U.S. patent number 3,699,498 [Application Number 05/033,211] was granted by the patent office on 1972-10-17 for devices for making electrical connections.
This patent grant is currently assigned to Bell Telephone Laboratories Incorporated, Western Electric Company Incorporated. Invention is credited to Edwin C. Hardesty, Charles L. Krumreich, Albert E. Mulbarger, Jr., Stephen W. Walden.
United States Patent |
3,699,498 |
Hardesty , et al. |
October 17, 1972 |
DEVICES FOR MAKING ELECTRICAL CONNECTIONS
Abstract
Identical miniature plugs are attached to both ends of a
telephone cord. The plugs are mated with miniature jacks in the
handset and in the base of a telephone. A plurality of stand-up,
blade terminals are positioned in spaced troughs of a housing of
the plug with each of the terminals having tangs that pierce the
insulation of insulated tinsel conductors of the cord placed in the
troughs and pressed into engagement with the tangs by associated
ribs formed in a lid of the housing which is welded ultrasonically
to the housing. The mating jack has a plurality of U-shaped
stand-up, blade terminals with provisions similar to the plug for
making electrical contact with conductors leading into the jack.
One leg of each of the U-shaped terminals of the jack is caused to
engage an associated one of the terminals in the plug when the plug
is inserted into the jack. The plug and the jack have facilities
for providing strain relief for both the cords and the individual
conductors.
Inventors: |
Hardesty; Edwin C. (Perry Hall,
MD), Krumreich; Charles L. (Indianapolis, IN), Mulbarger,
Jr.; Albert E. (Indianapolis, IN), Walden; Stephen W.
(Morral Township, Shelby County, IN) |
Assignee: |
Bell Telephone Laboratories
Incorporated (Berkeley Heights, NJ)
Western Electric Company Incorporated (New York,
NY)
|
Family
ID: |
26709425 |
Appl.
No.: |
05/033,211 |
Filed: |
April 30, 1970 |
Current U.S.
Class: |
439/248; 439/345;
379/438; 439/873; 379/428.01 |
Current CPC
Class: |
H01R
24/62 (20130101) |
Current International
Class: |
H01R
13/00 (20060101); H01R 13/46 (20060101); H01R
13/62 (20060101); H04M 1/00 (20060101); H01r
013/62 () |
Field of
Search: |
;339/65,64,66,91,97-99,103,107,206-208,210-211,213,217,221,47-49 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
Machine Design, "Ultrasonic Assembly", Kolb, 3-1967, pages
180-185..
|
Primary Examiner: McGlynn; Joseph H.
Claims
What is claimed is:
1. A device for making an electrical connection, which
comprises:
a plug assembly which includes,
mating dielectric parts having facilities for receiving a plurality
of conductors to confine and separate the conductors, one of the
mating parts having terminal-receiving facilities formed therein;
and
a plurality of electrically conductive terminals received in
associated ones of the terminal-receiving facilities of the one of
the mating parts, each of the terminals having a portion thereof
which extends into the associated one of the conductor-receiving
facilities of the one part and which includes means for engaging
electrically and for retaining engagement with associated ones of
the conductors positioned in the assembly when the parts are
mated;
the other one of the mating parts having means formed thereon for
causing the engaging means of the portions of the terminals to
engage electrically the associated ones of the conductors when the
parts are mated, and
a jack assembly designed to be mated with the plug assembly which
includes,
mating dielectric parts having facilities for receiving a plurality
of conductors and confining individually the conductors, one of the
mating parts having walls which define terminal-receiving passages,
the walls of portions of the passages designed to permit a
predetermined lateral deflection of the associated portions of the
associated terminals, the jack assembly having a cavity
complementary to at least portions of the plug assembly to permit
insertion of at least portions of the plug assembly into the jack
assembly, and
a plurality of electrically conductive terminals having at least
portions thereof received in the terminal-receiving passages, each
of the terminals of the jack assembly having a portion thereof
which extends into the associated one of the conductor-receiving
facilities and which includes means for engaging electrically and
being retained in engagement with the conductors positioned therein
when the parts of the jack assembly are mated,
the other one of the mating parts having means formed thereon for
causing the engaging means of the portions of the terminals to
engage electrically the associated ones of the conductors when the
parts are mated, and
portions of the terminals of the jack assembly being received in
the associated ones of the terminal-receiving facilities of the
plug assembly and caused to engage electrically with associated
terminals in the plug assembly when the plug assembly is inserted
into the cavity of the jack assembly,
the terminals mounted in the jack assembly having at least a
portion thereof anchored in the jack assembly and the portion
thereof which engages the associated terminal in the plug assembly
being received in the portions of the associated passage and
designed to have a predetermined lateral deflection to facilitate
the mating of the plug and jack assemblies and to maintain the
terminals of the jack assembly in electrical engagement with the
associated terminals of the plug assembly.
2. The device for making an electrical connection as set forth in
claim 1, wherein:
the mating dielectric parts of the plug assembly include means for
providing strain relief for the plurality of conductors and for
individual ones of the conductors positioned therein, and
the mating dielectric parts of the jack assembly includes
facilities for providing strain relief for the conductors
positioned therein.
3. An electrical connector as set forth in claim 1 wherein:
the one of the dielectric parts of the jack assembly is provided
with means formed transversely of the associated terminals for
supporting the associated terminals to prevent unintended relative
longitudinal movement between the terminals and the one dielectric
part of the jack assembly, and
each of the terminals associated with the jack assembly is
configured to be seated in engagement with the associated
supporting means to support the terminals against unintended
longitudinal movement when the plug assembly is inserted into the
cavity in the jack assembly.
4. The device for making an electrical connection of claim 1, which
further comprises:
means formed on at least one of the parts of the plug assembly and
on at least one of the parts of the jack assembly for concentrating
bonding energy and facilitating the bonding together ultrasonically
of parts of the plug assembly and the bonding together
ultrasonically of the parts of the jack assembly.
5. The device for making an electrical connection of claim 1, which
further comprises:
releasable latching means associated with the plug assembly and the
jack assembly for securing together the plug and jack assemblies to
prevent unintended uncoupling thereof.
6. A device for making an electrical connection, which
comprises:
a first unit which includes,
a first dielectric part having a plurality of conductor-receiving
troughs for receiving associated ones of a plurality of associated
conductors and having a plurality of terminal-receiving grooves
opening on a surface and communicating with the conductor-receiving
troughs; and
a second dielectric part designed to be mated with the first part
and having ribs extending from one surface thereof and received in
associated ones of the conductor-receiving troughs of the first
part when the second part is mated to the first part to confine the
conductors positioned therein between the rib and first part;
a plurality of first terminals inserted into the terminal-receiving
grooves of the first part, the first terminals having contact
portions and having conductor-input portions extending into the
associated one of the conductor-receiving troughs and which
includes means for engaging electrically and for retaining
engagement with the conductor positioned in the associated trough
when the second part is mated to the first part;
the ribs on the second dielectric part of the first unit being
effective to cause the engaging means of the portions of the
terminals to engage electrically the associated ones of the
conductors when the parts are mated, and
a second unit adapted to be mated with the first unit and which
includes,
a first dielectric part having a cavity complementary to at least
portions of the first unit designed to be received in the cavity,
the first part of the second unit having a plurality of
terminal-receiving grooves opening to an external surface thereof
for receiving associated ones of a plurality of associated
conductors, the first part also including a plurality of internal
grooves aligned with the terminal-receiving grooves and facing into
the cavity, the internal grooves cooperating with the
terminal-receiving grooves to define terminal-receiving passages,
and
a second dielectric part adapted to be mated with the first part of
the second unit, and having ribs formed thereon which project into
the associated ones of the terminal-receiving grooves to confine
the conductors between the ribs and the first part of the second
unit when the second part of the second unit is mated with the
first part of the second unit; and
a plurality of second terminals designed to be positioned in the
terminal-receiving passages and having conductor-engaging portions
which terminate in the terminal-receiving grooves and which
includes means for engaging electrically and for retaining in
engagement with the conductors positioned in the terminal-receiving
grooves when the second part of the second unit is mated to the
first part thereof,
the ribs on the second dielectric part of the second unit being
effective to cause the engaging means of the portions of the
terminals to engage electrically the associated ones of the
conductors when the parts are mated, and
each of the second terminals having a portion thereof anchored in
the second unit when the second part of the second unit is mated
with the first part of the second unit, and having a contact
portion adapted to be received in the associated internal groove of
the first part of the second unit and being capable of flexure,
with the deflection of the contact portion of the second terminal
being limited to within the associated internal groove,
at least portions of the first unit being insertable into the
cavity of the second unit to cause the contact portion of the
second terminal in the internal groove to be moved into the
associated terminal-receiving groove of the first unit to engage
the contact portion of the first terminal therein and establish and
maintain electrical connection therebetween.
7. A device for making an electrical connection, which
comprises:
a first assembly, which includes
a first subassembly which includes,
a first dielectric part having a passage formed therethrough with a
plurality of parallel longitudinally formed partitions projecting
into the passage to form a plurality of elongated
conductor-receiving troughs for confining and separating associated
individual conductors designed to be received therein against
lateral movement in the passage and having a plurality of
terminal-receiving grooves opening on a surface of the first part
and communicating with associated ones of the conductor-receiving
troughs, each of the terminal-receiving grooves having a flared
entrance opening on the surface of the first part extending
transverse to the other surface, each of the terminal-receiving
grooves having a restriction at one end and a shoulder projecting
transversely of and into the entrance at the other end; and
a second dielectric part having a plurality of ribs formed on one
surface thereof, the second part designed to be mated with the
first part with the ribs interposed between associated ones of the
partitions and extending into associated ones of the
conductor-receiving troughs for confining further transverse
movement of associated conductors; and
a plurality of first electrically conductive terminals mounted in
associated ones of the terminal-receiving grooves of the first part
and having one end in engagement with the shoulder and the other
end received in the restriction to confine the opposite ends of the
terminal,
each of the first terminals having barbs formed integrally
therewith on the ends thereof penetrating the material defining the
groove to secure the first terminals within the first part, and
having contact portions formed thereon protruding into the
associated ones of the conductor-receiving troughs so that when the
second part is mated with the first part and the ribs confine the
conductors positioned in the associated ones of the troughs, the
contact portions of the associated first terminals become engaged
electrically with the conductors,
each of the first terminals having a crown formed thereon for
engaging the opposed wall of the associated terminal-receiving
groove to maintain the terminal in engagement with the adjacent
wall of the associated terminal-receiving groove; and a second
assembly which includes,
a second subassembly including
a first dielectric part having a cavity complementary to at least
portions of the first subassembly designed to be received in the
cavity, the first part of the second subassembly having a plurality
of terminal-receiving grooves opening to an external surface
thereof and adapted to receive insulated conductors, and having a
plurality of internal grooves formed in one of the surfaces thereof
which face into the cavity, are aligned with associated ones of the
terminal-receiving grooves and extend transverse to the external
surface to cooperate with the associated terminal-receiving grooves
to define terminal-receiving passages, and
a second dielectric part, adapted to be mated with the first part
of the second subassembly having a plurality of ribs formed on one
surface thereof, the ribs being received in associated ones of the
grooves when the second part of the second subassembly is mated
with the first part of the second subassembly, and
a plurality of second electrically conductive terminals, each
having first and second legs, and designed to be positioned in the
terminal-receiving passages and having contact portions formed on
the first legs thereof which extend laterally of the associated
first legs and terminate in portions of the associated grooves
designed to receive associated conductors so that when the
conductors are positioned in the associated grooves and the second
part of the second subassembly is mated with the first part of the
second subassembly, the ribs confine the conductors and the contact
portions become engaged electrically therewith,
the second legs of the second terminals extending into the cavity
and being confined in associated ones of the internal grooves to
engage the associated one of the first terminals when the first
assembly is inserted into the cavity longitudinally of the
associated second legs of the second terminals,
the second terminals being anchored in the first part of the second
subassembly with the free ends of the second legs of the terminals
extending into the cavity and being designed to be capable of
deflection transversely, the transverse movement of the free ends
of the second legs being restricted by the associated internal
grooves to prevent misalignment of the second terminals and
facilitate insertion of the contact portion of each of the second
terminals into an associated one of the terminal-receiving grooves
in the first part of the first subassembly,
each of the second terminals having first and second crowns
projecting from opposite sides thereof the second crown being
adapted to engage the opposed wall of the associated
terminal-receiving groove in the first subassembly to urge the
associated first crown projecting from the other side of the second
terminal into engagement with the associated first terminal.
