U.S. patent number 3,866,295 [Application Number 05/442,959] was granted by the patent office on 1975-02-18 for apparatus for connecting conductors to which are back to back.
This patent grant is currently assigned to AMP Incorporated. Invention is credited to John James Tucci.
United States Patent |
3,866,295 |
Tucci |
February 18, 1975 |
Apparatus for connecting conductors to which are back to back
Abstract
An apparatus is disclosed for connecting wires to the terminals
in two connectors which are in back-to-back relationship which
comprises a jig for holding the connectors, wire positioning means
for locating the wires, and trimming and inserting means for
trimming the wires and inserting them into the terminals in the
connectors.
Inventors: |
Tucci; John James
(Winston-Salem, NC) |
Assignee: |
AMP Incorporated (Harrisburg,
PA)
|
Family
ID: |
23758876 |
Appl.
No.: |
05/442,959 |
Filed: |
February 15, 1974 |
Current U.S.
Class: |
29/566.3; 29/753;
29/760; 29/749; 29/757 |
Current CPC
Class: |
H01R
43/01 (20130101); Y10T 29/53265 (20150115); Y10T
29/53217 (20150115); Y10T 29/515 (20150115); Y10T
29/53252 (20150115); Y10T 29/53235 (20150115) |
Current International
Class: |
H01R
43/01 (20060101); H01r 043/04 () |
Field of
Search: |
;29/23MW,23DT,23DS,23D,23R,23J |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Eager; Thomas H.
Attorney, Agent or Firm: Raring; Frederick W. Seitchik; Jay
L. Keating; William J.
Claims
1. Apparatus for connecting wires to the wire receiving portions of
electrical contact terminals, said terminals being contained in two
electrical connectors, said contactreceiving portions being
arranged in side-by-side relationship in a row in each of said
connectors, said apparatus comprising:
a connector jig plate having connector locating means thereon for
locating said two connectors adjacent to each other with said rows
extending parallel to each other in spaced-apart relationship,
a wire locating jig, means for locating said wire locating jig on
said connector jig plate in at least partially surrounding
relationship to two connectors mounted on said connector jig plate
and with portions of said wire locating jig extending beside each
of said rows of contact terminals, in said connectors,
fixed wire shearing means having parallel spaced-apart fixed shear
bars, means on said fixed shearing means for positioning said fixed
shearing means on connectors mounted on said connector jig plate
with said fixed shearing bars extending parallel to said rows of
conductor-receiving portions of said contact terminals,
wire locating means on said wire locating jig for locating a
plurality of wires in parallel side-by-side relationship with each
wire being in alignment with corresponding terminals in each of
said connectors, and
movable shearing and insertion means movable along a path extending
towards said jig plate, said movable shearing and insertion means
having movable shearing edges for cooperation with said fixed
shearing edges and having inserting punches for inserting said
wires, after trimming, into said contact terminals whereby,
upon positioning said connectors in back-to-back relationship on
said connector jig plate, positioning said wire locating jig on
said jig plate in at least partially surrounding relationship to
said connectors, positioning said fixed shearing means on said
connectors, locating wires in said wire locating means on said wire
locating jig, and moving said movable shearing and insertion means
along said path towards said jig plate, said wires will be sheared
and portions of said wires extending
2. Apparatus as set forth in claim 1, said wire locating jig
comprising an open rectangular frame, said frame being in
completely surrounding
3. Apparatus as set forth in claim 2, said wire locating means
comprising wire locating combs on two opposite sides of said frame,
each of said two opposite sides extending beside one of said rows
of said contact
4. Apparatus as set forth in claim 3, said fixed wire shearing
means comprising an open rectangular frame, said fixed shear bars
comprising two
5. Apparatus for connecting wires to the wire-receiving portions of
electrical contact terminals contained in each of two multi-contact
electrical connectors, said wire receiving portions in each of said
connectors being arranged in spaced-apart relationship in a single
row which is proximate to the rearward side of the connector
housing, said apparatus comprising:
a connector jig plate having connector locating means thereon for
locating said connectors in back-to-back relationship with said
rows of terminals in said connectors in parallel spaced-apart
relationship and with corresponding contact terminals in said rows
in opposed alignment with each other,
a wire locating jig comprising an open rectangular frame member
having two opposite sides which constitute wire locating sides,
