ELECTRICAL CONNECTOR CLUSTER ASSEMBLY WITH MOTOR PROTECTION
United States Patent 3622948
The invention comprises an apparatus especially adapted for connecting hermetic compressor motor leads disposed in a cluster to a hermetic shell-mounted terminal of the type having three closely spaced pins with flat tabs thereon. The cluster assembly includes a block with cavities therein in an orientation in which the contact sockets are relatively flat and disposed at equilateral angles to each other so as to align with the tabs on the pins and so that the contact wires extend in a pinwheel arrangement at the edge of the block. An additional socket is provided in the block for reception of a thermal sensitive device that provides overload protection for the compressor motor, with the thermal sensitive device wired in series with one of the wires of the pinwheel arrangement.
US Patent References:
Thermostatic switch plug
Walder - May 1932 - 1857899
Electrical connector cluster assembly
Looke - October 1967 - 3345605
Thermostatic switch plug
Walder - May 1932 - 1857899
Electrical connector cluster assembly
Looke - October 1967 - 3345605
Application Number:
05/009377
Publication Date:
11/23/1971
Filing Date:
02/06/1970
View Patent Images:
Export Citation:
Assignee:
Westinghouse Electric Corporation (Pittsburgh, PA)
Primary Class:
Other Classes:
439/685, 337/197
International Classes:
H01R24/12; H01R33/72; H01R3/00
Field of Search:
339/30,147,191A,191L,191M,192R,192RL 337/92,197,198,268,269
Primary Examiner:
Leppink, James A.
Assistant Examiner:
Staab, Lawrence J.
Claims:
What is claimed is
1. a cluster assembly for making a gang connection to a plural post terminal including;
2. A cluster assembly for making a gang connection to a plural post terminal having:
3. The combination set out in claim 2 wherein:
4. The combination set out in claim 3, wherein;
5. The combination set out in claim 3 wherein;
6. The combination set out in claim 3 wherein;
7. The combination set out in claim 6 wherein;
1. a cluster assembly for making a gang connection to a plural post terminal including;
2. A cluster assembly for making a gang connection to a plural post terminal having:
3. The combination set out in claim 2 wherein:
4. The combination set out in claim 3, wherein;
5. The combination set out in claim 3 wherein;
6. The combination set out in claim 3 wherein;
7. The combination set out in claim 6 wherein;
Description:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electrical connector cluster assembly with an overload means and, more specifically, relates to an electrical connector cluster assembly and an overload protection means that are adapted for connecting a hermetic compressor motor to the hermetic shell-mounted terminal of the type having three closely spaced pins with flat tabs thereon.
2. Description of the Prior Art
Although the use of an electrical connector cluster assembly of the general type herein disclosed is known and has been described, for example, in U.S. Pat. No. 3,345,605, such connector cluster assemblies have not included any means for protecting the hermetic motor from overloading and thereby overheating so that such means had to be provided somewhere else within the hermetic shell and this required a consequent additional assembly operation and the added cost required by this assembly operation. The present invention obviates such a requirement.
The nature of the instant invention may be more readily appreciated if the environment in which the collector cluster assembly with overload protection is detailed. Small hermetic compressors of the type utilized in refrigerators, freezers and air conditioners are mass produced for incorporation in millions of such appliances each year. Most manufacturers of small hermetic compressors utilize a standard hermetic terminal which carries three pin conductors sealed in an insulating relationship through the shell of the hermetic compressor. Although collector cluster assemblies have been utilized to provide a convenient connection for the leads of the compressor motor to the pins provided in the side of the hermetic shell (e.g., U.S. Pat. No. 3,345,605 ), none of these cluster assemblies have heretofore utilized an overload protection as a portion of their assembly. Thus, this overload protection had to be provided alternately in the wiring leading to the hermetic shell or provided within the hermetic enclosure, itself. In both of these cases, the assembly of the hermetic compressor and its electrical connecting wires was somewhat complicated and thereby required more time and additional costs. If an overload protection was provided within the electrical connector cluster assembly, then a large amount of assembly time could be eliminated and the overload protector means prewired into the collector cluster assembly to provide the overload requirements of the compressor motor.