8. The device for making an electrical connection as set forth in
claim 7, which further comprises:
complementary means formed on the first and second parts of the
first subassembly transversely of the troughs for clamping a
plurality of the conductors therebetween and for anchoring
individual ones of the conductors to provide strain relief for the
plurality of conductors and for the individual ones of the
conductors; and
complementary means formed on the first and second parts of the
second subassembly for providing strain relief for the conductors
positioned therein.
9. The device for making an electrical connection as set forth in
claim 7, which further includes
the first part of the second subassembly is provided with means
formed transversely of the second terminals for supporting the
second terminals to prevent unintended relative longitudinal
movement between the terminals and the first part of the second
subassembly; and
each of the second terminals is configured to be seated in
engagement with the supporting means when the second terminals are
inserted into the terminal-receiving passages so that when the
first assembly is inserted into the second assembly, the second
terminals are supported against unintended longitudinal
movement.
10. The device for making an electrical connection as set forth in
claim 7, wherein:
the thickness of each of the first terminals plus the overall
thickness of the second terminals, including the projecting
dimensions of the first and second crowns, is greater than the
width of the terminal-receiving groove of the first part of the
first assembly to cause the second leg of each of the second
terminals to assume a serpentine configuration when the second leg
is caused to be moved into the associated one of the
terminal-receiving grooves and insure that the second crown thereof
presses into the opposed walls of the terminal-receiving groove and
that the first crown engages the associated first terminal with
sufficient pressure to establish adequate electrical contact
therebetween.
11. The device for making an electrical connection as set forth in
claim 7, wherein:
the contact portions formed on the first and second electrically
conductive terminals includes at least two tangs spaced along one
edge of each of the terminals, each of the tangs being
substantially wedge-shaped with a base thereof integral with the
main body portion of the terminal and with an apex thereof external
of the main body portion, each of the tangs being coined on one
side thereof, with the distance between the apices of the tangs as
measured orthogonally of the plane of the terminal being
predetermined to insure penetration of insulated conductors
positioned in the troughs and in the terminal-receiving grooves
when the second parts of the first and second dielectric
subassemblies are mated with the first parts of the first and
second dielectric subassemblies respectively.
12. The device for making an electrical connection as set forth in
claim 7, wherein:
the second leg of each of the second electrically conductive
terminals is formed with a portion thereof adjacent the free end
being bent out of the plane of the terminal to bias the first crown
thereof toward the first terminal in the associated
terminal-receiving groove to pre-align the free end thereof with
the flared entrance to facilitate the mating of the terminals with
the first assembly and to urge the bent portions of the second legs
toward the plane of the associated first terminals to create
adequate pressure contact between the first and second
terminals.
13. The device for making an electrical connection as set forth in
claim 7, which further comprises:
releasable latching means associated with the first and second
subassemblies and rendered effective subsequent to the insertion of
the at least portions of the first assembly into the cavity of the
second assembly for securing together the first and second
assemblies to prevent unintended uncoupling thereof.
14. The device for making an electrical connection, defined in
claim 7, and which further comprises:
the first part of the second subassembly having an overhanging
portion extending into the cavity thereof and having a slot cut
therein,
the second part of the first subassembly having a pair of spaced
latch-receiving grooves opening to the one surface thereof, one of
the ribs of the second part of the first subassembly having a lip
formed integrally therewith and extending partially transversely of
one of the latch-receiving grooves to overhang partially the one of
the latch-receiving grooves, further, the second part of the first
subassembly having a U-shaped slot formed in another surface
opposed to the one surface opening to a free end of the second part
and having a second slot connected to the U-shaped slot and opening
to a conductor-input end of the second part,
the first part of the first subassembly having spaced apertures
opening to said passage; and
a latch made of a resilient material and including a pair of
securing fingers each having an upstanding portion at one end
thereof, each of the securing fingers connected to a leg portion
extending reversely angularly of the associated securing finger,
each of the leg portions having a transversely extending arm
portion, the arm portions projecting toward one another, each one
of the arm portions connected to one end of a U-shaped release tab
designed to be received in the slot in the overhanging portion, the
latch being assembled to the second part of the first subassembly
with one of the securing fingers being urged past the lip to seat
the one securing finger in the associated one of the
latch-receiving grooves between the lip and the bottom of the
groove and with the other securing finger received in the other one
of the latch-receiving grooves, the upstanding portions projecting
externally of the second part, oriented toward the conductor-input
end of the second part of the first subassembly and being received
in the apertures of the first part to prevent unintended
longitudinal movement of the latch, the connection of the securing
fingers to the leg portions being oriented toward the end of the
second part which is the leading end moved into the cavity of the
second assembly, the release tab oriented toward the
conductor-input end of the second part of the first subassembly,
the device being assembled by depressing the release tab to move
the leg portions and the arm portions into the U-shaped slot and
the release tab into the second slot and causing relative movement
between the first and second assemblies to move the first assembly
into mating engagement with the second assembly whereafter the
release tab is permitted to be returned resiliently to a normal
position angled to the securing fingers to move the arm portions
thereof behind the overhanging portion to prevent unintended
uncoupling of the assemblies and to protrude angularly the release
tab through the slot in the overhanging portion.
15. The connector of claim 7, wherein the second electrically
conductive terminals are terminals being substantially U-shaped in
form and designed to be positioned in the grooves and having
contact tangs formed on the legs thereof which extend laterally of
the associated legs and terminate in portions of the associated
grooves designed to receive associated conductors so that when the
conductors are positioned in the associated grooves and the second
part of the second dielectric subassembly is mated with the first
part of the second dielectric subassembly, the ribs confine the
conductors and the tangs pierce the insulation of the conductors
and become engaged electrically therewith, the opposite legs of the
second terminals extending into the cavity and being confined in
associated ones of the internal grooves to engage the associated
one of the first terminals when the first dielectric subassembly is
inserted into the cavity longitudinally of the associated legs of
the second terminals, the second terminals being anchored in the
first part of the second dielectric subassembly with the free ends
of the legs of the terminals extending into the cavity being free
to be defected transversely, the transverse movement of the free
ends of the leg portions being restricted by the associated
internal grooves to prevent misalignment of the terminals and
facilitate insertion of the contact portion of each of the second
terminals into an associated one of the terminal-receiving grooves
in the first part of the first dielectric subassembly, each of the
second terminals having a first and a second crown projecting from
opposite sides thereof, the second crown being adapted to engage
the opposed wall of the associated terminal-receiving groove in the
first dielectris subassembly to urge the associated first crown
projecting from the other side of the second terminal into
engagement with the associated first terminal.
16. The device for making an electrical connection as set forth in
claim 7, wherein:
the first terminals are assembled to the first part of the first
subassembly with the edges thereof which are adjacent the surface
of the first part of the first dielectric subassembly being within
the terminal-receiving grooves thereof,
the internal grooves in the first part of the second subassembly
being defined by walls having edge surfaces which face into the
cavity and which are transverse to side surfaces of the walls;
and
the second terminals are assembled to the first part of the second
subassembly with portions of the second legs thereof protruding
beyond the edge surfaces of the walls of the internal grooves of
the first part and into the cavity, the protruding portions being
received in associated ones of the terminal receiving grooves of
the first assembly when the first and second assemblies are mated
together and the surface of the first part of the first subassembly
engages the edge surfaces of the walls of the internal grooves.
17. The device for making an electrical connection as set forth in
claim 16, wherein:
the first terminals are assembled to the first part of the first
subassembly with the edges thereof which are adjacent the surface
of the first part of the first dielectric subassembly being flush
therewith.
