CA1214836A - Electrical interconnection system - Google Patents
Electrical interconnection systemInfo
- Publication number
- CA1214836A CA1214836A CA000430928A CA430928A CA1214836A CA 1214836 A CA1214836 A CA 1214836A CA 000430928 A CA000430928 A CA 000430928A CA 430928 A CA430928 A CA 430928A CA 1214836 A CA1214836 A CA 1214836A
- Authority
- CA
- Canada
- Prior art keywords
- electrical
- bus
- conductors
- branch
- set forth
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
- H01R12/50—Fixed connections
- H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
- H01R12/65—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures characterised by the terminal
- H01R12/67—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures characterised by the terminal insulation penetrating terminals
- H01R12/68—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures characterised by the terminal insulation penetrating terminals comprising deformable portions
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
- H01R12/50—Fixed connections
- H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
- H01R12/61—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures connecting to flexible printed circuits, flat or ribbon cables or like structures
- H01R12/613—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures connecting to flexible printed circuits, flat or ribbon cables or like structures by means of interconnecting elements
- H01R12/616—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures connecting to flexible printed circuits, flat or ribbon cables or like structures by means of interconnecting elements having contacts penetrating insulation for making contact with conductors, e.g. needle points
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
- H01R4/2416—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type
- H01R4/2445—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type the contact members having additional means acting on the insulation or the wire, e.g. additional insulation penetrating means, strain relief means or wire cutting knives
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/01—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for connecting unstripped conductors to contact members having insulation cutting edges
Landscapes
- Multi-Conductor Connections (AREA)
- Connections By Means Of Piercing Elements, Nuts, Or Screws (AREA)
- Manufacturing Of Electrical Connectors (AREA)
- Coupling Device And Connection With Printed Circuit (AREA)
Abstract
ABSTRACT:
An electrical cable assembly comprises a main electrical bus to which branch electrical buses are electrically connected. The main bus and branch buses include a plurality of insulated electrical conductors extending crosswise to one another with electrical connectors electrically connecting selected electrical conductors of the buses together. The electrical connectors penetrate the insulation of the buses and make electrical connection with the electrical conductors. The terminated sections of the buses can be housed in housing members providing strain relief and insulation. Shielding can be applied onto the main bus and ground connections can be effected at the housing members.
An electrical cable assembly comprises a main electrical bus to which branch electrical buses are electrically connected. The main bus and branch buses include a plurality of insulated electrical conductors extending crosswise to one another with electrical connectors electrically connecting selected electrical conductors of the buses together. The electrical connectors penetrate the insulation of the buses and make electrical connection with the electrical conductors. The terminated sections of the buses can be housed in housing members providing strain relief and insulation. Shielding can be applied onto the main bus and ground connections can be effected at the housing members.
Description
~2141936 ELECTRICAL INTERCONNECTION SYSTEM
This invention relates to electrical connection systems and more particularly to electrical interconnection systems.
Electrical wiring harnesses are typically assembled from discrete electrical wires that are individually routed to preselected locations and subsequently bundled together. These harnesses are customarily assembled by manual application.
Machines have been developed to automatically assemble harnesses.
In either case, assembling such wire harnesses is time-consuming and expensive.
In accordance with one aspect of the present invention, there is provided an electrical cable assembly, comprising:
main electrical bus means including a multiplicity of electrical conductors isolated from one another by insulating jacket means;
branch electrical bus means including less electrical conductors than said main bus means isolated from one another by insulating jacket means, said branch electrical bus means crossing said main electrical bus means; electrical connector means selectively connecting electrical conductors of said branch electrical bus means to respective electrical conductors of said main electrical bus means; and dielectric means applied to the terminated section of the electrical connection harness thus formed insulating the electrical connections thereof.
According to another aspect of the present invention, there is provided a method of making an electrical cable assembly, comprising the steps of: feeding a main bus cable to a terminating ~r, ~2~41~;
station; feeding a length of a branch bus cable across said main bus cable; selectively applying electrical connectors to the crossed buses electrically connecting electrical conductors of the main bus cable to respective electrical conductors of the branch bus cable by means of leg members of the connectors pene-trating the insulation jackets of the bus cables at corners of the crossing of the conductors and conductor-engaging means of the connectors engaging the conductors; cutting the branch bus cable; and positioning a dielectric means onto the terminated sections of the buses.
