U.S. patent number 3,850,497 [Application Number 05/346,724] was granted by the patent office on 1974-11-26 for connector.
This patent grant is currently assigned to Bell Telephone Laboratories, Incorporated. Invention is credited to Charles Louis Krumreich, Albert Eugene Mulbarger, Jr., Stephen William Walden.
United States Patent |
3,850,497 |
Krumreich , et al. |
November 26, 1974 |
CONNECTOR
Abstract
A dielectric enclosure having a plug receiving cavity, one wall
of which includes a multiplicity of spaced orifices extending
generally parallel to the depth of the cavity and a like
multiplicity of grooves each of which extends from the front end of
an individual orifice to the cavity. Each orifice accommodates a
splicing member, the rear portion of which embraces an insulated
conductor and the forward portion of which clamps the bared end of
the conductor into engagement with the end of a wire spring
contact. The other end of each insulated conductor is terminated by
a cord tip, and the remainder of each wire spring contact comprises
a first portion that is positioned within the associated groove and
a second portion that extends rearwardly cantilever fashion within
the plug receiving cavity.
Inventors: |
Krumreich; Charles Louis
(Indianapolis, IN), Mulbarger, Jr.; Albert Eugene
(Indianapolis, IN), Walden; Stephen William (Morral
Township, Shelby County, IN) |
Assignee: |
Bell Telephone Laboratories,
Incorporated (Murray Hill, NJ)
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Family
ID: |
26926344 |
Appl.
No.: |
05/346,724 |
Filed: |
April 2, 1973 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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232804 |
Mar 8, 1972 |
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Current U.S.
Class: |
439/545; 439/877;
439/660 |
Current CPC
Class: |
H01R
24/62 (20130101) |
Current International
Class: |
H01r 011/08 ();
H02b 001/02 () |
Field of
Search: |
;339/17F,17L,17LM,91,119R,119L,125,126,128,107,176M,176MF,176MP,208,221
;179/100 ;248/27 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1,478,385 |
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Mar 1967 |
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FR |
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56,278 |
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Jun 1967 |
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DL |
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218,595 |
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Dec 1961 |
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OE |
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Primary Examiner: Frazier; Roy D.
Assistant Examiner: Staab; Lawrence J.
Attorney, Agent or Firm: Newman; H. L.
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of copending
application, Ser. No. 232,804, filed Mar. 8, 1972, and now
abandoned.
Claims
What is claimed is:
1. A connector comprising:
a dielectric enclosure including a plurality of spaced orifices
that extend from the front to the rear of the enclosure, each
orifice comprising a bore portion at the forward end thereof and a
counter bore portion at the rear end thereof, the enclosure further
including a plurality of grooves at the front end thereof, each
groove being associated with an individual orifice and extending
transversely to the longitudinal axis of that orifice, the grooves
being exposed to the exterior of the enclosure; and
a plurality of contact assemblies, each of which comprises a spring
contact, an insulated conductor, and a splicing member the rear
portion of which embraces the insulated conductor and the forward
portion of which clamps a bared end of the conductor to an end of
the spring contact, the forward portion of each splicing member
being accommodated in the bore portion of an individual orifice and
the rear portion being accommodated in the counter bore portion of
the orifice, the spring contact extending from the front end of the
orifice and including a first portion positioned within the
transverse groove associated with the orifice and a second portion
extending rearwardly from the first portion.
2. A connector as in claim 1 wherein each spring contact comprises
a wire spring contact formed of high tensile strength spring metal
and the splicing member comprises a U-shaped channel formed of
relatively malleable metal, the rear portion of the splicing member
being crimped about the insulated conductor and being larger in
cross section than the forward portion which is crimped about the
bared end of the conductor and an end of the wire spring contact in
such manner as to form a high pressure direct electrical connection
between the conductor and the wire spring contact.
3. A connector as in claim 1 wherein the enclosure further includes
a plug receiving cavity open to the front of the enclosure, the
second portion of the spring contacts extending rearwardly
cantilever fashion within the cavity.
4. A connector as in claim 3 wherein the enclosure further includes
a slotted wall at the rear of the plug receiving cavity, the free
ends of the second portion of each spring contact being
accommodated within an individual slot in the slotted wall.