18. An electrical connector, which comprises:
a first assembly which includes
a first dielectric subassembly which includes
a first part having a passage formed there-through with a plurality
of parallel longitudinally formed partitions projecting into the
passage to form a plurality of elongated conductor-receiving
troughs for confining associated individual conductors designed to
be received therein against lateral movement in the passage and
having a plurality of terminal-receiving grooves opening on a
surface of the first part and communicating with associated ones of
the conductor-receiving troughs, each of the terminal-receiving
grooves having a flared entrance opening on the surface of the
first part extending transverse to the other surface, each of the
terminal-receiving grooves having a restriction at one end and a
shoulder projecting transversely of and into the entrance at the
other end, the first part having a raised portion formed
transversely of the longitudinal axes of the passage and projecting
into the passage, and having a transversely extending channel in
the passage interposed between the raised portion and the troughs,
and
a second part having a plurality of ribs formed on one surface
thereof, the second part designed to be mated with the first part
with the ribs interposed between associated ones of the partitions
and extending into associated ones of the conductor-receiving
troughs for confining further transverse movement of associated
conductors, the second part also including a raised portion formed
transversely of the part and to cooperate with the raised portion
of the first part to clamp a plurality of the conductors
therebetween when the second part is mated with the first part, and
further having a ridge formed transversely of the ribs and
interposed between the ribs and the raised portion thereof for
cooperating with the channel of the first part to clamp the
conductors between the ridge and the channel when the second part
is mated with the first part to anchor the individual conductors;
and
a plurality of first electrically conductive terminals mounted in
associated ones of the terminal-receiving grooves of the first part
of the first dielectric subassembly and having one end in
engagement with the shoulder and the other end received in the
restriction to confine the opposite ends of the terminal, each of
the first terminals having barbs formed integrally therewith on the
ends thereof penetrating the material defining the grooves to
secure the first terminals within the first part, and having
contact tangs formed thereon protruding into the associated ones of
the conductor-receiving troughs so that when the second part is
mated with the first part and the ribs confine the conductors in
the associated ones of the troughs, the contact tangs on the
associated first terminals pierce the insulation of the associated
conductors and become engaged electrically with the conductors,
each of the first terminals having a crown formed thereon for
engaging the opposed wall of the associated terminal-receiving
groove to maintain the terminal in engagement with the adjacent
wall of the associated terminal-receiving groove; and a second
assembly which includes
a second dielectric subassembly including
a first part having a cavity complementary to at least portions of
the first dielectric subassembly designed to be received in the
cavity, the first part of the second dielectric subassembly having
a plurality of terminal-receiving grooves opening to two adjacent
transversely extending external surfaces thereof, the grooves
adapted to receive insulated conductors, and a plurality of
internal grooves formed in one of the surfaces thereof which face
into the cavity, are aligned with associated ones of the
terminal-receiving grooves on the transverse surfaces and extend
parallel to one of the transverse surfaces and transverse to the
other to cooperate with the associated terminal-receiving groove to
define generally U-shaped terminal-receiving passages, and
a second part, adapted to be mated with the first part of the
second dielectric subassembly having a plurality of ribs formed on
one surface thereof, the ribs being received in associated ones of
the grooves when the second part is mated with the first part of
the second dielectric subassembly, and
a plurality of second electrically conductive terminals being
substantially U-shaped in form and and designed to be positioned in
the U-shaped passages and having contact tangs formed on the legs
thereof which extend laterally of the associated legs and terminate
in portions of the associated grooves designed to receive
associated conductors so that when the conductors are positioned in
the associated grooves and the second part of the second dielectric
subassembly is mated with the first part of the second dielectric
subassembly, the ribs confine the conductors and the tangs pierce
the insulation of the conductors and become engaged electrically
therewith, the opposite legs of the second terminals extending into
the cavity and being confined in associated ones of the internal
grooves to engage the associated one of the first terminals when
the first dielectric subassembly is inserted into the cavity
longitudinally of the associated legs of the U-shaped second
terminals, the second terminals being anchored in the first part of
the second dielectric subassembly with the free ends of the legs of
the U-shaped terminals extending into the cavity being free to be
defected transversely, the transverse movement of the free ends of
the leg portions being restricted by the associated internal
grooves to prevent misalignment of the terminals and facilitate
insertion of the contact portion of each of the second terminals
into an associated one of the terminal-receiving grooves in the
first part of the first dielectric subassembly, each of the second
terminals having a first and a second crown projecting from
opposite sides thereof, the second crown being adapted to engage
the opposed wall of the associated terminal-receiving groove in the
first dielectric subassembly to urge the associated first crown
projecting from the other side of the second terminal into
engagement with the associated first terminal.
19. The connector of claim 18, wherein the internal grooves formed
in one of the surfaces which face into the cavity of the second
dielectric subassembly of the second assembly are formed in that
surface which is the least distance from the parallel external
surface thereof having the terminal-receiving grooves formed
therein.
20. The connector of claim 18, wherein the internal grooves formed
in one of the surfaces which face into the cavity of the second
dielectric subassembly of the second assembly are formed in that
surface which is most distant from the parallel external surface
thereof having the terminal-receiving grooves formed therein.
21. An electrical connector, which comprises:
a first assembly which includes,
a first dielectric subassembly which includes,
a first part having a passage formed therethrough with a plurality
of parallel longitudinally formed partitions projecting into the
passage to form a plurality of elongated conductor-receiving
troughs for confining associated individual conductors designed to
be received therein against lateral movement in the passage and
having a plurality of terminal-receiving grooves opening on a
surface of the first part and communicating with associated ones of
the conductor-receiving troughs, each of the terminal-receiving
grooves having a flared entrance opening on the surface of the
first part extending transverse to the other surface, each of the
terminal-receiving grooves having a restriction at one end and a
shoulder projecting transversely of and into the entrance at the
other end, the first part having a raised portion formed
transversely of the longitudinal axes of the passage and projecting
into the passage, and having a transversely extending channel in
the passage interposed between the raised portion and the troughs,
and
a second part having a plurality of ribs formed on one surface
thereof, the second part designed to be mated with the first part
with the ribs interposed between associated ones of the partitions
and extending into associated ones of the conductor-receiving
troughs for confining further transverse movement of associated
conductors, the second part also including a raised portion formed
transversely of the part and to cooperate with the raised portion
of the first part to clamp a plurality of the conductors
therebetween when the second part is mated with the first part, and
further having a ridge formed transversely of the ribs and
interposed between the ribs and the raised portion thereof for
cooperating with the channel of the first part to clamp the
conductors between the ridge and the channel when the second part
is mated with the first part to anchor the individual conductors;
and
a plurality of first electrically conductive terminals mounted in
associated ones of the terminal-receiving grooves of the first part
of the first dielectric subassembly and having one end in
engagement with the shoulder and the other end received in the
restriction to confine the opposite ends of the terminal, each of
the first terminals having barbs formed integrally therewith on the
ends thereof penetrating the material defining the groove to secure
the first terminals within the first part, and having contact tangs
formed thereon protruding into the associated ones of the
conductor-receiving troughs so that when the second part is mated
with the first part and the ribs confine the conductors in the
associated ones of the troughs, the contact tangs on the associated
first terminals pierce the insulation of the associated conductors
and become engaged electrically with the conductors, each of the
first terminals having a crown formed thereon for engaging the
opposed wall of the associated terminal-receiving groove to
maintain the terminal in engagement with the adjacent wall of the
associated terminal-receiving groove; and
a second assembly which includes
a second dielectric subassembly including
a first part having a cavity complementary to at least portions of
the first dielectric subassembly designed to be received in the
cavity, the first part of the second dielectric subassembly having
a plurality of terminal-receiving grooves opening to two adjacent
transversely extending external surfaces thereof, the grooves
adapted to receive insulated conductors and a plurality of internal
grooves formed in one of the surfaces thereof which face into the
cavity are aligned with associated ones of the terminal-receiving
grooves, on the transverse surfaces and extend parallel to one of
the transverse surfaces and transverse to the other to cooperate
with the associated terminal-receiving groove to define generally
U-shaped terminal-receiving passages, and
a second part, adapted to be mated with the first part of the
second dielectric subassembly, having a plurality of ribs formed on
one surface thereof, the ribs being received in associated ones of
the grooves when the second part is mated with the first part of
the second dielectric subassembly, and
a plurality of substantially U-shaped electrically conductive
terminals designed to be positioned in the U-shaped passages and
having contact tangs formed on the legs thereof which extend
laterally of the associated legs and terminate in portions of the
associated grooves designed to receive associated conductors so
that when the conductors are positioned in the associated grooves
and the second part of the second dielectric subassembly is mated
with the first part of the second dielectric subassembly, the ribs
confine the conductors and the tangs pierce the insulation of the
conductors and become engaged electrically therewith, the opposite
legs of the U-shaped terminals extending into the cavity and bring
confined in associated ones of the internal grooves to engage the
associated one of the first terminals when the first dielectric
subassembly is inserted into the cavity longitudinally of the
associated legs of the U-shaped terminals having the contact tangs
formed thereon being anchored in the first part of the second
dielectric subassembly, the portion of each of the U-shaped
terminals connecting the legs thereof being free to be twisted
about a joint with the leg having the tangs formed thereon and with
the free ends of the opposite legs of the U-shaped terminals
extending into the cavity being free to be defected transversely,
the transverse movement of the free ends of the leg portions being
restricted by the associated internal grooves to prevent
misalignment of the terminals and facilitate insertion of the
contact portion of each of the U-shaped terminals into an
associated one of the terminal-receiving grooves in the first part
of the first dielectric subassembly, each of the U-shaped terminals
having first and second crowns projecting from opposite sides
thereof the second crown being adapted to engage the opposed wall
of the associated terminal-receiving groove in the first dielectric
subassembly to urge the associated first crown projecting from the
other side of the U-shaped terminal in engagement with the
associated first terminal.
22. An electrical connector as set forth in claim 21, wherein:
the U-shaped terminals are made from a flat sheet of electrically
conductive material having a thickness t and formed so that the
thickness t is measured along a line perpendicular to the plane of
the U, the dimensions of the terminals in the plane of the U being
substantially greater than the thickness.
23. A plug assembly, which comprises:
a first dielectric part having a passage formed therethrough with a
plurality of parallel longitudinally formed partitions projecting
into the passage to form a plurality of elongated
conductor-receiving troughs for confining associated individual
conductors designed to be received therein against lateral movement
in the passage and having a plurality of terminal-receiving grooves
opening on a surface of the first part and communicating with
associated ones of the conductor-receiving troughs, each of the
terminal-receiving grooves having a flared entrance opening on the
surface of the first part extending transverse to the other
surface, each of the terminal-receiving grooves having a
resstriction at one end and a shoulder projecting transversely of
and into the entrance at the other end,
a second dielectric part having a plurality of ribs formed on one
surface thereof, the second part designed to be mated with the
first part with the ribs interposed between associated ones of the
partitions and extending into associated ones of the
conductor-receiving troughs for confining further transverse
movement of associated conductors; and
a plurality of electrically conductive terminals mounted in
associated ones of the terminal-receiving grooves of the first part
and having one end in engagement with the shoulder and the other
end received in the restriction to confine the opposite ends of the
terminal, each of the terminals having barbs formed integral
therewith on the ends thereof penetrating the material defining the
groove to secure the terminals within the first part, and having
contact portions formed thereon protruding into the associated ones
of the conductor-receiving troughs so that when the second part is
mated with the first part, the ribs confine the conductors in the
associated ones of the trough and cause the contact portions of the
associated first terminals to become engaged electrically with the
associated ones of the conductors, each of the terminals having a
crown formed thereon engaging the opposed wall of the associated
terminal-receiving groove to maintain the terminal in engagement
with the adjacent wall of the associated terminal-receiving
groove.
24. A plug assembly as defined in claim 23, which includes:
complementary means formed on the first and second dielectric parts
transversely of the troughs for clamping a plurality of the
conductors therebetween and for anchoring individual ones of the
conductors to provide strain relief for the plurality of conductors
and for the individual ones of the conductors.
25. A plug assembly as defined in claim 23, wherein:
the terminals are assembled to the first part with the edges
thereof which are adjacent the surface of the first part being
within the terminal-receiving grooves thereof.
