Insulation piercing wedge connector

In a wedge connector shell, the shell comprising a one-piece sheet metal member forming a receiving area for a wedge and an electrical cable, wherein the improvement comprises:

• the metal member having an insulation piercing section extending inward into the receiving area which is sized and shaped to pierce through an electrical insulation cover of the cable and make direct electrical contact with an electrical conductor of the cable, wherein the insulation piercing section comprises a tab of the sheet metal member which is folded to project inward generally perpendicular to a centerline axis of the shell, wherein the tab has teeth at a free end thereof.

In a wedge connector shell, the shell comprising a one-piece sheet metal member forming a receiving area for a wedge and an electrical cable, wherein the improvement comprises:

• the metal member having an insulation piercing section extending inward into the receiving area which is sized and shaped to pierce through an electrical insulation cover of the cable and make direct electrical contact with an electrical conductor of the cable, wherein the insulation piercing section comprises a flap of the sheet metal member that is folded about 180° into a receiving area of the shell.

A method of manufacturing a shell for an electrical wedge connector, the method comprising steps of:

• forming a flat sheet metal member into a general C-shape;
• and
• bending a section of the sheet metal member back upon itself wherein the section has a first portion directly adjacent an interior side of the general C-shape and a second portion extending in an inward direction generally perpendicular to a centerline axis of the C-shape.

An electrical wedge connector for receiving at least one insulated electrical cable and making electrical connection therewith, the cable having an inner electrical conductor section and an outer electrical insulation section, the wedge connector comprising:

• a wedge;
• and
• a shell having a receiving area suitably sized and shaped to receive the wedge and the cable therein with the cable being sandwiched between the wedge and a curved wall of the shell, the curved wall having at least one insulation piercing section, each insulation piercing section extending transverse to a path of insertion of the wedge into the shell and comprising a tab extending inwardly from the curved wall, the tab comprising a set of multiple piercers protruding inwardly, wherein each set of piercers extends from the curved wall in a row transverse to the path of insertion of the wedge into the shell.