5. A connector as in claim 4 wherein the enclosure comprises a base
and a top, the top comprising one wall of the plug receiving cavity
and including the orifices in which the contact assemblies are
supported, and the base comprising walls defining the remainder of
the plug receiving cavity and including the slotted wall.
6. A connector as in claim 5 wherein the base includes a pair of
spaced side walls and the top includes a pair of recesses formed in
the underside thereof adapted to accommodate the upper ends of the
side walls.
7. A connector adapted to be held in place between the edges of a
pair of adjacent holding walls, the edge of a first of the walls
including an opening the periphery of which is shaped to embrace a
portion of the connector, the connector comprising:
a dielectric enclosure having a plug receiving cavity open to the
front of the enclosure, a first of the walls defining the plug
receiving cavity including a plurality of orifices that extend from
the front to the rear of the enclosure, the orifices being spaced
both from one another and from the plug receiving cavity, the first
wall further including a plurality of grooves at the front end
thereof, each groove being associated with an individual orifice
and extending transversely to the longitudinal axis of that
orifice, the grooves extending to the plug receiving cavity and
being exposed to the exterior of the enclosure, the exterior of the
enclosure including a ledge engaged by the first holding wall and a
slot for accommodating an edge of the second holding wall, the slot
having a tongue located there within that is accommodated by a
complementary opening in the edge of the second holding wall for
locating the connector with respect to the second holding wall;
and
a plurality of contact assemblies, each of which comprises a spring
contact having a splicing member at one end, the splicing member of
each contact assembly being accommodated by an individual orifice,
the spring contact extending from the front end of the orifice and
including a first portion positioned within the transverse groove
associated with the orifice and a second portion extending
rearwardly cantilever fashion within the plug receiving
opening.
8. A connector adapted to be held in place between the edges of a
pair of adjacent holding walls, the edges of a first of the walls
including an opening the periphery of which is shaped to embrace a
portion of the connector, the connector comprising:
a dielectric enclosure having a plug receiving cavity open to the
front of the enclosure, a first of the walls defining the plug
receiving cavity including a plurality of orifices that extend from
the front to the rear of the enclosure, the orifices being spaced
both from one another and from the plug receiving cavity, the first
wall further including a plurality of grooves at the front end
thereof, each groove being associated with an individual orifice
and extending transversely to the longitudinal axis of that
orifice, the grooves extending to the plug receiving cavity and
being exposed to the exterior of the enclosure, the exterior of the
enclosure including a ledge engaged by the first holding wall and a
slot for accommodating an edge of the second holding wall, one of
the surfaces defining the slot including a protrusion for providing
frictional engagement with the second holding wall; and
a plurality of contact assemblies, each of which comprises a spring
contact having a splicing member at one end, the splicing member of
each contact assembly being accommodated by an individual orifice,
the spring contact extending from the front end of the orifice and
including a first portion positioned within the transverse groove
associated with the orifice and a second portion extending
rearwardly cantilever fashion within the plug receiving
opening.
9. A slip-on connector adapted to be secured in place between the
edges of a pair of adjacent holding walls, the edge of a first of
the holding walls including a shaped opening, the connector
comprising an enclosure having a plug receiving cavity that is open
to the front of the enclosure and a plurality of contacts that are
exposed to the interior of the cavity, the front end of the
enclosure including external side surfaces that are spaced from one
another the same distance as and have the same configuration as the
sides of the opening in the first holding wall, the front end of
the enclosure also including a ledge extending on each side of the
plug receiving cavity for engagement by the first holding wall, the
enclosure further including a slot for accommodating an edge of the
second holding wall, the slot having a tongue located therewithin,
the tongue being accommodated by a complementary opening in the
edge of the second holding wall for locating the connector with
respect to the second holding wall.
10. A slip-on connector adapted to be secured in place between the
edges of a pair of adjacent holding walls, the edge of a first of
the holding walls including a shaped opening, the connector
comprising an enclosure having a plug receiving cavity that is open
to the front of the enclosure and a plurality of contacts that are
exposed to the interior of the cavity, the front end of the
enclosure including external side surfaces that are spaced from one
another the same distance as and have the same configuration as the
sides of the opening in the first holding wall, the front end of
the enclosure also including a ledge extending on each side of the
plug receiving cavity for engagement by the first holding wall, the
enclosure further including a slot for accommodating an edge of the
second holding wall, the surfaces defining the slot including a
protrusion for providing frictional engagement with the second
holding wall.