said wire locating sides having wire locating means therein for
locating a plurality of wires in parallel side-by-side relationship
with said wires spaced apart by distances corresponding to the
spacing between said contact terminals in said rows, means for
positioning said locating jig on said jig plate with said wire
locating sides extending on each side of said rows of terminals in
connectors on said jig plate,
fixed wire shearing means comprising an open rectangular frame
having opposite sides which constitute shearing sides having
shearing edges, means for locating said fixed wire shearing means
on connectors mounted on said jig plate with said shearing edges
extending parallel to said rows of terminals, and
movable shearing edge and insertion means movable along a
predetermined path extending towards said jig plate and having two
parallel shearing edges for cooperation with said fixed shearing
edge means and having insertion punches for inserting said wires
into said wire-receiving portions of said terminals whereby,
upon placement of said connectors, said wire locating jig, and said
fixed wire shearing means on said jig plate and upon positioning
wires in said wire locating means with the axes of said wires
extending between corresponding terminals, and upon movement of
said movable shearing and insertion means towards said jig plate,
said wires are sheared adjacent to said terminals and inserted into
said contact receiving portions whereby corresponding terminals in
said rows are connected to each other.
Description
BACKGROUND OF THE INVENTION
This invention relates to a connector assembly for making tap
connections with selected conductors in a multi-conductor cable and
to a preferred form of apparatus for the manufacture of the tap
connector assembly. The connector disclosed herein which is used in
the connector assembly is disclosed and claimed in U.S. Pat. No.
3,760,335 and the preferred form of apparatus shown herein
incorporates the general teachings of U.S. Pat. Nos. 3,758,935 and
3,766,622. The instant invention is also related to the inventions
disclosed and claimed in applications Ser. Nos. 442,958, 442,960,
and 442,941, filed of even date herewith. These co-pending
applications disclose apparatus for several different types of wire
inserting operations and these other apparatus have one or more
parts in common with the instant apparatus.
It is common practice in the telephone industry and in other
industries to use multi-conductor cables consisting of a
predetermined number of wires contained in a continuous surrounding
sheath. A multi-conductor cable can be connected to an identical
cable by simply connecting the wires in both cables to
multi-contact electrical connectors which, when mated with each
other, connect corresponding wires in the two cable ends. The
connector shown in the above-identified U.S. Pat. No. 3,760,335 is
widely used for this purpose.
It is sometimes desirable to connect tap wires to a limited number
of the conductors in a cable. There are known methods of making tap
connections to a cable in which standard multi-contact connectors
are used but these known methods require soldering and potting
techniques and are very inconvenient and time-consuming. The
instant invention is thus directed to the achievement of an easily
manufactured connector assembly comprising two connectors which can
be coupled to connectors on the end of cables and which has
laterally extending tap wires connected to some of the terminals in
the connector assembly. This arrangement permits the use of a
standard connector, for example, of the type shown in U.S. Pat. No.
3,760,335 for making such tap connections. The invention is also
directed to the provision of suitable tooling for the manfacture of
tap connector assemblies.
It is accordingly an object of the invention to provide an improved
connector assembly for effecting tap connections to a
multi-conductor cable. A further object is to provide a tap
connector assembly which can be manufactured in a short time and
which is capable of providing tap connections to predetermined
conductors in a multi-conductor cable. A further object is to
provide an improved apparatus for the manufacture of connector
assemblies of the type comprising two connectors in back-to-back
relationship having wires extending between corresponding contact
terminals in the assembly.
These and other objects of the invention are achieved in preferred
embodiments thereof which are briefly described in the foregoing
abstract, which are described in detail below, and which are shown
in the accompanying drawing in which:
FIG. 1 is a perspective view of a connector jig plate which forms a
part of the preferred form of apparatus in accordance with the
invention.
FIG. 2 is a perspective view of a wire positioning jig which forms
part of the apparatus.