According to a further aspect of the present invention, there is provided an electrical connector for electrically con-necting insulated round electrical conductors disposed crosswise of each other, comprising: a body section having L-shaped legs in cross section, aligned slots between adjacent legs, one of the aligned slots cutting through the insulation covering one of the electrical conductors and electrically connecting with the elec-trical conductor while the other of the aligned slots cuts through the insulation covering the other of the electrical con-ductors and electrically connecting with the electrical conductor.
According to yet another aspect of the present invention,there is provided an electrical connector for electrically con-necting insulated flat electrical connectors disposed crosswise of each other, comprising: a body section having inwardly-direc-ted wedge-shaped members for penetrating the insulation of one of the electrical conductors and being embeddable into the electrical conductors, leg members extending outwardly from the body section lZ14~;
and having pointed ends for penetrating through the insulation of the crossed electrical conductors straddling them with the pointed ends being bendable back through the insulation covering the other conductor and into penetrating engagement with the other electrical conductor.
The invention will now be described in greater detail with reference to the accompanying drawings, in which:
FIGURE 1 is a perspective and exploded view of a main electrical bus, branch electrical bus, connectors to selectively interconnect electrical conductors of the buses, and housing members to house the interconnected sections of the buses.
FIGURE 2 is a perspective view showing the elements of Figure 1 assembled.
FIGURE 3 is a perspective view of parts of crossed buses with electrical connectors exploded therefrom.
FIGURE 4 is similar to Figure 3 with one of the connec-tors in a terminated position and the other in a part-terminated position.
FIGURE 4A is a perspective view of an alternative embodiment of the electrical connector.
FIGURE 5 is a part cross-sectional view of a housing member showing a ground contact with interconnected buses and another housing member exploded therefrom.
FIGURE 6 is a view similar to Figure 5 in an assembled condition.
~2~4836 FIGURE 7 is a perspective view of another alternative embodiment of an electrical connector exploded from crossed buses.
FIGURE 8 is a cross-sectional view of the electrical connector of Figure 7 in a terminated condition with electrical conductors of the crossed buses .
FIGURE 9 is a perspective view of a further embodiment of an electrical connector exploded from crossed buses.
FIGURE 10 is a cross-sectional view of the electrical connector of Figure 9 in a terminated condition with electrical conductors of the crossed buses .
FIGURE 11 is a perspective view of a harness making operation for electrically interconnecting branch electrical buses to a main electrical bus.
FIGURE 12 is a large perspective view of the programmable terminating equipment of Figure 11.
FIGURE 13 is a flow diagram of the harness making operation of Figures 11 and 12.
Figures 1 through 6 illustrate an electrical interconnection system relatlng to a main electrical bus 10 to which is electrically connected branch electrical buses 12 to form an electrical harness for use in electronic controlled equipment or the like. Main electrical bus 10 is in the form of a multl-conductor cable with electrical conductors 14 disposed in an insulatlng jacket 16 so that electrical conductors 14 extend parallel to and insulated from one another. Electrical conductors 14 are typically of a size to carry electronic signals therealong in either direction and the conductors can either be stranded or single conductors. Branch electrical buses 12 are of the same construction with electrical conductors 18 covered 97~0 -3-~214~
by insulating jacket 20; branch buses 12 may not have as many conductors as main bus 10.
Part of the electrical conductors in main electrical bus 10 and branch electrical buses 12 can be larger for the purpose of supplying power to electronic equipment if desired.
Figures 3 and 4 best illustrate electrical connectors 22 for electrically connecting electrical conductors 18 of branch bus 12 to electrical conductors 14 of main bus 10. Electrical connectors 2 are stamped and formed from a suitable metal strip in strip form and they are formed into a body sectlon 23 having a rectangular configuration with slots 24 located in opposing sides and slots 26 located in the other opposing sides. The entrances to slots 24 and 26 are beveled. Legs 28 have an L-shape in cross section and are located at each of the corners of electrical connectors 22. Electrical connectors 22 can have a round configuration if desired as shown in Figure 4A.