SUMMARY OF THE INVENTION
In accordance with the principles of this invention, a mounting block is provided with a number of connector cavities for holding a series of connectors in a proper array to fit the pins extending from a hermetic enclosure. Connectors including their ferrules are formed to accommodate the cavities provided in the mounting block, with these cavities being arranged so that each conductor emerges from the edge of the mounting block at a location closely adjacent to the connector cavity. Disposed outwardly of the connector cavities and substantially aligned with a base of the block, is an additional cavity which is shaped so as to rigidly hold therein an overload protector element. This cavity includes a trough portion for the overload protector and a part of the terminals which extend from the overload protector, with a lead attached to one of these terminals extending to the other two wires extending from the connector block and the other of the leads extending from the opposite terminal of the overload protector around the mounting block to one of the three connectors disposed in one of the connector cavities. The cavity provided for the overload protector includes means for aligning the terminals which extend therefrom and also means formed by a substantially semiannular groove for holding the overload protector in the proper location within the cavity.
DRAWING DESCRIPTION
FIG. 1 is a plan view of the rear or cover side of a cluster assembly and overload protector according to the instant invention;
FIG. 2 is a plan view of the rear side of the mounting block with the cover removed and the connectors omitted;
FIG. 3 is a sectional side view corresponding to one taken along line III--III of FIG. 2;
FIG. 4 is a plan view of the cover for the mounting block;
FIG. 5 is a fragmentary perspective view of one corner of the mounting block with a connector for the corner cavity shown in exploded relation to the block; and
FIG. 6 is a view similar to FIG. 5, but showing the overload protector in exploded relation to its cavity.
DETAILED DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail in connection with the accompanying drawings which illustrate one embodiment thereof by way of example and wherein a connector cluster assembly 8 is shown in FIG. 1 in its assembled form with three electrical conductors 10, 12, and 14 emerging from three underlying cavities 16, 16 and 16. These cavities are situated at peripherally spaced locations about the edge of a generally truncated, peak-shaped insulating block 18, and are at equilateral angles to one another in the truncated triangular portion of the insulating block. The lead wires 10 and 12 are wrapped around the peripheral edge of the insulating block 18 from their point of emergence to form a three wire group with another wire conductor 20 that extends outwardly from a cavity 24 in the rectangular part of the insulating block 18. These three electrical conductors are fastened together outwardly of the truncated, peak-shaped insulating block 18 by any suitable means such as a cord 26 wrapped around them, this cord being disposed at that point where they may be forced into a closely adjacent position to form a grouping that extends to and is connected to an electrical supply (not shown).
A cover 28 that protects the rear face of insulating block 18 is generally hexagonally shaped with an extending tail that projects from one side of the hexagon shape. This cover is placed over the rear of the insulating block 18 and abuttingly fits with three of its side edges 30, 30 and 30 against tabs 32, 34, and 36 provided integral with the peak-shaped insulating block 18. These tabs take the form of raised abutments at three corners of the block 18 and therefore conveniently locate the cover 28 relative to the block 18 when these two elements are in assembled relationship. The cover 28 is conventionally fastened to the block 18 by a rivet or screw 36 that may extend through a bore 38 in the peak-shaped insulating block 18 (FIG. 3) with a nut or a peened over rivet head (not shown) being disposed in a blind bore 40 that communicates and is coaxially aligned with the bore 38.
Referring now to FIGS. 2, 3 and 5, the three cavities generally denoted 16 are provided adjacent each corner of the block 18 to receive a connector 42 secured to the end of a motor lead wire. Each connector includes conventionally shaped clip portions 44, 44 adapted for a slip-on connection to a hermetic terminal pin, a ferrule portion 46 which is crimped onto its respective bare lead wire and generally encompasses the lead wire conductor so as to be attached to it, both physically and electrically, and an intermediate web portion 48 disposed so as to extend between ferrule portion 46 and the clip portions 44, 44. It should be noted that the web portion 48 is disposed at an acute angle to the plane of the ends of the clip portions 44, 44 so that each connector 42 can seat on a substantially similar shaped portion of the underlying cavity 16.
Each cavity 16 which receives a connector 42 includes a clip receiving opening 50 that extends between a rear face 52 and a front face 53 of the truncated peak-shaped mounting block 18. Each clip receiving opening merges with a receiving trough-shaped recess 54 in the block 18 disposed outwardly of it, relative to the sides of the mounting block. Each trough-shaped recess is open at one end to the edge of the block and open adjacent its other end to a wall 56 having its edge 58 recessed from the rear face of the block 18. The trough-shaped recess 54 that receives the ferrule portion 46 and the edge 58 are generally cut across a corner of the triangular portion of the peak-shaped block 18 with only one end of the trough-shaped recess 54 open to the edge of the block.