26. A plug assembly as defined in claim 23, wherein:
the contact portion formed on the terminals includes at least two
tangs spaced along one edge of each of the terminals, each of the
tangs being substantially wedge-shaped with a base thereof integral
with the main body portion of the terminal and with an apex thereof
external of the main body portion, each of the tangs being coined
on one side thereof, with a distance between the apices of the
tangs as measured orthogonally of the plane of the terminal being
predetermined to insure penetration of insulated conductors
positioned in the troughs when the second part is mated to the
first part.
27. A jack assembly, which includes:
a first dielectric part having a cavity complementary to at least
portions of a mating electrical connector designed to be received
in the cavity, and having a plurality of terminal-receiving grooves
opening to an external surface thereof and adapted to receive
insulated conductors, and having a plurality of internal grooves
formed in one of the surfaces thereof which face into the cavity,
and are aligned with associated ones of the terminal-receiving
grooves to cooperate with the associated terminal-receiving grooves
to define terminal-receiving passages;
a second dielectric part, adapted to be mated with the first part
and having a plurality of ribs formed on one surface thereof, the
ribs being received in associated one of the grooves when the
second part is mated with the first part; and
a plurality of electrically conductive terminals designed to be
positioned in the terminal-receiving passages and having contact
portions formed on first leg portions thereof which extend
laterally of the associated leg portions and terminate in portions
of the associated grooves designed to receive associated conductors
so that when the conductors are positioned in the associated
grooves and the second part is mated with the first part, the ribs
confine the conductors and cause the contact portions to become
engaged electrically with the associated conductors, the terminals
having second leg portions, further the terminals being anchored in
the first part with the free ends of the second leg portions of the
terminals extending into the cavity and being free to be deflected
transversely of the free ends of the second leg portions and being
restricted by the associated internal grooves to prevent
misalignment of the second terminals, each of the terminals having
first and second crowns projecting from opposite sides thereof.
28. A jack assembly as set forth in claim 27, which includes:
complementary means formed on the first and second parts to provide
strain relief for the conductors positioned therein.
29. A jack assembly as set forth in claim 27, wherein:
the first part is provided with means formed transversely of the
terminals for supporting the terminals to prevent unintended
relative longitudinal movement between the terminals and the first
part; and
each of the terminals is configured to be seated in engagement with
the supporting means to support the terminals against unintended
longitudinal movement.
30. A jack assembly as defined in claim 27, wherein:
the internal grooves in the first part are defined by walls having
edge surfaces which face into the cavity and which are transverse
to side surfaces of the walls; and
the terminals are assembled to the first part with portions of the
second leg portions thereof protruding beyond the edge surfaces of
the walls of the internal grooves and into the cavity.
31. A jack assembly as defined in claim 27, wherein:
the contact portions formed on the terminals include at least two
tangs spaced along one edge of each of the terminals, each of the
tangs being substantially wedge-shaped with a base thereof integral
with the main body portion of the terminal and with an apex thereof
external of the main body portion, each of the tangs being coined
on one side thereof with a distance between the apices of the tangs
as measured orthogonally of the plane of the terminal being
predetermined to insure penetration of insulated conductors
positioned in the first part when the second part is mated with the
first part.
32. A jack assembly as set forth in claim 27, wherein:
the second leg of each of the terminals is formed with a portion
thereof adjacent the free end being bent out of the plane of the
terminal to bias the first crown thereof toward the wall of the
associated internal groove.
33. An electrical connector for terminating an insulated conductor
and for engaging electrically a component external to the
connector, which comprises:
a dielectric housing, which includes at least one
conductor-receiving trough and at least one terminal-receiving
opening, the terminal-receiving opening including a groove
overlying and extending generally parallel to the at least one
trough and a slot communicating with the at least one trough, the
length of the groove being exposed to the exterior of the
connector; and
at least one electrically conductive flat blade-like terminal
positioned within the at least one terminal-receiving opening,
which includes:
an internal contact portion positioned within the slot and having
facilities for piercing the insulation of and making electrical
engagement with the conductor in the at least one trough,
an external contact portion positioned within the groove of the
terminal-receiving opening and having facilities for making
electrical engagement with the component external to the connector
to establish an electrical connection with the component.
34. An electrical connector for terminating a cord having a
plurality of insulated conductors, and for making engagement with
conductors external to the connector, which comprises:
a dielectric housing including a plurality of troughs, each trough
receiving an individual insulated conductor therein, and a
plurality of terminal-receiving openings, each opening comprising a
groove overlying and extending generally parallel to an individual
conductor-receiving trough and a slot extending between the groove
and the associated trough, the length of the groove being exposed
to the exterior of the connector; and
a plurality of electrically conducting terminals, each terminal
being positioned within an associated individual terminal-receiving
opening and comprising a flat blade-like member including:
an internal contact portion positioned within the slot of the
associated opening and having facilities for piercing the
insulation of and making electrical engagement with an individual
conductor positioned within the associated conductor-receiving
trough, and
an external contact portion positioned within the groove of the
associated opening and having facilities for making engagement with
conductors external to the connector.
35. The electrical connector of claim 34, wherein the juncture of
the groove with the associated slot is of a size to permit the
internal contact portion of the associated terminal to pass
therethrough.
36. The electrical connector of claim 34, wherein each of the
terminals is maintained within the associated terminal-receiving
opening to expose an edge portion of the external contact portion
to the external face of the connector.
37. The electrical connector of claim 34, wherein each terminal
includes a plurality of barbs that penetrate the material defining
the associated terminal-receiving opening when the terminal is
inserted therein to secure the terminal within the housing.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to devices for making an electrical
connections; and more particularly, to miniature devices for making
electrical connections between conductors and electrically
conductive terminals wherein the conductive terminals are assembled
with dielectric members to form plugs and jacks and for then mating
the plugs and jacks to make electrical connections between the
terminals of the plugs and the terminals of the jacks.
2. Description of the Prior Art
In the communications industry, there has been an increasing demand
for plug type electrical connectors on straight and retractile
handset and line cords which are used to connect a base and a
handset of a telephone, and to connect the base of the telephone to
a terminal block. Efforts have been made to develop plug type
connectors having provisions for facilitating the installation
thereof.
One of the plug type connectors which has been in use for some
time, in particular model telephone sets, is described in U.S. Pat.
No. 3,369,214, issued on February 13, 1968, to C.L. Krumreich et
al. In the presently used plugs, a plurality of terminals are
applied to each of a plurality of insulated conductors included in
a jacketed length of cordage. These terminals are mounted within a
dielectric structure which is secured to the associated cordage.
The dielectric portions of the plugs which are attached to both
ends of a length of the cordage cooperate with receptacles in the
handset and the base of the telephone to align properly the
terminals of the plug with mating terminals within the handset and
the base.
Although the plug, described in U.S. Patent 3,369,214, functions
satisfactorily, the increased demand has required the introduction
of manufacturing economies in both the plug assembly and the
attachment of the plug to the associated cordage. Many conventional
retractile cords are formed of conductors which are enclosed within
a resilient plastic jacket that is rendered retractile after being
wound on a mandrel and subjected to relatively high temperatures.
From a manufacturing standpoint, it becomes more efficient for an
operator to attach plug type connectors to each of a plurality of
straight cords draped over a handling dolly before the cords have
been rendered retractile.
The plug described in U.S. Pat. No. 3,369,214 includes a number of
plastic parts which are riveted together. As the riveted plugs are
subjected to the high temperatures needed to render the cords
retractile, the stresses introduced by the riveting of the plastic
parts together may manifest themselves in distortions of the
plastic components of the plug. Hence, when the plugs are formed of
molded pieces of plastic which are riveted together, it becomes
impractical to preassemble the plugs to cordage which will
eventually be rendered retractile. The retractile cords must be
handled individually by an operator doing the attachment process
with accompanying loss in operator handling time.
In a subsequently developed plug, as is disclosed in an application
for U.S. patent, Ser. No. 758,502, filed Sept. 9, 1968, in the name
of E.C.Hardesty, an electrical connector for a retractile type
electrical cord was provided which could be assembled to the cord
before the cord is heat treated to render the cord retractile.
Moreover, the connector can be exposed to the same environments to
which the cord is exposed for treatment without the connector
incurring any degradation of its properties.
The connecting device described in the Hardesty application can be
fabricated by using conventional molding techniques with provisions
for electrical conductors having electrically conductive terminals
attached thereto, and which can be readily assembled to, and
disassembled from, an integral dielectric portion without
distortion of the terminals.
Although the connecting device described in the Hardesty
application overcomes some of the problems previously alluded to,
the size of that device is such that it may not be conveniently
adapted for use on all model telephones.
There is still a need for a universal type of electrical connecting
unit which may be readily assembled to a retractile cord and which
has miniature-enough dimensions so that the device may be readily
assembled to a mating unit in the handset and to the base of any
model telephone. Such a device must be capable of being
preassembled to cordage either prior to or subsequent to rendering
the cordage retractile, must be capable of being easily inserted in
the mating units in the telephone components by either a subscriber
or an installer and must be small enough so that it may be
compatible with existing telephone and terminal structures with
minimum modifications thereto, and with future miniature electronic
telephone sets.
It is an object of the invention to provide a device for making
electrical connections wherein conductive terminals are assembled
with dielectric members to form a plug and a jack and to cause the
terminals to engage electrically conductors positioned within the
plug and the jack, and for making electrical connections between
the terminals of the plugs and the terminals of the jacks.
It is a further object of the invention to provide a device for
making electrical connections between telephone apparatus, and
which is of relatively small dimensions so that the device may be
adapted to be used in existing telephone apparatus with minimum
modifications thereto and which may be installed easily by either a
subscriber or an installer.
It is another object of this invention to provide a plug which may
be attached to each end of a retractile cord by automated methods
of and apparatus for manufacture and which may be preassembled
thereto prior to or subsequent to the cords being rendered
retractile and which is adapted to be received in a mating jack
positioned in the base and in the handset of a telephone set by
either a subscriber or an employee-installer.
SUMMARY
With these and other objects in mind, the present invention
contemplates a device for making an electrical connection which
includes a plug assembly having mating dielectric parts which are
provided with facilities for receiving a plurality of conductors to
confine and separate the conductors. One of the mating parts has
terminal-receiving facilities formed therein and has a plurality of
electrically conductive terminals positioned in the
terminal-receiving facilities. The terminals of the plug assembly
are designed to become, and to be retained, engaged electrically
with associated ones of the conductors positioned in the assembly
when the parts are mated.
The device also includes a jack assembly having a dielectric
portion which has a cavity complementary to at least portions of
the plug assembly to permit insertion of at least portions of the
plug assembly into the jack assembly. The dielectric portion of the
jack assembly includes mating dielectric parts having facilities
for receiving a plurality of conductors and for confining
individually the conductors. One of the mating parts of the jack
assembly has walls which define terminal-receiving passages. The
jack assembly also includes a plurality of electrically conductive
terminals with at least portions positioned in the passages in the
one part of the jack assembly and designed to become, and be
retained, engaged electrically with conductors positioned therein
when the parts of the jack assembly are mated. The walls of
portions of the terminal-receiving passages are designed to permit
a predetermined lateral deflection of the associated portions of
the associated terminals.