When it is desired to electrically connect selected ones of electrical conductors 18 of branch bus 12 with electrical conductors 14 of main bus 10, legs 28 of electrical connectors 22 are forced through insulating jacket 20 so that slots 24 displace the insulation surrounding electrical conductor 18 and legs 28 penetrate insulating jacket 16 while slots 26 displace the insulation surrounding electrical conductor 14 selected to be connected with electrical conductor 18 on each side of their selected crossing locations thereby electrically connecting the selected conductors together. In this way, electrical conductors of main bus 10 and electrical conductors of branch bus 12 can be selected for interconnection by electrical connectors 22 thereby resultlng in a programmed interconnection therebetween in lZ1419;~;
accordance with the needs of the electr~nic equipment to which branch bus 12 is to be electrically connected by means of a suitable electrical connector ( not shown) terminated to the conductors of branch bus 12.
Electrical connectors 22 in a strip form can be inserted into a terminated position by a program-operated applicator of the type illustrated in Figures 11 and 12, legs 28 penetrate through insulatlng jackets 20, 16 of buses 10, 12 and respectively straddle electrical conductors 18, 14 with slots 24 displacing the insulation covering conductors 18 and making electrical connection with the conductors, whereas slots 26 displace the insulation covering electrical conductors 14 and aiso make electrical connection therewith as illustrated in Figure 4. In this way, selected conductors 18 of bus 12 are electrically connected with selected conductors 14 of bus 10 thereby programmably interconnecting these electrical conductors together in accordance with an established program.
The terminated sections of branch buses 12 to main bus 10 are preferably encased in housing member 30 to protect the terminations and to provide a strain relief, as well as to secure .he housing members in position to the equipment or within the equipment itself. Housin~3 member 30 comprises hermaphroditic cover members 32 molded from a suitable dielectrical material. Each cover member 32 includes hook members 34 at each corner with slots 36 and latching members 38 adjacent thereto.
Latching members 38 have beveled surfaces 40 and latching surfaces 42.
A rectangular wall 44 extends outwardly from an inside surface of cover member 32 and is spaced inwardly from slots 36 and latching member 38.
Aligning members 46 also extend outwardly from the inner surface of cover members 32 at opposite corners of wall 44 and they are insertable into 9780 -5~
~.2148:~6 holes 47 as cover members 32 are latchably mated together and they serve to align latching members 3% with their respective slots. Bus 10 ancl buses 12 extend through housing member 30 when cover members 32 are latchably secured together with the terminated areas of the buses disposed within the area defined by walls 44.
In operation, a section of branch bus 12 terminated to main bus 10 via electrical connectors 22 is positioned within wall 44 of cover member 32, then another cover member 32 is latchably connected to cover member 32 via latching members 38 positioned in respective slots 36 with latching surfaces 42 engaging the outer surfaces of cover members 32, aligning members 46 and holes 47 aligning respective cover members 32 relative to one another and latching members being aligned relative to respective slots 36 to enable the cover members ~o be latched together so that bus 12 and bus 10 extend through housing member 30 with the terminated areas thereof and electrical connectors being protected and insulated by housing member 30. If desired, screws or bolts 48 engage hook members 34 to secure housing 30 in position as illustrated in Figure 2. Beveled surfaces 40 facilitate movement of latching members 38 outwardly as cover members 32 move to~3ether in a latched condition. Projections 39 are spaced inwardly from respective slots 36 and they serve as a surface against which a screwdriver or the llke is positioned to apply a force against latching members 38 to move them from a latched position.
After branch electrical buses 12 are terminated to main electrical bus 10 at selected locations therealong via electrical connectors 22, main bus 10 can be shielded if desired to provide a shielded electrical harness that will comply with Federal Communications Commission regulations. To shield 97%0 -6-~2148316 main bus 10, a piece of insulating tape 50 is secured onto main bus 10 covering legs 28 of connectors 32 that extend therethrough to insulate them. Thereafter, a sheet of conductlve foil 52 having the same width as bus 10 is adhered to bus 10 thereby supplying a shield therefor.
Conductive foil can also be applied to branch buses 12.