FIG. 3 is a perspective view of a fixed shear means which forms
part of the apparatus.
FIG. 4 is a side view of an apparatus in accordance with the
invention, this view showing the positions of the parts to
insertion of wires into the wire-receiving portions of terminals in
two back-to-back connectors mounted on the apparatus.
FIG. 5 is a view taken along the lines 5--5 of FIG. 4.
FIG. 6 is a fragmentary sectional side view showing portions of the
apparatus, this view showing the positions of the parts immediately
prior to severing of the wires and insertion of the wires into the
contact terminals.
FIG. 7 is a view similar to FIG. 6 but showing the positions of the
parts at the conclusion of the wire inserting operation.
FIG. 8 is a sectional side view of a tap connector assembly in
accordance with the invention.
FIG. 9 is a fragmentary perspective view of a connector of the type
used in the practice of the invention.
FIG. 10 is a diagramatic view showing tap wires extending to the
wires in a cable.
FIG. 11 is a diagramatic view showing the manner of effecting tap
connections in accordance with the invention.
FIG. 12 is a perspective view of a top connector assembly in
accordance with the invention having covers assembled to the
connectors.
FIG. 13 is a perspective view similar to FIG. 12 but with the
covers removed.
The invention is herein disclosed as an embodiment containing two
connectors of the type shown in FIG. 9 and described fully in the
above-identified U.S. Pat. No. 3,760,335. In accordance with the
teachings of that patent, wires 2 are connected to the wire
receiving portions 4 of electrical contact terminals 6 which are
contained in the housing 10 of the connector 8. The housing has a
mating face 12 and a rearward face 14. A central rib 16 extends
from the rearward side or face and a plurality of side-by-side
contact receiving cavities 18 extend through the housing on the
upper and lower sides of the rib. Each cavity contains an
individual terminal 6 and each terminal has a forward contact
portion 20, an intermediate shank 22, and the previously identified
wire receiving portion 4 which comprises two plate-like members 24,
26 which are connected at their upper ends by strap sections 28.
The wire 2 is moved laterally of its axis into the gap between the
strap members 28 and into slots 30 in the plate sections, the width
of these slots being such that the insulation of the wire is
penetrated and electrical contact is established with the
conducting core. When the terminals are mounted in the cavities,
the contact portions extend forwardly and into a trough-like recess
32 in the mating face 12 which is adapted to receive a
complementary male connector.
Adjacent terminals in the two rows are separated from each other by
barriers 36 and the end barriers 38 extend somewhat beyond the
other barriers 36 as shown. The housing 10 is provided with a
radially extending flange 34 by means of which it may be mounted in
a panel or the like.
FIG. 10 diagramatically illustrates the problem of tapping into a
cable. The cable 90 has a plurality of conductors 2 and has a
continuous insulating sheath surrounding all of the conductors as
shown. Where tap wires must be connected to some of the conductors
2, the sheath can be removed and the tap wires 92-2, 94-2, 96-2,
and 98-2 can be simply connected to the pre-determined wires 2 in
the cable as by soldering. This method would not be practical but
is shown here only by way of illustration.
Referring now to FIGS. 12 and 13, the connector assembly 9 in
accordance with the invention for making tap type connection
comprises two connectors 8, 8' in back to back relationship with
the corresponding contact terminals 6 in the two connectors in
opposed alignment. Short sections of wire 2 extend between the
wire-receiving portions of corresponding opposed terminals and
electrically connect them to each other excepting for the wires
extend between the terminals on the extreme right in FIG. 13. The
wire 94-2 extends from the terminal on the extreme right in the
connector 8' to the terminal on the extreme right in the connector
8 and is doubled back upon itself and extends thence laterally as
shown. The wire 92-4 is similarly connected to the next adjacent
terminal in the connector 8', to a corresponding terminal in the
connector 8, and extends laterally beside the wire 94-2. Additional
tap wires can be added in the same manner, only two such wires
being shown in the interest of clarity.
It is advantageous to provide a cover (FIG. 12) to the rearward
sides of the two connectors in the assembly in surrounding
relationship to the wires 2 which extend between the connectors.