11. A slip-on connector adapted to be secured in place between the
edges of a pair of adjacent holding walls, the edge of a first of
the holding walls including a shaped opening, the connector
comprising an enclosure including external side surfaces that are
spaced from one another the same distance as and have the same
configuration as the sides of the opening in the first holding
wall, the enclosure also including a ledge for engagement by the
first holding wall and a slot for accommodating an edge of the
second holding wall, the slot having a tongue located therewithin,
the tongue being accommodated by a complementary opening in the
edges of the second holding wall.
12. A slip-on connector adapted to be secured in place between the
edges of a pair of adjacent holding walls, the edge of a first of
the holding walls including a shaped opening, the connector
comprising an enclosure including external side surfaces that are
spaced from one another the same distance as and have the same
configuration as the sides of the opening in the first holding
wall, the enclosure also including a ledge for engagement by the
first holding wall and a slot for accommodating an edge of the
second holding wall, the surfaces defining the slot including a
protrusion for providing frictional engagement with the second
holding wall.
Description
FIELD OF THE INVENTION
This invention relates to the field of electrical connectors and to
subassemblies thereof.
BACKGROUND OF THE INVENTION
The direction of electrical technology today is toward smaller and
smaller components, and this is no less true with respect to
electrical connectors than it is with respect to other discrete
components. However, one major problem in this movement toward
miniaturization of connectors is manufacturability. As connectors
become smaller, they typically become more difficult and
consequently more expensive to manufacture.
SUMMARY OF THE INVENTION
The connector of the present invention lends itself to
miniaturization, but in addition, it is designed so that elements
of the connector can be assembled by automated machinery.
An illustrative embodiment of the connector comprises a dielectric
enclosure having a plug receiving cavity at the front end thereof.
One of the walls that defines the cavity includes a multiplicity of
orifices that are spaced both from one another and from the cavity
and extend from the front to the rear of the enclosure. The front
end of this wall also includes a multiplicity of grooves, each of
which is exposed to the exterior of the enclosure and extends from
an individual orifice to the plug receiving cavity.
Each orifice accommodates a splicing member that is essentially the
same size as the orifice. The rear portion of each splicing member
embraces an insulated conductor while the forward portion clamps
the bared end of the conductor into engagement with the end of a
wire spring contact. The other end of each insulated conductor is
terminated by a cord tip, and the remainder of each wire spring
contact comprises a first portion that is positioned within the
associated groove and a second portion that extends rearwardly
cantilever fashion within the plug receiving cavity.
One method of assembling the connector is to cut off a preselected
length of insulated conductor fed from a reel, and simultaneously
strip the insulation from both ends. One bared end is then placed
in a strip fed cord tip, while the other bared end is placed in a
strip fed splicing member concurrently with a reel fed length of
wire spring contact. The cord tip is thereafter crimped to join it
to the insulated conductor, and the splicing member is crimped to
join the conductor to the wire spring contact, after which the
contact is cut to length. A multiplicity of such contact assemblies
are formed simultaneously, and the splicing member of each is
inserted into one of the orifices with the wire spring contact
extending out of the forward end. The assembly is completed by the
wire spring contacts being formed to the desired configuration.
DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded perspective showing the connector of this
invention;
FIG. 2 is a sectional view showing one of the orifices of the
connector;
FIG. 3 is a similar view to FIG. 2 showing a contact assembly
positioned within the orifice;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3 showing
the manner in which the splicing member of the contact assembly
connects the insulated conductor to the wire spring contact;
and
FIG. 5 and 6 are exploded perspective views showing alternative
embodiments of the connector of the invention, these embodiments
being adapted to be secured in place between two adjacent holding
walls.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 of the drawing, a connector in accordance with
the present invention comprises a dielectric enclosure 10
consisting of a base 100 and a top 200. The base 100 includes a
pair of side walls 110 upstanding from a bottom 120, and the inside
of each side wall has a ledge 112 that extends from the front of
the wall to an inwardly extending flange 114 at the rear of the
wall. The base 100 further includes a front wall 130 upstanding
from the bottom 120 and a rear wall 140 extending between the side
walls 110 adjacent to the upper ends thereof. The front wall 130
has a single notch 135 formed in its upper surface while the rear
wall 140 has four parallel slots 145 formed in its upper surface.