Each housing member 30 can have secured thereto a grounding contact 54 to ground conductive foil 52 at each of housing members 30 or selected ones thereof as desired. Ground contact 54 comprises an elongated member 56 having securing members 58 that are wedgingiy secured in slots 60 located in one side of wall 44. Spring contact fingers 62 are bent back over elongated member 56 for electrical connection with conductive foil 52 when the terminated sections of buses 10, 12 are housed in housing member 30 within the walls 44 as illustrated in Figure 6.
Spring ground contact 64 extends outwardly from elongated member 56 and is positioned along an inside surface 66 of a channel section 68 of cover members 32 with spring ground contact 64 extending between an outer end of an extension 70 of wall 44 which also extencls between the sidewalls of channel section 68. A vertical section 72 of contact 64 extends along extension 70. The free end of contact 64 is almost located coincident with the axis of hole 74. A ground wire 76 is inserted into hole 74 through the beveled entrance thereto and is forced against the inner end of channel section 68 by the spring action of spring ground contact 64 as illustrated in Figure 6 thereby biting into ground wire 76 and securely maintaining ground wire 76 in electrical engagement therewith. Ground wire 76 can then be appropriately connected to a suitable ground. In this ~2~483~
way a number of ground connections can be made for appropriately grounding conductive foil shield 52 at a number of locations.
Figures 7 through 10 illustrate alternative embodiments of electrical connectors for use in conjunction with electrically connecting flat conductors 78 insulatively positioned in a parallel orientation in insulatlng jacket 80 with flat electrical conductors 84 disposed in a parallel orientation in insulatlng jacket 86 of a branch electrical bus 88 flat electricai conductors 78 84 crossing one another. Electrical connector ~0 illustrated in Figures 7 and 8 has a circular body section 92 from which depends legs 94 that are pointed at their outer ends. Triangular shaped members 96 are located centrally of body section 92 and they extend parallel to the axis thereof.
Electrical connectors 90 have been formed in accordance with conventional metal stamping and forming practices in strip form if desired and legs 94 are inserted through the insulating jackets of overlapping buses 82 88 with conductors 78 84 extending normal to one another so that legs 94 straddle such conductors at a selected point of interconnection so that when electrical connector 90 is moved to a terminating position legs 94 clear the crossed electrical conductors at such terminatlng location with triangu!ar shaped members 96 penetrating through insulatlng jacket 86 into penetrating engagement with conductor 84 and the pointed ends of legs 94 are directed inwardly toward the axis of connector 90 penetrating insulating jacket 80 and penetrating into conductor 78 as illustrated in Figure 8 thereby electrically connecting these conductors together and also breaking down any oxicles therebetween.
~2148,36 Electrical connector 90A of Figures 9 and 10 is identical in configuration to electrical connector 90 of Figures 7 and 8 except that body section 92A is rectangular in configuration rather than circular;
otherwise electrical connector 90A is identical to electrical connector 90 and the termination thereof to terminate conductors 78, 84 is the same as that disclosed in relation to the termination of electrical connector 90 of Figures 7 and 8 except that pointed ends of legs 94A are not directed towards the axis of electrical connector 90A.
Figures 11 and 12 illustrate a harness making operation for making an electrical harness in an automatic manner under prog ram control . As shown in Figure 11, main electrical bus 10 is fed from a reel 98 through a cable length sensing station 100 to sense the length of cable that is to be removed from reel 98. Bus 10 is fed to a terminating station 102 at which is located a table 104 along which bus 10 moves and is held in position thereon by hold-down members 106 that can be actuated by electromagnetic means or air- or fluid-operated meanC.. Branch bus 12 is fed from reel 108 across main bus 10 along table 104 with bus 12 passing by cable length sensing station 110 that senses the length of cable that is desired to be removed from reel 108. A program-controlled terminating device 112 operates through an opening 114 in table 104 to automatically insert electrical connectors 22, 90 or 90A from a strip of connectors 116 fed to terminating device 112 from a supply reel (not shown) thereby interconnecting the conductors of buses 10, 12 in accordance with a programmed termination scheme. Electric motors 118 are operationally connected to terminating device 112 to move the terminating dies thereof to their programmed locations for insertion of the electrical connectors into 9780 _9_ ~Z~83~i the crossed buses electrically connecting selected electrical conductors tog ethe r .