Each of the connectors 42 seats in a cavity 16 with its clip portions 44, 44 fitting in the clip receiving opening 50 and extends between the rear face 52 and the front face 53 of the block 18. The ferrule portion 46 lies in the trough 54 and the recessed edge 58 of the block receives the web portion 48 of the connector 42. The opening, trough and recessed edge are designed to allow freedom of movement of the connector in the cavity so that the connector is essentially self-aligning with the pins on which it is pushed to make an electrical connection.
The orientation of each of the cavities 16 is such that the lead wires emerge from the edges of the blocks in what may be aptly termed pinwheel fashion. As such, the lead wires emerge at an obtuse angle relative to the adjacent edges of the mounting block so that the flexible leads may be easily wrapped around the edges of the mounting block without departing from it.
The lead wire 12 extends from what may be considered the uppermost cavity 16 in this manner, and is then attached to an overload device 60 such as a conventional thermal sensitive device disposed within the cavity 24. A terminal 62, rigidly attached to the overload device 60, may provide an easy connection between this electrical conductor and the overload device 60. The cavity 24 is formed with a substantially semicircular shape 64 (FIGS. 3 and 6) for nearly its full linear extend. Adjacent the ends of the cavity 24, the semicircular recess 64 is terminated by means of walls 66, 66. Each of the walls 66, 66 includes extending through it, a U-shaped channel 68 which opens outwardly to the edge of the mounting block to thereby provide a guiding and alignment means for the electrical terminal which extends outwardly therethrough from the overload device 60. Of course, the opposite end of the overload device 60 includes a terminal 70 similar to the aforementioned terminal 62. This terminal (terminal 70) has attached to it the electrical connector 20, with this electrical connector taking a very sharp turn around what may be considered the bottom edge of the insulating block 18 to form one of the wires of the three wire assemblage which are tied together by the cord 26.
In order to properly transversely space the overload device 60 within the cavity 24, a semicircular groove means 72 is provided immediately between the walls 66, 66. The overload device includes, adjacent one of its ends, an integral circular flange 74 which fittingly is inserted into the semicircular groove 72 to thereby positively position the overload device 60 within the cavity 24.
With the completion of the binding of the connecting wires 10, 14 and 20, the truncated, peak-shaped insulating block 18 and the three electrical connectors extending therefrom form essentially a single assemblage which may be easily handled and engaged, for example, with a three-prong plug which may be disposed on the wall of the hermetic shell for the compressor (not shown). Such a plug is shown in FIG. 5 of U.S. Pat. No. 3,345,605 and reference may be had thereto for a more complete understanding of the manner of the connection of the electrical connector cluster assembly with overload protection of the instant invention to such a plug member.
It will be appreciated from the foregoing description that a cluster assembly with overload protection has been provided which may be easily utilized as a single assembly and plugged to a three-prong plug provided for it. Because of its construction, overload protection for a compressor is provided which is in a series relationship with one of the electrical connectors that forms the three-connector assembly. At the same time, the thickness of the cluster assembly is held to a minimal value since the electrical connectors, their terminals and the overload protection means are disposed in cavities formed in the mounting block.
Although a single embodiment of the invention has been disclosed, it will be apparent to those skilled in the art that many modifications can be made therein without exercising the inventive faculty.
1. Field of the Invention
This invention relates to an electrical connector cluster assembly with an overload means and, more specifically, relates to an electrical connector cluster assembly and an overload protection means that are adapted for connecting a hermetic compressor motor to the hermetic shell-mounted terminal of the type having three closely spaced pins with flat tabs thereon.
2. Description of the Prior Art
Although the use of an electrical connector cluster assembly of the general type herein disclosed is known and has been described, for example, in U.S. Pat. No. 3,345,605, such connector cluster assemblies have not included any means for protecting the hermetic motor from overloading and thereby overheating so that such means had to be provided somewhere else within the hermetic shell and this required a consequent additional assembly operation and the added cost required by this assembly operation. The present invention obviates such a requirement.