Portions of the jack-assembly terminals are received in the
associated ones of the terminal-receiving facilities of the plug
assembly to engage electrically with the associated plug-assembly
terminals when the plug assembly is inserted into the cavity of the
jack assembly. Each of the jack-assembly terminals has at least a
portion thereof anchored in the jack assembly and has the portion
thereof which engages the associated terminal in the plug assembly
being received in the portions of the associated passage and
designed to have a predetermined lateral deflection to facilitate
the mating of the plug and jack assemblies, and to maintain good
electrical contact between the jack-assembly terminals and the
plug-assembly terminals.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will be more
readily understood in the following detailed description of
specific embodiments thereof when read in conjunction with the
accompanying drawings in which:
FIG. 1 is a perspective view of a telephone set showing a
retractile cord having an inventive plug attached to each end
thereof and inserted into an inventive jack in a handset and a base
portion of the telephone set;
FIG. 2 is an exploded perspective view of the inventive device
which illustrates the plug aligned with, but disassembled from the
inventive jack;
FIG. 3 is an enlarged exploded sectional view of the inventive plug
of FIG. 2 which illustrates individual conductors of a jacketed
cord which are to be confined between a mating lid and base of the
plug and further illustrating one of a plurality of stand-up blade
terminals aligned with the plug for assembly thereto;
FIG. 4 is a plan view of the base of the plug of FIG. 2 which
illustrates several details of that portion of the base which mates
with the lid;
FIG. 5 is a bottom plan view of the base of the plug of FIG. 2
which illustrates a plurality of terminal-receiving grooves having
flared entrances;
FIG. 6 is a bottom plan view of the lid of the plug of FIG. 2 which
illustrates several details of that portion of the lid which mates
with the base;
FIG. 7 is a top plan view of the lid of the plug of FIG. 2.
FIG. 8 is an enlarged exploded sectional view of the inventive jack
of FIG. 2 taken along lines 8--8 which illustrates a housing and a
cover with one of a plurality of terminals aligned with the jack
for mounting on the housing;
FIG. 9 is an end elevational view of the housing of the jack of
FIG. 2 taken along lines 9-9 thereof;
FIG. 10 is a bottom plan view of the cover of the jack shown in
FIG. 8;
FIG. 11 is an end elevational view of the housing of the jack of
FIG. 2 taken along lines 11--11 thereof;
FIG. 12 is a sectional view of the inventive device of FIG. 2,
which illustrates an assembled one of the plugs inserted into a
cavity in an assembled one of the jacks in, for example, the base
portion of a telephone;
FIG. 13 is a complete sectional view of the assembled device of
FIG. 12 taken along lines 13--13 thereof which illustrates the
mating of the terminals of the plug with the terminals of the
jack;
FIG. 14 is a view similar to FIG. 13 with the plug withdrawn from
the cavity in the jack;
FIG. 15 is an exploded perspective view of the inventive device
which illustrates the inventive plug aligned with, but disassembled
from, another embodiment of the inventive jack;
FIG. 16 shows an elevational view, partially in section, of a
handset portion of a telephone showing still another embodiment of
the inventive jack, and
FIG. 17 is an enlarged sectional view of the embodiment of the
inventive jack of FIG. 16.
DETAILED DESCRIPTION
Referring now to FIG. 1, there is shown a telephone, designated
generally by the numeral 30, which includes a base, designated
generally by the numeral 31, and a handset, designated generally by
the numeral 32. A retractile cord, designated generally by the
numeral 33, interconnects the base 31 and the handset 32. A line
cord (not shown) interconnects the base 31 and a terminal block
(not shown). The line cord (not shown) in general use today is a
straight cord.
The retractile cord 33 is provided with a plug, designated
generally by the numeral 34, at the handset end thereof, and with a
plug, designated generally by the numeral 36 at the base end
thereof. The plug 34 is adapted to be mated with a jack, designated
generally by the numeral 38, which is mounted in the handset 32,
while the plug 36 is adapted to be mated with a jack, designated
generally by the numeral 37, mounted in the base 31 of the
telephone 30. The plugs 34 and 36 attached to opposite ends of any
one cord 33 are identical and are designed to be received
universally in any one of the jacks which will be installed in the
telephone apparatus. However, in the event that retractile cords be
used for both the line cord and the handset cord, then precautions
would have to be taken so that an installer may readily identify
which is the line cord and which is the set cord.
In FIG. 2, there is shown an exploded perspective view of the plug
34 and the jack 37 which embody the principles of the invention.
The retractile cord 33 includes a jacket 39 and a plurality of
insulated conductors 41--41. A portion of the jacket 39 is removed
from the cord 33 adjacent each end thereof to facilitate connecting
the conductors 41-41 at each end of the cord to one of the plugs
34-34.
As can best be seen in FIGS. 2 and 3, the plug 34 includes a rigid,
dielectric base portion, designated generally by the numeral 42,
and a mating rigid, dielectric lid portion, designated generally by
the numeral 43. The rigid, dielectric base and lid portions 42 and
43, respectively, can be easily molded by using conventional
injection-molding techniques. Referring now to FIGS. 2 and 4, it
can be seen that the base portion 42 includes a passage 44 having a
plurality of spaced parallel longitudinally formed partitions
46--46 formed integrally with the base portion. The partitions
46--46 project into the passage 44 and together with a side wall 47
and a side wall 48 of the base portion form a plurality of
conductor-receiving troughs 49--49 for receiving the individual
conductors 41--41 of the cord 39. The conductor-receiving troughs
49--49 confine the conductors 41--41 against lateral movement in
the passage 44.
A plurality of parallel-formed terminal-receiving grooves 53-53
(see FIG. 5) are formed in the base portion 42 to open to a surface
52 with each one of the grooves being associated and aligned with
an associated one of the conductor-receiving troughs 49--49. Each
one of the terminal-receiving grooves 53-53 communicates with the
associated one of the conductor-receiving troughs 49--49 by a
slotted opening 54 (see FIGS. 4 and 5). Moreover, each one of the
terminal-receiving grooves 53-53 has a flared entrance 56 which
opens to a surface 57 (see FIG. 5) which extends transversely of
the surface 52 of the base portion 42. Each of the
terminal-receiving grooves 53--53 has a restrictive portion 58 (see
FIG. 5) formed at one end thereof and a shoulder 59 projecting
transversely of and into the entrance 56 at the other end
thereof.
In order to provide strain relief for the cord 33, a raised portion
61 (see FIGS. 2 and 3) is formed integrally with the base portion
42 transverse of a longitudinal axis of the passage 44 and
projecting into the passage. In order to provide strain relief for
the conductors 41--41, the base portion 42 is formed with a
transversely extending channel 62 (see FIGS. 2 and 3) which is
interposed between the raised portion 61 and the
conductor-receiving troughs 49--49. The base portion 42 has several
additional features for facilitating the assembly of the cord 33
and the lid portion 43 therewith.
The base portion 42 of the plug 34 also includes a guideway 63
opening to the outwardly facing surface of each of the side walls
47 and 48 thereof (see FIGS. 2 and 4). Finally, in order to
facilitate the bonding ultrasonically of the lid portion 43 to the
base portion 42, a plurality of energy directors or guides 64--64
are formed integrally with a top surface 66 of the walls 47 and 48
and along top surfaces of the partitions 46--46 (see FIGS. 2 and
4). The energy directors 64--64 are dimensioned to provide for
adequate bonding of the lid portion 43 to the base portion 42 in
accordance with the specifications provided by manufacturers of
commercial ultrasonic equipment. For example, reference is made to
an article by D. J. Kolb, "Designing PLastic Parts for Ultrasonic
Assembly" printed in the Mar. 16, 1967 issue of Machine Design.
Prior to the assembly of the lid portion 43 with the base portion
42 of the plug 34, electrically conductive terminals 71--71 are
assembled to the base portion. As can best be seen in FIGS. 2 and
3, each one of the terminals 71--71 is generally L-shaped and made
from a generally flat strip of and electrically conductive
resilient material such as phosphor-bronze. Moreover, each one of
the terminals 71--71 includes at least one contact tang 72 which is
used to pierce the insulation of an associated one of the
conductors 41--41 to establish electrical contact therewith.
The terminals 71-71, shown in FIG. 2, have two contact tangs 72-72
formed integrally therewith to facilitate penetration of the
insulation of the conductors 41--41 to insure engagement of the
tangs with the conductive portions of the conductors. To this end,
the tangs 72--72 are coined so that one side of one of the tangs is
sloped in one direction while the opposite side of the other one of
the tangs is sloped in another direction at some angle to the one
direction.
Each one of the terminals 71--71 is also formed with a plurality of
anchoring barbs 73--73 which penetrate the material defining the
terminal-receiving grooves 53--53 and the slotted openings 54--54
of the base portion 42 when the terminals are assembled therewith
in order to secure the terminals within the base portion.
As shown in FIGS. 2 and 3, the terminals 71--71 are assembled to
the base portion 42 by aligning the terminals with associated ones
of the terminal-receiving grooves 53--53. Each one of the terminals
71--71 is aligned with the associated one of the terminal-receiving
grooves 53-53 so that an extended portion 74 (see FIG. 3) of the
terminal is aligned with the associated one of the slotted openings
54--54. Then, as the terminal 71 is moved into the associated one
of the terminal-receiving grooves 53--53, a leading end 76 thereof
is moved into engagement with the shoulder 59 (see FIG. 5) formed
at the other end of the terminal-receiving groove. A trailing end
77 of the terminal 71 is received in the restrictive portion 58
(see FIG. 5) of the aligned terminal-receiving groove 53. In this
way, the terminal 71 is restrained from unintended longitudinal
movement relative to the base portion 42.
As can be seen in FIGS. 2 and 3, each of the terminals 71--71 is
also formed with a crown 78 for engaging the opposed wall of the
associated slotted opening 54. The crown maintains the terminal 71
to one side of the terminal-receiving groove 53 to prevent lateral
displacement thereof during the insertion process in the associated
one of the terminal-receiving grooves and maintains the terminal in
engagement with the adjacent wall of the groove. In this way, a
contact portion 79 of each of the terminals 71--71 is seated
properly within the associated one of the terminal-receiving
grooves 53--53, with the leading end 76 of each of the terminals in
engagement with the shoulder 59 and with the trailing end received
in the restrictive portion 58.