After bus 12 has been terminated to bus 10, bus ~ 2 is cut from its supply and bus l O is moved to insulation applying station 120 at which insulating tape 50 is appiied to bus 10 covering the exposed legs of the connectors. Bus 12 is then moved to shield applying station 122 where conduct~ve foil 52 is adhesively secured to the bottom surface of bus 10 whereafter housing member 30 is positioned onto the terminated sections of buses 10, 12.
After other branch buses 12 have been terminated to main bus 10, insulating tape 50 applied onto bus 10, conductive foil 52 secured thereto, and housing members 30 secured in positlon over the terminated sections of the buses, bus 10 is then cut from supply reel 98 and a completed harness has now been made. If desired, only housing member 30 can be positioned onto the terminated sections of the buses withcut applying insulating tape or conductlve foil. Insulating tape and foil may be applied to both sides of the main and branch cables.
Figure 13 depicts a flow diagram for making a harness in accordance with the equipment illustrated in Figures 11 and 12, and the harness making operation can be under the control of a programmable controller that is microprocessor operated. Insulating tape can be applied onto main bus cable and branch bus cable if concluctive foil is to be aclhesively secured onto both sides of the maln bus cable. If conductlve foil is secured onto the main bus cable, then grounding contact 54 is included in the housing member.
This invention relates to electrical connection systems and more particularly to electrical interconnection systems.
Electrical wiring harnesses are typically assembled from discrete electrical wires that are individually routed to preselected locations and subsequently bundled together. These harnesses are customarily assembled by manual application.
Machines have been developed to automatically assemble harnesses.
In either case, assembling such wire harnesses is time-consuming and expensive.
In accordance with one aspect of the present invention, there is provided an electrical cable assembly, comprising:
main electrical bus means including a multiplicity of electrical conductors isolated from one another by insulating jacket means;
branch electrical bus means including less electrical conductors than said main bus means isolated from one another by insulating jacket means, said branch electrical bus means crossing said main electrical bus means; electrical connector means selectively connecting electrical conductors of said branch electrical bus means to respective electrical conductors of said main electrical bus means; and dielectric means applied to the terminated section of the electrical connection harness thus formed insulating the electrical connections thereof.
According to another aspect of the present invention, there is provided a method of making an electrical cable assembly, comprising the steps of: feeding a main bus cable to a terminating ~r, ~2~41~;
station; feeding a length of a branch bus cable across said main bus cable; selectively applying electrical connectors to the crossed buses electrically connecting electrical conductors of the main bus cable to respective electrical conductors of the branch bus cable by means of leg members of the connectors pene-trating the insulation jackets of the bus cables at corners of the crossing of the conductors and conductor-engaging means of the connectors engaging the conductors; cutting the branch bus cable; and positioning a dielectric means onto the terminated sections of the buses.
According to a further aspect of the present invention, there is provided an electrical connector for electrically con-necting insulated round electrical conductors disposed crosswise of each other, comprising: a body section having L-shaped legs in cross section, aligned slots between adjacent legs, one of the aligned slots cutting through the insulation covering one of the electrical conductors and electrically connecting with the elec-trical conductor while the other of the aligned slots cuts through the insulation covering the other of the electrical con-ductors and electrically connecting with the electrical conductor.
According to yet another aspect of the present invention,there is provided an electrical connector for electrically con-necting insulated flat electrical connectors disposed crosswise of each other, comprising: a body section having inwardly-direc-ted wedge-shaped members for penetrating the insulation of one of the electrical conductors and being embeddable into the electrical conductors, leg members extending outwardly from the body section lZ14~;
and having pointed ends for penetrating through the insulation of the crossed electrical conductors straddling them with the pointed ends being bendable back through the insulation covering the other conductor and into penetrating engagement with the other electrical conductor.
The invention will now be described in greater detail with reference to the accompanying drawings, in which:
FIGURE 1 is a perspective and exploded view of a main electrical bus, branch electrical bus, connectors to selectively interconnect electrical conductors of the buses, and housing members to house the interconnected sections of the buses.
