 which is cylindrical in shape, however in another embodiment the cross sectional shape of the pillar 36 may be octagonal, square, hexagonal or any shape as per the shape of the hollow receptacle 32 and vice versa.

[0039] The mating of pillar 36 and strips 42 of the plug 14 along with the hollow receptacle 32 and socket cavity box 30 respectively provides very good mechanical connection and require no bolt/thread for holding them together. The serrations 40 on the inner surface of the socket cavity box 30 also aid in better grip.

[0040] The more contact area between the mating parts also leads to reduced contact resistance and ensures good current flow from the connector. The less contact resistance also ensures reduced I2R losses, heat dissipation and increased reliability for the connection.

[0041] Referring to FIG.4, that illustrates a schematic diagram of alternate design of the socket 121, according to another embodiment of the present invention. The socket 121 is similar to the socket 12 of FIG. 2 having a busbar connecting portion 18 and plug connecting portion 20. The busbar connecting portion 18 is similar to the design of FIG.2, however the plug connecting portion 20 is different. In an embodiment of the present invention, the connecting means 16 includes socket cavity box 301 and a socket pillar 50 in the plug connecting portion 20 and a plurality of strips 52 in the socket connecting portion 24 which extend vertically along the axis of the plug 141 and bent towards its centre to form a conical shape, such that the conical shape at an open end forms a circle which is adapted to fit over the socket pillar 50 and inside the socket cavity box 30.

[0042] The socket pillar 50 is located at the centre of the socket cavity box 30. The socket cavity box 301 is circular in shape with its outside wall forming a square shape. The socket pillar 50 is a solid cylinder concentrically extending from the axis of socket cavity box 301 with its length equal to the depth of the socket cavity box 301. Unlike hollow receptacle 32 which is a hollow cylinder in the design of FIG.2, here the cylinder is solid forming the socket pillar 50.

[0043] Now referring to FIG. 5 that illustrates a schematic diagram of alternate design of the plug 141 which is adapted to connect with the socket 121, according to one embodiment of the present invention. The alternate design of plug 141 has similar portions as the plug 14 of FIG. 3. The plug 141 also includes a socket connecting portion 24 and a conductor connecting portion 26. The conductor connecting portion 26 is also similar to the design of FIG.3, however the socket connecting portion 24 includes connecting means in the form of a plurality strips 52 which extend vertically along the axis of the plug 141 and bend towards its centre to form a conical shape.

[0044] The plurality of strips 52 forming the conical shape at the top, forms a circle whose diameter is adapted to fit over the socket pillar 50 of the socket 121. The plurality of strips 52 acts as spring and when inserted in the socket cavity box 301, snugly fits in the cavity to make the connection forming the connector 10.In one preferred embodiment of the present invention, the socket pillar 50 assures correct alignment of the plurality of strips 52 during assembly of the plug 14 and the socket 12 to assure uniform contact. The plurality of strips 52 should have uniform contact over the socket pillar 50 to have the least contact resistance. The socket pillar 50 also prevents the collapsing of the plurality of strips 52 during assembly of the plug 14 and the socket 12. When the connection is made between the socket 12 and the plug 14, the socket pillar 50 aligns and guides the plurality of strips 52, preventing any unwanted bending of the strips 52, thereby having uniform contact.

[0045] In yet another embodiment of the present invention, each of the plurality of strips 52 may further include a groove cut along its width on the straight portion of the strip. The groove further adds to the spring effect of the strips. The connecting means 16 when inserted in the plug connecting portion of the socket gets engaged due to the spring effect and the serrations provided on inner surface of socket cavity box 301.

[0046] The mating of socket pillar 50 with the inner surface of the strips 52 and serration on inside surface of socket cavity box 301 with outer surface of strips respectively provides very good mechanical connection and require no bolt/thread for holding them together.

[0047] The cross sectional shape of the conductor connecting portion 26 is also dependent on the shape and size of the conductor and is designed to suit the conductor used in making the electrical circuit.