Finally, the base 100 has hollow cylindrical bosses 150 at the
sides thereof for accommodating fasteners that secure the connector
in place.
The top 200 of the enclosure 10 has a pair of recesses 210 formed
in the underside 220 thereof, the recesses being of a size and
space so as to accommodate the upper ends of the side walls 110 of
the base 100. In addition, the top 200 has four staggered orifices
230 that are spaced both from one another and from the underside
220. As shown in FIG. 2, each orifice 230 extends from the front to
the rear of the top 200 and includes a bore portion 232 at the
forward end thereof and a counterbore portion 234 at the rear end
thereof. Furthermore, the interior of the counterbore portion 234
includes a plurality of spaced axially extending ribs 235.
Referring now to both FIG. 1 and 2, the front of the top 200
includes four parallel grooves 240, each of which extends from the
front end of an individual orifice 230 to the underside 220. The
entire length of each groove 240 is exposed to the exterior of the
top 200 and the bottom surface of each groove is inclined
rearwardly. The spacing between the grooves 240 is the same as the
spacing between the slots 145 in the rear wall 140 in the base 100,
and the location of the grooves with respect to the recesses 210 is
the same as the location of the slots with respect to the side
walls 110. Consequently, when the top 200 is placed on the base
100, the grooves 240 are in registration with the slots 145.
Turning to FIG. 3 and 4, the connector further includes four
contact assemblies 300, each of which comprises a wire spring
contact 310 joined to an insulated lead wire 320 by a splicing
member 330. The wire spring contact 310 is formed from a high
tensile strength spring material such as spring temper phosphor
bronze, while the splicing member 330 is formed from a relatively
malleable material such as brass. The splicing member 330 comprises
a U-shaped channel having a bottom and two side walls extending in
generally the same direction from the bottom, and a first portion
332 at one end of the channel is smaller in cross-section than a
second portion 334 at the other end. The larger portion 334
accommodates the insulated lead wire 320 while the smaller portion
332 accommodates the tail end of the wire spring contact 310 and
the bared end 322 of the lead wire. The channel when crimped around
these elements is formed into a sleeve that tightly grips the
elements and prevents them from being displaced with respect to one
another. The high pressure direct engagement of the bared end 332
of the lead wire 320 with the wire spring contact 310 provides a
good electrical connection therebetween. The other end of the
insulated lead wire 320 is terminated by a cord tip 340.
Referring also to FIG. 2, each splicing member 330 is accommodated
by an individual orifice 230 in the top 200 by first inserting the
unformed wire spring contact 310 through the orifice and then
inserting the splicing members into the orifice. The crimping
portion 332 of each splicing member 330 is slightly smaller than
the bore 232 of each orifice 230, but the crimped portion 334 of
each splicing member, while slightly smaller than the counter-bore
234, is slightly larger than the spacing between the tops of the
ribs 235. Hence, there is an interference fit therebetween, and
when each splicing member 330 is inserted into its associated
orifice 230, the ribs 235 clamp it in place.
Once the splicing members 330 are secured within the orifice 230,
each wire spring contact 310 is formed to provide a first portion
312 that is positioned within the associated groove 240, the groove
being slightly wider than the diameter of the contact. In addition,
each wire spring contact 310 is formed to provide a second portion
314 that extends rearwardly cantilever fashion beneath the
underside 220 of the top 200, and the second portion is of a length
so that when the top is positioned on the base 100 (FIG. 1), the
free end of the contact is accommodated by the corresponding slot
145 in the rear wall 140 of the base. The slots 145 serve to
maintain the second portions 314 of the contacts 310 in parallel
alignment.
Referring again to FIG. 1, the top 200 is advantageously joined to
the base 100 by ultrasonic bonding, energy directors 212 being
provided in the recesses 210 of the top to facilitate this
operation. The enclosure 10 thereby formed includes a plug
receiving cavity that is bounded by the underside 220 at the top,
the side walls 110 at the side, and the upper surfaces of the
ledges 112 at the bottom. The notched front wall 130 serves as a
catch for the latch of the plug accommodated by the opening, and
the flanges 114 serve as stops for limiting the rearward motion of
the plug.
An example of a plug adapted to mate with the connector of this
invention is disclosed in the copending application Ser. No.
232,803, filed the same day as the present application, now U.S.