This cover means comprises two identical parts 104 each of which
has a flat plate like section 106 and a depending latch arm 108 at
its end. The latch arm of each cover part is adapted to engage a
boss 110 on a short depending arm at the other end of the part so
that the two cover parts are latched to each other. Each cover part
has a flange (not shown) which extends into the space between the
barriers 36 and the rearwardly facing side of the housing as shown
in FIG. 4 of the above-identified U.S. Pat. No. 3,760,335. The
covers thus serve to hold the two connectors in assembled
relationship to each other and avoid the imposition of any stresses
on the wires.
Referring now to FIG. 11, a tap connection in accordance with the
invention is thus made by cutting the cable 90 and installing
conventional connectors 100-8 and 102-8 on the cut ends of the
cable, these connectors being of the type shown in FIG. 9. Each
wire in the cut ends of the cable is connected to one of the
terminals in one of the connectors 100-8; 102-8 and this
installation is, therefore, in all respects, conventional. The
connectors 102-8 and 100-8 are then coupled to the connectors 8'
and 8 of the tap connector assembly 9. Upon such coupling of all of
the connectors, the conductors in the righthand portion of the
cable 90 will all be connected to the conductors in the lefthand
portion 90' through the connector 100-8 the connector 8, through
the wires extending between the connectors 8', 8, and through the
connector 102-8. In addition, the laterally extending tap wires
92-2, 94-2 96-2 and 98-2 will be connected to predetermined wires
in the cable.
Referring now to FIGS. 1-5, a preferred form of apparatus for
manfacturing the tap connector assembly 9 comprises a connector jig
plate 40 having parallel spaced apart ribs 42 on its upper surface
41. Spaced apart notches 44 are provided in the ribs and are
dimensioned to receive the enlarged end barriers 38 of the
connectors so that when the connectors are positioned with the
rearwardly facing sides of their flanges against the ribs 42 and
with their barriers extending into the notches 44, the connectors
will be precisely positioned with respect to each other on the jig
plate.
The wires are located in the apparatus by wire positioning jig 46
(FIG. 2) in the form of a rectangular frame having sides 48 and
ends 50. Spaced apart notches 52 are provided in the lower edges of
the ends 50 to locate this wire positioning jig on the connector
jig and the distance between the opposed surfaces of the ends 50 is
equal to the distance between the extreme side portions 11 of the
flanges 34. When the wire positioning jig is thus positioned on the
jig plate, it will be precisely located with reference to the
connectors 8, 8' on the jig plate. The wires are located by means
of wire combs or wire jigs 54 which are T-shaped blocks bonded to
the inner surfaces of the sides 48. The upper surfaces of the wire
combs have spaced apart recess 58, the distance between adjacent
recesses being equal to the spacing between adjacent terminals in
the connectors 8, 8' so that wires located in the recesses with
intermediate portions extending across the wire jig will be in
alignment with corresponding terminals in the two connectors
mounted on the jig plate.
The lower or fixed tooling further comprises a fixed wire shear 60
(FIG. 3) having parallel side bar members 62 and end sections 64.
The side bar members 62 have spaced apart notches 66 which are
adapted to receive portions of the wires and the inner edges 68
(FIG. 6) at the inner ends of these notches function as fixed
shearing edges for the wires in cooperation with movable shearing
means described below. The fixed shearing member 60 is dimensioned
such that it will fit snugly between the opposed rearwardly facing
surfaces of the two connectors mounted in the lower tooling as best
shown in FIG. 6 so that the wire-receiving portions of the
terminals will be in alignment with the edges 68 and with a wire
located in the associated recesses 58 in the wire combs.
The lower tooling described above is mounted on the platen 80 of a
press (FIG. 4) having a neck portion 78 and a head 76 which
contains a reciprocable ram 74.
The upper or movable tooling comprises a pair of shearing and
inserting tool blocks 70, mounted on each side of a tool mounting
block 72 which is in turn mounted on the lower end of the ram 74.