[0048] The connector 10 further includes an insulating casing to enclose the connector within it, preventing the chances of electric shock to the linemen during use. The plug 14 and socket 12 may be made of copper, brass, aluminum or any conducting material used in the art for making connectors.

[0049] When an electrical connection has to be made between a busbar and a conductor, the conductor is crimped in the plug 14 at the conduction connection portion 26 and the socket 12 is connected to the busbar via its flanges. Now the two parts of the connector 10: plug 14 and socket 12 are connected by inserting the socket connecting portion 24 of the plug in the socket cavity box 30 of the socket thereby making the connection.

[0050] The connection is very quick and done in a single step without use of any external tools. The quick and easy connection helps the linemen immensely during installation or maintenance activity for the equipment. The connection is temporary and can be disconnected as easily as the connection is made, just by pulling the plug 14.

[0051] The electrical connector 10 of the present invention may provide below advantages in terms of:
- Ease of Installation : One step connect/disconnect mechanism
- Low Contact Resistance: Springs at the periphery of plug increases the surface area between the mating parts, thereby reducing the contact resistance
- Good Mechanical Connection: The spring on plug along with serrations on the socket provide good grip for a good and reliable mechanical connection between mating parts
- Shock proof – The insulating casing encloses all live parts of the connector thus making it safe
- Scalability: The connector may be scaled for more number of conductors to be connected to a busbar
- Low I2R loss

[0052] Although a particular exemplary embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized to those skilled in the art that variations or modifications of the disclosed invention, including the rearrangement in the configurations of the parts, changes in steps and their sequences may be possible. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as may fall within the spirit and scope of the present invention.

[0053] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching.

[0054] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims.
,CLAIMS:WE CLAIM:

1. An electrical connector for connecting a flat conductor with a circular conductor, comprising:
- a socket having a flat conductor connecting portion and a plug connecting portion;
- a plug having a circular conductor connecting portion and a socket connecting portion; and
- a connecting means for connecting the socket connecting portion with the plug connecting portion.

2. The electrical connector according to claim 1, wherein the flat conductor is a busbar and the circular conductor is a conductor wire.

3. The electrical connector according to claim 1, wherein the flat conductor connecting portion includes at least two parallel flanges with a plurality of holes to receive the flat conductor between the flanges and mount the socket on the flat conductor.

4. The electrical connector according to claim 3, wherein the flat conductor includes a plurality of holes corresponding to the plurality of holes on the flanges and are adapted to be connected using a nut and a bolt.

5. The electrical connector according to claim 1, wherein the circular conductor connecting portion is a hollow cyclinder to receive the circular conductor and adapted to be crimped to hold the circular conductor.

6. The electrical connector according to claim 1, wherein the connecting means includes:
- a socket cavity box and a hollow receptacle in the plug connecting portion, the hollow receptacle is located at the centre of the socket cavity box; and
- a plug cavity box and a pillar in the socket connecting portion, such that the plug cavity box is adapted to be received inside the socket cavity box and the pillar is adapted to be received in the hollow receptacle.

7. The electrical connector according to claim 6, wherein the connecting means further comprises:
- a plurality of serrations on the inner surface of the socket cavity box and the hollow receptacle; and
- a plurality of spring strips on the periphery of the plug cavity box such that it engages with the plurality of serrations to lock the plug with the socket.

8. The electrical connector according to claim 1, wherein the connecting means includes:
- a socket cavity box and a socket pillar in the plug connecting portion, the socket pillar is located at the centre of the socket cavity box; and
- a plurality of strips in the socket connecting portion, such that the strips extend vertically along axis of the plug and bent to form a conical shape which is adapted to fit over the socket pillar and inside the socket cavity box.

9. The electrical connector according to claim 8, wherein the socket pillar assures correct alignment of the plurality of strips during assembly of the plug and the socket to assure uniform contact.

10. The electrical connector according to claim 8, wherein the socket pillar prevents inside collapsing of the plurality of strips during assembly of the plug and the socket.