When each one of the terminals 71--71 is assembled properly with
the base portion 42, the tangs 72--72 thereof protrude through the
associated one of the slotted openings 54--54 into the associated
one of the conductor-receiving troughs 49--49. Moreover, the proper
positioning of the terminals 71--71 in the grooves 53--53 centers
the tangs 72--72 within the troughs 49--49 to align the tangs with
the longitudinal axes of the associated conductors 41--41 and
maintain the tangs in alignment therewith to insure that the tangs
engage the conductive portion of the insulated conductors. Finally,
when the terminals 71--71 are assembled properly to the base
portion 42, the edges of the terminals opposite the contact tangs
72--72 are flush with the surface 52. The base portion 42 is in
condition to receive the cord 33 and the conductors 41--41 and then
to be assembled to the lid portion 43.
Referring now to FIGS. 2, 6 and 7, there is shown the lid portion
43 which is designed to be mated with the base portion 42 to form
the plug 34. The lid portion 43 includes a plurality of spaced
parallel longitudinally formed ribs 81--81 which project from a
surface 82 thereof. When the lid portion 43 is aligned with the
base portion 42, each one of the ribs 81--81 is aligned with an
associated one of the conductor-receiving troughs 49--49.
The conductors 41--41 are separated and individual ones thereof
placed in the associated ones of the conductor-receiving troughs
49--49 to be confined laterally between adjacent ones of the
partitions 46--46. Then, when the lid portion 43 is mated with and
bonded ultrasonically to the base portion 42, the ribs 81--81 are
interposed between associated ones of the partitions and extend
into associated ones of the conductor-receiving troughs 49--49. The
ribs 81--81 engage the associated ones of the conductors 41--41 in
the associated ones of the conductor-receiving troughs 49--49 and
confine the conductors between the ribs and the bottom of the
troughs while the conductors are confined laterally between the
adjacent ones of the partitions 46--46. The tangs 72--72 of the
associated ones of the terminals 71--71 are caused to penetrate the
insulation of the conductors 41--41 and establish electrical
contact between the terminals and the conductors.
The thickness of the terminals 71--71 is smaller than the diameter
of the conductors 41--41 and the mating of the lid portion 43 to
the base portion 42 could tend to roll the conductors laterally and
squeeze the conductors between the associated terminal and the wall
of the associated trough 49 instead of achieving the required
penetration of the insulation by the tangs 72--72. However, the
coining of the contact tangs 72--72 is accomplished to have the
dimensions transverse of the terminals between the tips of the
contact tangs to be such that the insulation of the conductors
41--41 will necessarily be penetrated when the lid portion 43 is
mated to the base portion 42.
The lid portion 43 has several additional features for facilitating
the assembly of the cord 33 and conductors therewith. As can best
be seen in FIG. 3, the lid portion 43 is formed with raised portion
83 (see also FIG. 6). transversely of the ribs 81--81 and which
cooperates with the raised portion 61 of the base portion 42 to
clamp the jacket 39 of the cord 33 therebetween (see FIG. 12) to
provide strain relief for the jacketed portion of the cord. It will
be observed from FIG. 12 that the cooperating raised portions 61
and 83 have a rounded configuration to avoid sharp corners which
constitute high stress areas and could be melted during the
ultrasonic bonding of the lid portion 43 to the base portion
42.
Moreover, the lid portion 43 is also formed with a ridge 84 formed
transversely of the ribs 81--81 and interposed between the ribs and
the raised portion 83. When the lid portion 43 is assembled to the
base portion 42, the ridge 84 cooperates with the channel 62 to
form a labyrinth and cause the individual conductors 41--41 to
follow a tortuous path therethrough (see FIG. 12). This provides a
snubbing action for the individual conductors 41--41 thereof (see
FIG. 3) and provides strain relief for the individual
conductors.
Additionally, the lid portion 43 includes a pair of spaced grooves
85--85 (see FIG. 6) which open to a surface which is adjacent the
base portion 42 when the lid portion is mated to the base portion.
One of the ribs 81--81 which is adjacent one of the grooves 85--85
includes a lip 90 formed integrally therewith. The lip 90 projects
partially across and is undercut to space the lip above the bottom
of one of the grooves 85--85. The grooves 85-85 and the lip 90 are
used for mounting facilities which latch the plug 34 to the jack
37.
The lid portion 43 is provided with facilities for assembly thereof
with the base portion 42. A positioning key 86 (see FIGS. 2 and 6)
is formed integrally with the lid portion 43 on each side thereof
and projects laterally from the surface 82 thereof. In the assembly
of the plug 34, the lid portion 43 is aligned with the base portion
42 to align the ribs 81 with the conductor-receiving troughs 49--49
and to align the positioning keys 86--86 with the guideways 63--63
formed in the base portion. Then, when the lid portion 43 is moved
into engagement with the base portion 42 to engage the surface 82
thereof with the energy guides 64--64, the positioning keys 86-86
are received in the guideways 63--63 to prevent inadvertent
relative movement between the base portion and the lid portion
during the ultrasonic bonding of the lid portion to the base
portion.
Additional facilities are provided for facilitating the assembly of
the plug 34 to the jack 37. As can best be seen in FIG. 7, the lid
portion 43 has a recess 87 having a narrow portion 88 extending
from one end thereof. The lid portion 43 is formed with a T-shaped
block 91, spaced from side walls 93 and 94 of the lid portion,
projecting into the recess 87 and having a tongue 92 for guiding
the plug 34 into the jack 37. Also, the lid portion 43 is formed
with a pair of spaced bumpers 80--80 projecting from a leading end
thereof.
Moreover, a latch, designated generally by the numeral 95, which,
for example, may be made from a flat piece of resilient metal or
from a plastic material, is attached to the lid portion 43 spanning
the T-shaped block 91. The latch 95 is formed to have a pair of
spaced securing fingers 96--96 (see FIG. 3), having hooked ends,
which are mounted in the grooves 85--85 in the lid portion 3, with
the hooked ends projecting outwardly from one end thereof. The
other ends of the securing fingers 96--96 are then reversely bent
to form spaced side or leg members 97--97. One of the fingers
96--96 is pressed past the overhanging lip 90 and snapped into
place in the groove 85 so that the finger is retained between the
groove and the base to prevent unintended lateral movement thereof.
When the lid portion 43 is mated with the base portion 42, the
hooked ends of the fingers cooperate with holes 89--89 in the base
portion to prevent unintended longitudinal movement. The side
members 97--97 are formed to continue laterally toward one another
with arm portions 98--98 which are joined to a release tab 99. When
an operator depresses the release tab 99, the side members 97--97
are designed to be received in the space between the T-shaped block
91 and the side walls 93 and 94, and the release tab is designed to
be moved into the narrower portion 88 of the recess 87.
In describing the jack 37, reference is made to FIGS. 2 and 8-14.
The jack 37 is used to connect electrically a plurality of
conductors 101--101 (see FIG. 12) from within the handset 32, for
example, to a plurality of terminals, designated generally by the
numerals 102--102. Each of the terminals 102--102 is generally
U-shaped and made from a substantially flat piece of electrically
conductive spring-like stock material such as phosphor-bronze
having a thickness t. As can be observed from FIG. 2, the thickness
of the terminals 102--102 is substantially less than the dimensions
of the terminals in the plane of the U. Each of the terminals
102--102 has a first leg 103 connected to a second opposite leg 104
by a connecting portion 105. The first leg 103 has at least one
contact tang 106 formed integrally with, and extending laterally
therefrom. The first leg 103 also has an upstanding portion 107
formed at a free end thereof (see FIGS. 2 and 8). The second leg
104 has a first crown or dimple-like projection 108 and a second
crown 109 projecting laterally from opposite sides thereof (see
FIGS. 2 and 8). Finally, each of the terminals 102--102 has a
cutout portion 110 at the intersection of the connecting portion
105 and the second leg 104. Moreover, as can best be seen in FIGS.
2 and 14, each of the second legs 104--104 is formed so that a
portion thereof adjacent the free end is bent out of the plane of
the terminal. This prestresses the terminal 102 and presets the
terminal to insure that the leading ends of the terminals will be
received in the flared entrances 56--56, and cause additional
pressure to insure the engagement of the crown 108 with the
associated one of the terminals 71--71 when the plug 34 is mated
with the jack 37.
The jack 37 includes a housing, designated generally by the numeral
111 (see FIG. 2) in which are mounted the terminals 102--102. The
housing 111 is made from a block of rigid dielectric material
similar to that used to construct the plug 34. In order to mate the
plug 34 with the jack 37, the jack housing 111 has a cavity 112,
complementary to at least portions of the plug, formed therein and
opening to a surface 113 of the housing. The cavity 112 is defined
in part by spaced side walls 114 and 116, a bottom wall 117, a rear
wall 118 (see FIG. 8), a main body portion 119 of the housing, and
an overhang 120.
Also, the housing 111 is formed with a plurality of spaced parallel
terminal-receiving grooves 121--121 opening to two adjacent
transversely extending external surfaces 122 and 123 thereof (see
FIG. 11). Each of the terminal-receiving grooves 121-121 has a
narrow terminal-receiving portion 124 for receiving the first leg
103 of one of the terminals 102-102 and a somewhat wider
conductor-receiving portion 126 which opens to the surface 122. The
conductor-receiving portions 126--126 of the terminal-receiving
grooves 121--121 extend from the surface 123 (see FIGS. 8 and 9) to
a point spaced from the external wall 113. However, the
terminal-receiving portions 124--124 extend from the surface 123
through the main body portion 119 to the surface 113.
As can best be seen in FIG. 11, the portions of the
terminal-receiving grooves 121--121 which open to the surface 123
are aligned with associated ones of a plurality of grooves 125--125
cut in the rear wall 118. The grooves 125--125 terminate in
associated ones of a plurality of holes 130--130 which open into
the cavity 112. The holes 130--130 have portions thereof which are
somewhat wider than the slots 125--125 to facilitate insertion of
the second legs 104--104 of the terminals 102--102 having the
crowns 108 and 109 into the cavity 112.
In order to complete the provisions for mounting the terminals
102--102 in the housing 111, the main body portion 119 of the
housing has a lip 127 which extends above the surface 122 (see
FIGS. 2 and 9). A plurality of slotted openings 128--128 are cut
through the lip 127 and connect with associated ones of the
terminal-receiving portions 124--124 of the terminal-receiving
grooves 121--121. In the embodiment shown in FIGS. 2 and 11, the
rear wall 118 extends only partially along the side walls 114 and
116 toward the body portion 119. Finally, the bottom wall 117 is
formed with a plurality of internal grooves 129--129 (see FIGS. 2
and 9) which face into the cavity 112 and a bridge 131 (see FIG. 8)
spanning the grooves.
The terminal-receiving grooves 121--121 and 125--125 and the
internal grooves 129--129 define generally U-shaped passages for
receiving the terminals 102--102. Each of the terminals 102--102 is
mounted in the housing 111 with the first leg 103 thereof anchored
in the terminal-receiving portion 124 of the associated one of the
terminal-receiving grooves 121--121 with the tangs 106--106 thereof
protruding into the conductor-receiving portion 126 (see FIG. 12).
