US 5,488,268 AGranted

Electrical connector with improved centering of mating terminal pins, for a fluorescent-lighting ballast

AssigneeMagneTek, Inc.

InventorsFred P. Bauer, Stuart E. Sanders, Raymond H. Van Wagener, Mark R. Opperthauser

Life of this patent

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Abstract

One half-connector terminates a set of leads in the ballast, for carrying electrical power to and from the ballast coils. Another half-connector terminates another set of leads outside the ballast, connected e.g. to carry power to lamp sockets. Male contacts, preferably formed very inexpensively as bared ends of one set of leads, are held in a first of the half-connectors; female contacts, connected to the other set of leads, are held in a second of the two half-connectors. Through-holes in the second half-connector each hold one female contact; each hole has a necked-down section, forward from the contact, and some device (preferably an ultrasonically displaced slug) to retain the contact. In one aspect of the invention, each hole also has a bore whose transverse preformed dimension is biggest immediately rearward from the necked-down forward section. In a second aspect of the invention, each necked-down section has a large-mouthed funnel to guide even a badly bent male contact into the female contact, accommodating weak tips of the bared wire ends. The first aspect of the invention enables low-cost use of the second.

Claims29

Dependent claims

In combination, a ballast and connecting apparatus for use in a fluorescent-lamp fixture having lamp sockets;

said combination comprising:
at least one electrical winding mounted within the ballast;
two pluralities of electrical leads within the fluorescent-lamp fixture:
one plurality of electrical leads within the ballast and operatively connected to the winding, for carrying electrical power to and from the winding, and
another plurality of electrical leads extending through such fixture substantially outside the ballast, at least some of these leads being operatively connected with lamp sockets of such fixture for carrying electrical power to the sockets;
two mutually matable electrical half-connectors, one for terminating said one plurality of leads and another for terminating said other plurality of leads;
a plurality of individual electrical male contacts, formed from or operatively connected to one of the two pluralities of electrical leads respectively, and fixed within a first of the two half-connectors;
a plurality of individual electrical female contacts, operatively connected to the other of the two pluralities of electrical leads respectively, and fixed within a second of the two half-connectors;
a plurality of through-holes defined within the second half-connector, each said through-hole holding a respective one of the female contacts, and each through-hole having:
a rearward end for receiving insertion of one female contact,
a forward end for receiving insertion of a part of one male contact, extending from the first half-connector, into the female contact to complete connections from the ballast winding to the lamp sockets,
a necked-down section, forward from a forward tip of the female contact in that hole, and
a preformed bore whose transverse preformed dimensions along the entire length of the bore rearward from the necked-down forward section are at least as great as its transverse dimensions immediately rearward from the necked-down forward section;
and
means for retaining each female contact in its respective bore.

12 more elements

In combination, a ballast and connecting apparatus for use in a fluorescent-lamp fixture having lamp sockets;

said combination comprising:
at least one electrical winding mounted within the ballast;
two pluralities of electrical leads within the fluorescent-lamp fixture:
one plurality of electrical leads within the ballast and operatively connected to the winding, for carrying electrical power to and from the winding, and
another plurality of electrical leads extending through such fixture substantially outside the ballast, at least some of these leads being operatively connected with lamp sockets of such fixture for carrying electrical power to the sockets;
two mutually matable electrical half-connectors, one for terminating said one plurality of leads and another for terminating said other plurality of leads;
a plurality of individual electrical male contacts, formed from or operatively connected to one of the two pluralities of electrical leads respectively, and fixed within a first of the two half-connectors;
a plurality of individual electrical female contacts, operatively connected to the other of the two pluralities of electrical leads respectively, and fixed within a second of the two half-connectors;
a plurality of through-holes defined within the second half-connector, each said through-hole holding a respective one of the female contacts, and each through-hole having:
a rearward end for receiving insertion of one female contact,
a forward end for receiving insertion of a part of one male contact, extending from the first half-connector, into the female contact to complete connections from the ballast winding to the lamp sockets,
a necked-down section, forward from a forward tip of the female contact in that hole, and
a funnel-shaped forward opening, defined in a forward face of the necked-down forward section, for guiding said part of the corresponding male contact into the female contact;
and
means for retaining each female contact in its respective hole.

12 more elements

Dependencies are inferred from the claim text.

Facts

Application: 08/224,811Filed 8 Apr 1994 · continuation in part
Priority: 4 Apr 1991
Granted: 30 Jan 1996
Term ends: Not estimatedThe source records don’t support an estimate.

Classification7 codes

H01R 13/6633
With built-in single component: with inductive component, e.g. transformer
H01F 38/10
High-leakage transformers or inductances: ballasts, e.g. for discharge lamps
H01R 24/76
Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure: with sockets, clips or analogous…
H01R 13/627
Means for facilitating engagement or disengagement of coupling parts or for holding them in engagement: snap or like fastening

Family

Serial680,699Parent of this continuation-in-part · filed 4 Apr 1991
Serial9,645Parent of this continuation-in-part · filed 14 May 1993
US 5,260,678 AParent of this continuation-in-part · filed 9 Nov 1993
US 5,350,316 AParent of this continuation-in-part · filed 27 Sep 1994
US 5,488,268 AThis patent

From the US filing history. Foreign family members aren’t listed.