Pat. No. 3,761,869. Furthermore, when the connector is mated with a
plug of this type, the slotted rear wall 140 may be eliminated
inasmuch as the plug itself serves to capture the portions 314 of
the wire spring contacts 310 and locate them in registration with
the contacts of the plug.
Referring to FIGS. 5 and 6, it is seen that the enclosure of the
connector of this invention may take many different shapes and
rather than being formed by the joining of multiple parts it may be
advantageously formed as a unitary member. Furthermore, rather than
being secured in place by means of fasteners, the connector may be
simply slipped into place and secured between the edges of two
adjacent walls.
Thus, in the embodiment shown in FIG. 5 the enclosure 10' includes
side walls 110' that extend forward of the front wall 130', the
forward ends of the side walls being inclined and having outwardly
extending flanges 116'. In addition, the upper ends of the side
walls 110' extend forward of the top 200' to provide ledges
118'.
The bottom 120' of the enclosure 10' includes a slot 122' that
extends the entire width of the enclosure, and the rear wall of the
slot comprises a cantilevered vane 124' that has a forwardly
protruding foot 125' at the lower end and side extremities thereof.
In addition, the bottom 120' includes a laterally extending tab
126' having a depending stud 128'.
The connector shown in FIG. 5 is secured between a holding wall
410, which is inclined at the same angle as the forward ends of
side walls 110', and a holding wall 420 having an upstanding
portion 422 and a horizontal portion 424. The lower end of the
holding wall 410 has an opening 412 formed therein, and the sides
of the opening are spaced from one another the same distance as and
having the same configuration as the external surfaces of the side
walls 110' adjacent to the flanges 116'. The upstanding portion 422
of the holding wall 420 has a thickness that is slightly less than
the width of the slot 122', while the horizontal portion 424 has a
hole 425 therein that conforms to the shape of the stud 128'.
The connector is secured in place by positioning the enclosure 10'
so that the slot 122' overlies the upstanding portion 422 of the
holding wall 420 and the stud 128' overlies the hole 425 in the
horizontal portion 424. The connector is then moved downward
causing the foot 125' of the vane 124' to engage the edge of the
upstanding portion 422. Continued downward movement of the
connector results in the rearward deflection of the vane 124' and
the insertion of the upstanding portion 422 into the slot 122'.
This is followed by the insertion of the stud 128' into the hole
425 as the bottom 120' of the enclosure 10' moves into engagement
with the horizontal portion 424.
The positioning of the stud 128' in the hole 425 serves to properly
locate the connector with respect to the holding wall 420 while the
deflected vane 124 acts to press the foot 125' against the
upstanding wall portion 422 to provide frictional engagement
therewith. With the connector in position, the holding wall 410 is
moved downward to place the sides of the opening 412 astride the
side walls 110' immediately behind the flanges 116' and to place
the top of the opening in engagement with the ledges 118'.
Referring now to FIG. 6, in this embodiment the enclosure 10"
includes side walls 110" that extend forward of the top 200" to
provide ledges 118". In addition, the bottom 120" includes a slot
122" that extends the entire width of the enclosure 10" and has a
tongue 123" positioned therein.
The connector is secured between holding walls 430 and 440. The
holding wall 430 has an opening 432 in the lower end thereof of a
size and shape to embrace the exterior of the side walls 110" at
the forward end of the enclosure 10". The holding wall 440 has an
opening 442 in the upper end thereof that is of a size and shape to
embrace the tongue 123", the wall having a thickness that is
slightly less than the width of the slot 122".
The connector is secured in place by positioning the enclsoure 10"
so that the slot 122" overlies the wall 440 and the tongue 123" is
in alignment with the opening 442. The connector is then moved
downward to place the tongue 123' into the opening 442 and to move
the portion of the wall 440 immediately adjacent the opening into
the slot 122". The wall 430 is thereafter moved downward to place
the sides of the opening 432 astride the side walls 110" and the
top of the opening in engagement with the ledges 118".
As can be surmised from FIGS. 5 and 6, the walls 410 and 430
respectively overlap the walls 420 and 440, and in the usual
situation the walls are the sides of a pair of structures that are
secured together to form an enclosure for electrical components,
the connector serving to provide electrical connection to those
components.
Although three embodiments of the invention have been shown and
described, it will be understood that these are only illustrative
and that various modifications may be made therein without
departing from the scope and spirit of this invention as defined in
the appended claims.
* * * * *