The connecting leg 105 of each of the terminals 102--102 is
received in the portion of the terminal-receiving groove 121 which
opens to the external surface 123 and in the associated one of the
grooves 125--125 in the rear wall 118. Finally, the second leg 104
of each of the terminals 102--102 is inserted through the
associated one of the holes 130--130 and is positioned in an
associated one of the grooves 129--129 with the cutout portion 110
seated in engagement with the bridge 131.
It will be recalled that the terminals 71--71 are flush with the
surface 52 of the base portion 42 of the plug 34. However, in jack
37, the second legs 104--104 are not flush with the tops of the
walls of the grooves 129--129, but instead protrude thereabove. The
portion of each of the second legs 104--104 which protrudes above
the tops of the groove walls is thus made available for receipt in
an associated one of the terminal-receiving grooves 53--53 when the
plug 34 is mated to the jack 37.
It should be observed from FIGS. 2 and 9 that the width of each of
the grooves 129--129 in a direction transverse to the longitudinal
axis of the grooves is somewhat larger than the thickness of the
second leg 104 of the terminal 102 to be received therein. After
the terminals 102--102 are mounted in the terminal-receiving
grooves 121--121, it is unnecessary to provide support for the
second legs 104-104 thereof. However, the grooves 129--129 function
to insulate the second legs 104--104 from one another and limit the
lateral movement of the second legs. In this way the deflection of
the second legs 104-104 of the terminals 102--102 is controlled to
prevent the second legs from being turned out of alignment with the
longitudinal axis of the jack 37 when the plug 34 is inserted into
the jack.
The terminals 102--102 are mounted in the housing 111 so that the
first legs 103--103 are anchored therein. This causes bending
stresses to be developed in the second legs 104--104 which are free
to be deflected in the grooves 129--129 as the second legs are
mated with the terminals 71--71 of the plug 34. The resiliency of
the material of the terminals 102-102 causes the pre-stressed legs
104--104 to maintain the crown 108 in engagement with the
associated one of the terminals 71--71.
Because of the mounting arrangement of the terminals 102--102 in
the housing 111, the terminals may be subjected to torsional
stresses when the plug 34 is inserted into the jack 37. Although
the first legs 103--103 of the terminals 102--102 are anchored in
the housing 111, the second legs 104--104 are designed to be
deflected laterally within predetermined limits. The deflection of
the second legs 104--104 may be accompanied by a certain amount of
twist in the connecting legs 105--105 which permits a controlled
reduction of the bending stresses in the second legs. The mounting
of the terminals 102--102 is designed to optimize the engagement
thereof with the terminals 71--71 without causing unduly high
bending stresses in the terminals 102--102.
The housing 111 has several additional features to facilitate the
assembly and installation thereof with telephone apparatus. The
housing 111 includes a stud 132 formed with the bottom wall 117 and
depending therefrom. The stud 132 is received in an opening (not
shown) in the telephone base 31, for example, to position
accurately the jack 37 therein. A mounting lug 133 extends
laterally from each of the side walls 114 and 116 to permit
attachment of the jack 37 to the telephone 30 or a terminal block
(not shown). The housing 111 is also formed with a guide slot 134
in the overhang 120 of the main body portion 119 thereof for
receiving the tongue 92 of the lid portion 43 of the plug 34 to
guide the plug into the cavity 112. A pair of spaced alignment keys
136--136 are formed integrally with the housing 111 and extend from
the surface 122 thereof (see FIGS. 2 and 9) to facilitate assembly
of the housing with a cover 141.
As can best be seen in FIGS. 2 and 10, the cover 141 is adapted to
be mated with the housing 111. The cover 141 has a plurality of
ribs 142--142 (see FIG. 10) formed on one surface thereof and which
are received in associated ones of the terminal-receiving grooves
121--121 when the cover is mated with the housing 111. In order to
facilitate the alignment of the cover 141 with the housing 111, the
cover has alignment slots 143--143 cut in opposed lateral edges
thereof for receiving the alignment keys 136--136. Moreover, a
plurality of energy guides 144--144 are formed on an underside
thereof to facilitate the bonding ultrasonically of the cover 141
to the housing 111. The cover 141 has a notch 145 formed along one
edge thereof with the notch dimensioned to receive the lip 127.
Finally, the cover 141 has a plurality of cul-de-sacs 146--146
formed along a trailing edge thereof and aligned with associated
ones of the terminal-receiving grooves 121--121. The cul-de-sacs
146-146 are formed having an inner portion which is sized to that
of the diameter of one of the conductors 101--101. But the entrance
to each of the cul-de-sacs 146--146 is somewhat narrowed (see FIG.
10) so that one of the conductors must be compressed between
opposing bights 147--147 to be moved into the inner nesting
portion. When the cover 141 is bonded to the housing 111, the
conductors 101--101 are pressed into associated ones of the
cul-de-sacs 146--146 to provide strain relief for the conductors
during the use of the telephone 30. A raised portion 148 formed on
the underside of the cover 141 presses the conductor 101 against
the surface 122 to provide additional strain relief for the
conductors.
It should be appreciated that the mini plug 34 and jack 37 have
dimensions small enough so that the jack may be installed in
existing telephone apparatus. For example, the terminals 71--71 are
approximately 0.345 inch long with a thickness of 0.010 inch. The
plug 34 measures approximately 0.595 inch along a longitudinal axis
through the passage 144 thereof, by 0.332 inch wide, by 0.360 inch
deep as measured from the surface 52 of the base portion 42 to the
external surface of the lid portion 43 when the lid portion is
mated with the base portion. The housing 111 of the jack 37 has an
approximate length of 0.400 inch, a width of 0.470 inch and a
height of 0.770 inch.
Moreover, it should be appreciated that the terminals 71--71 and
102--102 are mounted in the plug 34 and the jack 37, respectively,
with a minimum center to center spacing of approximately 60 mils
which permits the miniature sizes of the dielectric parts. The
mounting arrangement of the terminals 71--71 and 102--102 together
with the conductors permits terminals to be of a blade, stand-up
type with the thickness thereof being generally smaller than the
cross sectional dimension of the conductors.
In order to mate the plug 34 and the jack 37, a subscriber or an
installer moves the plug 34 into proximity of the jack 37 and
aligns the plug with the jack so that the tongue 92 is aligned with
the guide slot 134 in the housing 111.
With the tongue 92 aligned with the guide slot 134 in the housing
111, the operator moves the plug 34 along a path of travel parallel
to the longitudinal axis of the passage 44 in the plug and into the
cavity 112 until the bumpers 80--80 of the lid portion 43 engage
the rear wall 118. The seating of the cutout portion 110 of the
terminals 102--102 with the bridge 131 resists the forces imparted
to the terminals as the terminals are moved into the flared
entrances 56--56 of the plug 34.
The second leg 104 of each of the stand-up blade terminals 102--102
of the jack 37 is received in an associated one of the
terminal-receiving grooves 53--53 of the base portion 42 to engage
the associated ones of the terminals 71--71 of the plug 34 (see
FIGS. 12 and 13). Because of the pre-set of portions of the second
legs 104--104, the crowns 108, which are moved first into the
associated ones of the grooves 53--53 tend to be urged into
engagement with the associated ones of the terminals 71--71. As can
best be seen in FIG. 13, the crown 109 on each of the second legs
104--104 of the terminals 102--102 engages the opposed wall of the
associated terminal-receiving groove 53 to further urge the crown
108 of the terminal into engagement with the associated one of the
first terminals 71--71 secured within the terminal-receiving groove
in the plug 34.
The overall thickness of the terminal 102 including the projecting
dimension of the crowns 108 and 109, plus the thickness of the
terminal 71 is greater than the width of each of the
terminal-receiving grooves 53--53. Thus, when the terminals 71--71
are positioned in the grooves 53--53, the remaining width of the
grooves is less than the overall thickness of the terminal 102.
Then, when portions of the second legs 104--104 of the associated
terminals 102--102 are moved into the terminal-receiving grooves,
the crowns 109--109 press against the walls of the associated
grooves. Moreover, the relation between the overall thickness of
the leg 104 and the useable width of the terminal-receiving groove
53 causes the second leg to assume a serpentine shape when the
contact portion of the second leg is caused to be moved into the
associated one of the terminal-receiving grooves. This urges the
crowns 108--108 into engagement with the terminals 71--71 (see FIG.
13) to insure adequate contact pressure between the crowns 108--108
and the terminals 71--71.
It may also be observed from FIGS. 2 and 12 that the latch 95
provided on the plug 34 is used to secure the plug within the jack
37. In this regard, the insertion of the plug 34 into the jack
cavity 112 causes the latch 95 to be urged into the recess 87 of
the lid portion 43 of the plug. Then, when the plug 34 is
positioned properly within the jack cavity 112, the resiliently
mounted latch 95 is biased upwards from the recess 87 of the lid
portion 43 of the plug to move the arm portions 98--98 toward the
main body portion 119 of the jack 37 until the arm portions are
captured and retained behind the overhand 120 as the release tab 99
protrudes through the guide slot 134 (see FIG. 12).
Then, when it is desired to disconnect the plug 34 from the jack
37, the subscriber or installer merely depresses the release tab 99
and withdraws slidably the plug from within the cavity 112. A
replacement cord 33 provided with a plug 34 at each end thereof may
be connected easily to the telephone 30.
Turning now to FIG. 15, there is shown a jack 150 which is an
alternate embodiment of the jack 37 that embodies the principles of
the present invention. In FIG. 15, there is also shown a mating
plug identical to the plug 34 shown in FIG. 2, except that it is
inverted from the position shown in FIG. 2 to mate with the jack
150 to engage a plurality of terminals 152--152 in the jack with
associated ones of the terminals 71--71 of the plug.
Each of the terminals 152--152 is made from a generally flat strip
of electrically conductive spring-like material such as phosphor
bronze and is generally U-shaped having a first leg 153 and a
second opposed leg 154 connected therebetween by a portion 155. The
leg 153, a portion of the leg 154 and the connecting portion 155
lie substantially in the same plane. A portion of the second leg
154 adjacent the free end thereof is prebent out of the plane to
prestress the second leg to function similar to the second leg 104
of the terminals 102--102. The first leg 153 is provided with at
least one contact tang 156 which pierces the insulation of
associated ones of conductors (not shown) and with an upstanding
portion 157 for anchoring the terminal against longitudinal
movement relative to the jack 150. Finally, the second leg 154 of
each of the terminals 152--152 is provided with a crown 158 and a
crown 159 formed integrally with and protruding from opposed sides
of the second leg.