The nature of the instant invention may be more readily appreciated if the environment in which the collector cluster assembly with overload protection is detailed. Small hermetic compressors of the type utilized in refrigerators, freezers and air conditioners are mass produced for incorporation in millions of such appliances each year. Most manufacturers of small hermetic compressors utilize a standard hermetic terminal which carries three pin conductors sealed in an insulating relationship through the shell of the hermetic compressor. Although collector cluster assemblies have been utilized to provide a convenient connection for the leads of the compressor motor to the pins provided in the side of the hermetic shell (e.g., U.S. Pat. No. 3,345,605 ), none of these cluster assemblies have heretofore utilized an overload protection as a portion of their assembly. Thus, this overload protection had to be provided alternately in the wiring leading to the hermetic shell or provided within the hermetic enclosure, itself. In both of these cases, the assembly of the hermetic compressor and its electrical connecting wires was somewhat complicated and thereby required more time and additional costs. If an overload protection was provided within the electrical connector cluster assembly, then a large amount of assembly time could be eliminated and the overload protector means prewired into the collector cluster assembly to provide the overload requirements of the compressor motor.
SUMMARY OF THE INVENTION
In accordance with the principles of this invention, a mounting block is provided with a number of connector cavities for holding a series of connectors in a proper array to fit the pins extending from a hermetic enclosure. Connectors including their ferrules are formed to accommodate the cavities provided in the mounting block, with these cavities being arranged so that each conductor emerges from the edge of the mounting block at a location closely adjacent to the connector cavity. Disposed outwardly of the connector cavities and substantially aligned with a base of the block, is an additional cavity which is shaped so as to rigidly hold therein an overload protector element. This cavity includes a trough portion for the overload protector and a part of the terminals which extend from the overload protector, with a lead attached to one of these terminals extending to the other two wires extending from the connector block and the other of the leads extending from the opposite terminal of the overload protector around the mounting block to one of the three connectors disposed in one of the connector cavities. The cavity provided for the overload protector includes means for aligning the terminals which extend therefrom and also means formed by a substantially semiannular groove for holding the overload protector in the proper location within the cavity.
DRAWING DESCRIPTION
FIG. 1 is a plan view of the rear or cover side of a cluster assembly and overload protector according to the instant invention;
FIG. 2 is a plan view of the rear side of the mounting block with the cover removed and the connectors omitted;
FIG. 3 is a sectional side view corresponding to one taken along line III--III of FIG. 2;
FIG. 4 is a plan view of the cover for the mounting block;
FIG. 5 is a fragmentary perspective view of one corner of the mounting block with a connector for the corner cavity shown in exploded relation to the block; and
FIG. 6 is a view similar to FIG. 5, but showing the overload protector in exploded relation to its cavity.
DETAILED DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail in connection with the accompanying drawings which illustrate one embodiment thereof by way of example and wherein a connector cluster assembly 8 is shown in FIG. 1 in its assembled form with three electrical conductors 10, 12, and 14 emerging from three underlying cavities 16, 16 and 16. These cavities are situated at peripherally spaced locations about the edge of a generally truncated, peak-shaped insulating block 18, and are at equilateral angles to one another in the truncated triangular portion of the insulating block. The lead wires 10 and 12 are wrapped around the peripheral edge of the insulating block 18 from their point of emergence to form a three wire group with another wire conductor 20 that extends outwardly from a cavity 24 in the rectangular part of the insulating block 18. These three electrical conductors are fastened together outwardly of the truncated, peak-shaped insulating block 18 by any suitable means such as a cord 26 wrapped around them, this cord being disposed at that point where they may be forced into a closely adjacent position to form a grouping that extends to and is connected to an electrical supply (not shown).
A cover 28 that protects the rear face of insulating block 18 is generally hexagonally shaped with an extending tail that projects from one side of the hexagon shape. This cover is placed over the rear of the insulating block 18 and abuttingly fits with three of its side edges 30, 30 and 30 against tabs 32, 34, and 36 provided integral with the peak-shaped insulating block 18. These tabs take the form of raised abutments at three corners of the block 18 and therefore conveniently locate the cover 28 relative to the block 18 when these two elements are in assembled relationship. The cover 28 is conventionally fastened to the block 18 by a rivet or screw 36 that may extend through a bore 38 in the peak-shaped insulating block 18 (FIG. 3) with a nut or a peened over rivet head (not shown) being disposed in a blind bore 40 that communicates and is coaxially aligned with the bore 38.