Each tool block 70 has depending flanges 82, 84 at its lower end
and spaced apart insertion punches 86 are mounted in the tool block
between these flanges, one insertion punch being provided for each
terminal in the connectors. The outside edges 88 of the blocks 70
function as shearing edges in cooperation with the fixed shearing
edges 68 as is apparent from FIG. 7.
The first step in the manufacture of a tap connector assembly 9 is
to connect most of the corresponding terminals in the connectors 8,
8' to each other by the short lengths of the wire shown in FIG. 13
excepting those terminals (shown on the right in the FIG. 7) to
which the tap wires are to be connected. To form these
straight-through connections, the connectors are located on the jig
block (FIG. 1) and the wire positioning jig 46 is then positioned
on the jig block in surrounding relationship to the connectors. The
fixed shearing member 60 then is positioned as shown in jig 6
between the rearwardly facing sides of the connectors 8, 8'. Short
lengths of wire are then positioned in corresponding recess 58 in
the wire combs of the wire positioning jig so that intermediate
portions of the wires extend above corresponding contact terminals
as shown in FIG. 6. Wires are not positioned in the recesses 58
which are above the terminals to which the tap wires are to be
connected.
The ram 74 is moved downwardly to move the upper tooling downwardly
from the position of FIG. 6 to the position of FIG. 7. During such
movement of the upper tooling, the individual wires 2 are engaged
by the tool blocks 70 and moved downwardly and into the slots 30 in
the wire receiving portions of the terminals. During movement of
the wires past the edges 68, the wires are trimmed and only with
central portions of the wires are moved into the terminals. The
notches 66 in the side bars 62 guide the wires accurately towards
the terminals during their downward movement.
The ram is then raised, the fixed tooling is removed from the jig
plate, and the connector is reversed so that the remaining row of
terminals are on the upper side. The process described above is
then repeated to connect corresponding terminals in the two
connectors in the remaining rows to each other with short lengths
of wire. If tap wires are to be connected to any of the terminals
in the remaining row, the terminals which are to receive these tap
wires are not connected at this time.
In order to connect the tap wires 92-2, 94-2, 96-2, and 98-2 to the
terminals, the fixed shear 60 is removed from the lower tooling and
the tap wires are positioned as shown in FIG. 8 with the end of
each tap wire located above the wire receiving portion of a
terminal in one connector and with the wire dressed rightwardly
towards the corresponding terminal in the other connector. The wire
is reversely bent so that a double fold of wire is located over the
conductor receiving portion of the terminal in the righthand
connector and the wire is dressed from this terminal laterally.
After the required number of tap wires have been positioned in the
connector in this manner, the ram 72 is lowered so that these tap
wires will be inserted into the wire receiving portions of the
terminals. The folded portions of the wires are inserted into the
terminals in the righthand connector in FIG. 8 and are not sheared
since the fixed shear 60 also briefly removed from the lower
tooling. If tap wires are to be connected to selected terminals in
the remaining row of terminals, the connector assembly is reversed
so that the remaining row faces upwardly and the procedure for
connecting tap wires as described above is repeated. It is
desirable to dress the tap wires laterally and between the two rows
of short wire sections as shown and the tap wires are led to the
assembly through suitable opening in the cover. In the embodiment
shown, the four tap wires are contained in an insulating sheath
which has been stripped away at its end.
It will be understood that variations of the procedure can be
carried out or practiced if desired. The tap wires may vary in
number according to the requirements of a particular situation and
can be connected to any of the terminals in either of the
connectors rather than to terminals at the ends of the connectors
as shown.
A salient advantage of the invention is that tap connections to
conductors in a cable can be made in a short time with standard
connectors of the type which are also used with the same cable for
end connections. The tap connections are easily serviced or
changed; that is more tap connections can be added if desired by
simply moving the assembly 9 and replacing it with another assembly
for a tap conductors extending to the desired terminals. The tap
connections can be removed from the cable by removing the tap
assembly 9 and simply coupling the connector 100-8 directly to the
connector 102-8.
Changes in construction will occur to those skilled in the art and
various apparently different modifications and embodiments may be
made without departing from the scope of the invention. The matter
set forth in the foregoing description and accompanying drawings is
offered by way of illustration only.
* * * * *