The first and second legs 153 and 154, respectively, of the jack
150 are spaced apart a substantially lesser distance than the first
and second legs 103 and 104 of the terminals 102--102 of the jack
37. The distance between the legs 103 and 104 of the terminals
102--102 must be sufficient to receive the plug 34 therebetween
(see FIG. 2), with the contact portions 79--79 of the terminals
71--71 engaging an upper portion of the second legs 104--104 of the
terminals 102--102 (as viewed in FIG. 2) which faces into the U and
is closest to the first leg thereof. In the present jack
embodiment, the plug 34 is received in the jack 150 so that a lower
portion (as viewed in FIG. 15) of the second legs 154--154 engage
the contact portions 79-79 of the plug terminals 71--71.
The dielectric portion of the jack 150 is similar to that of the
jack 37 and includes a housing 161 molded from a block of
dielectric material and having a cavity 162 opening to a surface
163 thereof. The cavity 162 is defined by a side wall 164, a side
wall 166, a bottom wall 167, a rear wall 168, and a main body
portion 169 of the housing.
The housing 161 has a plurality of terminal-receiving grooves 171
which open to transversely extending external surfaces 172 and 173
thereof. The external grooves 171 each have a narrow
terminal-receiving portion 174 for receiving the first leg 153 of
one of the terminals 152--152 and a wider conductor-receiving
portion 176 for receiving the conductors (not shown). The tangs
156--156 of the terminals 152--152 protrude into the
conductor-receiving portions 176--176 of the grooves 171--171 to
pierce the insulation of the conductors (not shown) and establish
electrical contact between the conductors (not shown) and the
terminals.
The conductor-receiving portions 176--176 of the grooves 171--171
extend from the surface 173 to a point spaced from the surface 163
of the main portion 169 of the housing 161. On the other hand, the
terminal-receiving portions 174--174 extend from the surface 173
through a lip 177 to the surface 163. The rear wall 168 of the
housing 161 is formed with a plurality of parallel spaced slotted
openings (not shown) with each one of the slotted openings aligned
with an associated one of the grooves 171--171. Finally, a surface
of the main body portion 169 which faces into the cavity 162 is
formed with a plurality of internal grooves 179--179 with the space
between adjacent ones of the grooves aligned with associated ones
of the slotted openings (not shown) and with associated ones of the
grooves 171--171.
The grooves 171--171, the slotted openings (not shown) and the
internal grooves 179--179 define a generally U-shaped
conductor-receiving passage. The terminals 152--152 are mounted in
the housing 161 with the first leg 153 of each of the terminals
received in the associated one of the terminal-receiving portions
174--174, the connecting portion 155 of each terminal is received
in the associated one of the slotted openings (not shown), and an
upper portion (as viewed in FIG. 15) of the second leg 154 of each
terminal is received in an associated one of the grooves 179--179.
The upstanding portions 167--167 are received in slotted grooves
178--178 which are continuations of the grooves 171--171 and which
are cut through the lip 177.
It should be observed that the second leg 154 of each of the
terminals 152--152 is cantilevered from the connecting portion 155
thereof into the cavity 162. The material defining the grooves
179--179 serves to insulate the second legs 154--154 from each
other, and to limit the amount of lateral movement of the second
legs. In this way, the second leg 154 may pivot or flex from the
line of intersection with the connecting portion 155 thereof to
facilitate insertion of the plug 34 into the cavity 162 with the
accompanying receipt of the terminals 152--152 in associated ones
of the terminal-receiving grooves 53--53 in the plug 34.
In this embodiment, the grooves which limit the lateral movement
are formed in the internal face of the main body portion 169
whereas in the hereinabove described embodiment, the grooves were
formed in the bottom wall 117 of the housing 111.
Also, in this embodiment, the housing 161 has a mounting lug 183
attached to and extending from each of the side walls 164 and 166.
Moreover, the housing 161 has a guide slot 184 formed in the bottom
wall 167 for receiving the tongue 92 on the lid portion 43 of the
mating plug 34. As with the heretofore described embodiment, the
alignment of the tongue 92 with the guide slot 184 aligns the plug
34 with the cavity 162 to permit the assembly of the plug with the
jack 150. The housing 161 also includes a pair of spaced alignment
keys 186--186 extending from the surface 172 thereof.
As can best be seen in FIG. 15, the bottom wall 167 of the housing
has a strip 188 formed therearound so that when the plug 34 is
received in the cavity 162 and the release tab 99 of the latch 95
is depressed and then biased away from the plug, the arm portions
98--98 lock behind the strip 188 to secure the plug within the jack
150.
Further, it can be seen in FIG. 15 that the jack 150 is provided
with a cover 191 for engaging the top surface 172 of the housing
161. The cover 191 has a plurality of ribs 192--192 formed on the
underside thereof and a pair of spaced alignment slots 193--193 for
receiving the alignment keys 186--186. Also the cover 191 has
energy guides (not shown) projecting therefrom for engaging the
surface 172 to facilitate the welding ultrasonically of the cover
to the housing 161. When the cover 191 is welded to the housing
161, the ribs 192--192 are received in associated ones of the
grooves 171--171 to move the conductors (not shown) to the bottoms
of the conductor-receiving portions 176--176. This causes the
contact tangs 156--156 of the terminals 152--152 to pierce the
insulation of the conductors (not shown) to establish electrical
contact therebetween.
Still another embodiment of the invention is shown in FIG. 16 with
a jack, designated generally by the numeral 200, mounted in a
portion of a telephone handset 32. The jack 200 is adapted to be
mated with the plug 34 which is universally connectable to all of
the embodiments of the inventive jack.
As can best be seen in FIG. 17, the plug 200 includes at least one
electrically conductive terminal, designated generally by the
numeral 202, having a first leg 203 connected to a second leg 204.
The first leg 203 includes a plurality of contact tangs 206--206
projecting laterally therefrom and an anchoring lug 207 projecting
laterally from an opposite side thereof. The axes of the first and
second legs 203 and 204, respectively, are at some angle to one
another. Unlike the terminals 102--102 and the terminals 152--152,
the terminals 202--202 are not U-shaped.
The second leg 204 of each of the terminals 202--202 includes a
first crown 208 on one side thereof and a second crown 209 on the
opposite side thereof. Finally, each of the terminals 202--202 has
an enlarged portion 210 extending laterally of a free end
thereof.
Referring again to FIG. 17, the at least one terminal 202 is shown
mounted in a housing, designated generally by the numeral 211, of
the jack 200. The housing 211 has a cavity 212 for receiving at
least portions of the mating plug 34 and also includes a plurality
of terminal-receiving grooves 213--213 for receiving the terminals
202--202. Each groove 213 has a wider portion for receiving an
associated one of a plurality of insulated conductors 214--214.
Moreover, when the terminals 202--202 are mounted in the
terminal-receiving grooves 213--213 of the housing 211, the contact
tangs 206--206 protrude into the wider portions of the grooves.
The housing 211 is also formed with a plurality of keyways 216--216
which open to the terminal-receiving grooves 213--213 for receiving
the terminal anchoring lugs 207--207 when the terminals 202-202 are
positioned in the grooves. In this way, the terminals 202--202 are
anchored against unintended longitudinal movement thereof relative
to the housing 211 when the plug 34 is mated with the jack 200.
The housing 211 is adapted to be mated with a cover 217 having a
plurality of ribs 218--218 which are designed to be received in
associated ones of the terminal-receiving grooves 213--213 to
confine the individual conductors 214--214 and cause the contact
tangs 206-206 to penetrate the insulation and establish electrical
contact therewith. The cover 217 also includes a bridge 219
projecting therefrom to clamp the conductors between the cover and
the housing to provide strain relief therefor.
In the previous two embodiments of the inventive jack, the contact
or second leg 104 and 154 of each of the terminals 102 and 152,
respectively, of the jack was received in the associated one of the
internal grooves 129 and 179, respectively, formed in the housing
and which opened into the cavity 112 and 162, respectively. In this
embodiment, the terminal-receiving passage is completed by grooves
221--221 formed in the underside of the cover 217 and which face
into the cavity 212. When the terminals 202--202 are received in
the terminal-receiving grooves 213--213, the enlarged portions
210--210 thereof are received in associated ones of the internal
grooves 221--221. The material between the grooves 221--221 serves
to insulate adjacent ones of the second legs 204--204 of the
terminals and also limits the lateral movement thereof.
In mating the plug 34 with the jack 200, the plug is inserted into
the cavity 212, so that the second legs 204--204 of the terminals
202--202 are received in associated ones of the terminal-receiving
grooves 53--53 of the base portion 42 of the plug. As the free ends
of the terminals 202--202 are moved into the flared entrances
56--56 and into the terminal-receiving grooves, the crown 209
engages the opposed wall of the terminal-receiving groove to urge
the crown 208 on the opposite side of the terminal into engagement
with the associated terminal 71 in the base portion 42 of the plug
34. The plug 34 is moved slidably into the cavity 212 in a path of
motion along the longitudinal axes of the terminals 202--202 until
the plug engages a rear wall 222 of the housing 211.
The principles of the present inventions greatly facilitate the
installations of telephone sets. For example, the plug 34
hereinbefore described is designed to be used with all telephone
sets. For example, the plug 34 hereinbefore described is attached
to each end of all telephone cords, retractile and straight. The
straight cords may be used to connect electrically the base portion
31 of the telephone set 30 with a wall terminal, (not shown). The
retractile cords 33--33 are used to connect electrically the
handset 32 with the base 31 of a telephone 30.
Several different construction jacks which embody the principles of
this invention are used in the different telephones 30--30
depending on the designs of the handset and base portions thereof.
All of the different construction jacks are adapted to be mated
with one of the universal plugs 34--34. The installation of a cord
by an installer or a replacement cord by an installer or a
subscriber is greatly facilitated. Moreover, the universal
adaptability of the plug 34 with any type jack makes possible the
reduction of inventories required for cords having different plug
ends.
The base portion 42 is made of a material which withstands
prolonged exposure to high temperature atmosphere to which the
cords 33--33 are exposed when the cords are rendered retractile.
Hence, the plugs 34--34 may be attached to the retractile cords
33--33 before the cords are rendered retractile. The dielectric
portion of the plug 34 is preferably molded from polycarbonate of
an injection molding grade which remains distortion-free at
temperatures up to a range of 280.degree. to 290.degree. F at
atmospheric pressure. An example of such material is Lexan
2805-112, available from the General Electric Company of
Pittsfield, Mass. The temperatures to which the cord 33 is exposed
in order to set the retractile shape in the cord is 265.degree. F.
Thus the polycarbonate in the dielectric portions can readily
tolerate the retractile-setting temperature of 265.degree. F
without suffering any undesired change of shape. Moreover, the
material from which the plugs 34--34 are constructed may be
pigmented to match the color of the telephone 30.
It is to be understood that the above-described arrangements are
simply illustrative of the principles of the invention. Other
arrangements may be devised by those skilled in the art which will
embody the principles of the invention and fall within the spirit
and scope thereof.
* * * * *