Referring now to FIGS. 2, 3 and 5, the three cavities generally denoted 16 are provided adjacent each corner of the block 18 to receive a connector 42 secured to the end of a motor lead wire. Each connector includes conventionally shaped clip portions 44, 44 adapted for a slip-on connection to a hermetic terminal pin, a ferrule portion 46 which is crimped onto its respective bare lead wire and generally encompasses the lead wire conductor so as to be attached to it, both physically and electrically, and an intermediate web portion 48 disposed so as to extend between ferrule portion 46 and the clip portions 44, 44. It should be noted that the web portion 48 is disposed at an acute angle to the plane of the ends of the clip portions 44, 44 so that each connector 42 can seat on a substantially similar shaped portion of the underlying cavity 16.
Each cavity 16 which receives a connector 42 includes a clip receiving opening 50 that extends between a rear face 52 and a front face 53 of the truncated peak-shaped mounting block 18. Each clip receiving opening merges with a receiving trough-shaped recess 54 in the block 18 disposed outwardly of it, relative to the sides of the mounting block. Each trough-shaped recess is open at one end to the edge of the block and open adjacent its other end to a wall 56 having its edge 58 recessed from the rear face of the block 18. The trough-shaped recess 54 that receives the ferrule portion 46 and the edge 58 are generally cut across a corner of the triangular portion of the peak-shaped block 18 with only one end of the trough-shaped recess 54 open to the edge of the block.
Each of the connectors 42 seats in a cavity 16 with its clip portions 44, 44 fitting in the clip receiving opening 50 and extends between the rear face 52 and the front face 53 of the block 18. The ferrule portion 46 lies in the trough 54 and the recessed edge 58 of the block receives the web portion 48 of the connector 42. The opening, trough and recessed edge are designed to allow freedom of movement of the connector in the cavity so that the connector is essentially self-aligning with the pins on which it is pushed to make an electrical connection.
The orientation of each of the cavities 16 is such that the lead wires emerge from the edges of the blocks in what may be aptly termed pinwheel fashion. As such, the lead wires emerge at an obtuse angle relative to the adjacent edges of the mounting block so that the flexible leads may be easily wrapped around the edges of the mounting block without departing from it.
The lead wire 12 extends from what may be considered the uppermost cavity 16 in this manner, and is then attached to an overload device 60 such as a conventional thermal sensitive device disposed within the cavity 24. A terminal 62, rigidly attached to the overload device 60, may provide an easy connection between this electrical conductor and the overload device 60. The cavity 24 is formed with a substantially semicircular shape 64 (FIGS. 3 and 6) for nearly its full linear extend. Adjacent the ends of the cavity 24, the semicircular recess 64 is terminated by means of walls 66, 66. Each of the walls 66, 66 includes extending through it, a U-shaped channel 68 which opens outwardly to the edge of the mounting block to thereby provide a guiding and alignment means for the electrical terminal which extends outwardly therethrough from the overload device 60. Of course, the opposite end of the overload device 60 includes a terminal 70 similar to the aforementioned terminal 62. This terminal (terminal 70) has attached to it the electrical connector 20, with this electrical connector taking a very sharp turn around what may be considered the bottom edge of the insulating block 18 to form one of the wires of the three wire assemblage which are tied together by the cord 26.
In order to properly transversely space the overload device 60 within the cavity 24, a semicircular groove means 72 is provided immediately between the walls 66, 66. The overload device includes, adjacent one of its ends, an integral circular flange 74 which fittingly is inserted into the semicircular groove 72 to thereby positively position the overload device 60 within the cavity 24.
With the completion of the binding of the connecting wires 10, 14 and 20, the truncated, peak-shaped insulating block 18 and the three electrical connectors extending therefrom form essentially a single assemblage which may be easily handled and engaged, for example, with a three-prong plug which may be disposed on the wall of the hermetic shell for the compressor (not shown). Such a plug is shown in FIG. 5 of U.S. Pat. No. 3,345,605 and reference may be had thereto for a more complete understanding of the manner of the connection of the electrical connector cluster assembly with overload protection of the instant invention to such a plug member.
It will be appreciated from the foregoing description that a cluster assembly with overload protection has been provided which may be easily utilized as a single assembly and plugged to a three-prong plug provided for it. Because of its construction, overload protection for a compressor is provided which is in a series relationship with one of the electrical connectors that forms the three-connector assembly. At the same time, the thickness of the cluster assembly is held to a minimal value since the electrical connectors, their terminals and the overload protection means are disposed in cavities formed in the mounting block.
Although a single embodiment of the invention has been disclosed, it will be apparent to those skilled in the art that many modifications can be made therein without exercising the inventive faculty.