FIGURE 2 is a perspective view showing the elements of Figure 1 assembled.
FIGURE 3 is a perspective view of parts of crossed buses with electrical connectors exploded therefrom.
FIGURE 4 is similar to Figure 3 with one of the connec-tors in a terminated position and the other in a part-terminated position.
FIGURE 4A is a perspective view of an alternative embodiment of the electrical connector.
FIGURE 5 is a part cross-sectional view of a housing member showing a ground contact with interconnected buses and another housing member exploded therefrom.
FIGURE 6 is a view similar to Figure 5 in an assembled condition.
~2~4836 FIGURE 7 is a perspective view of another alternative embodiment of an electrical connector exploded from crossed buses.
FIGURE 8 is a cross-sectional view of the electrical connector of Figure 7 in a terminated condition with electrical conductors of the crossed buses .
FIGURE 9 is a perspective view of a further embodiment of an electrical connector exploded from crossed buses.
FIGURE 10 is a cross-sectional view of the electrical connector of Figure 9 in a terminated condition with electrical conductors of the crossed buses .
FIGURE 11 is a perspective view of a harness making operation for electrically interconnecting branch electrical buses to a main electrical bus.
FIGURE 12 is a large perspective view of the programmable terminating equipment of Figure 11.
FIGURE 13 is a flow diagram of the harness making operation of Figures 11 and 12.
Figures 1 through 6 illustrate an electrical interconnection system relatlng to a main electrical bus 10 to which is electrically connected branch electrical buses 12 to form an electrical harness for use in electronic controlled equipment or the like. Main electrical bus 10 is in the form of a multl-conductor cable with electrical conductors 14 disposed in an insulatlng jacket 16 so that electrical conductors 14 extend parallel to and insulated from one another. Electrical conductors 14 are typically of a size to carry electronic signals therealong in either direction and the conductors can either be stranded or single conductors. Branch electrical buses 12 are of the same construction with electrical conductors 18 covered 97~0 -3-~214~
by insulating jacket 20; branch buses 12 may not have as many conductors as main bus 10.
Part of the electrical conductors in main electrical bus 10 and branch electrical buses 12 can be larger for the purpose of supplying power to electronic equipment if desired.
Figures 3 and 4 best illustrate electrical connectors 22 for electrically connecting electrical conductors 18 of branch bus 12 to electrical conductors 14 of main bus 10. Electrical connectors 2 are stamped and formed from a suitable metal strip in strip form and they are formed into a body sectlon 23 having a rectangular configuration with slots 24 located in opposing sides and slots 26 located in the other opposing sides. The entrances to slots 24 and 26 are beveled. Legs 28 have an L-shape in cross section and are located at each of the corners of electrical connectors 22. Electrical connectors 22 can have a round configuration if desired as shown in Figure 4A.
When it is desired to electrically connect selected ones of electrical conductors 18 of branch bus 12 with electrical conductors 14 of main bus 10, legs 28 of electrical connectors 22 are forced through insulating jacket 20 so that slots 24 displace the insulation surrounding electrical conductor 18 and legs 28 penetrate insulating jacket 16 while slots 26 displace the insulation surrounding electrical conductor 14 selected to be connected with electrical conductor 18 on each side of their selected crossing locations thereby electrically connecting the selected conductors together. In this way, electrical conductors of main bus 10 and electrical conductors of branch bus 12 can be selected for interconnection by electrical connectors 22 thereby resultlng in a programmed interconnection therebetween in lZ1419;~;
accordance with the needs of the electr~nic equipment to which branch bus 12 is to be electrically connected by means of a suitable electrical connector ( not shown) terminated to the conductors of branch bus 12.
Electrical connectors 22 in a strip form can be inserted into a terminated position by a program-operated applicator of the type illustrated in Figures 11 and 12, legs 28 penetrate through insulatlng jackets 20, 16 of buses 10, 12 and respectively straddle electrical conductors 18, 14 with slots 24 displacing the insulation covering conductors 18 and making electrical connection with the conductors, whereas slots 26 displace the insulation covering electrical conductors 14 and aiso make electrical connection therewith as illustrated in Figure 4. In this way, selected conductors 18 of bus 12 are electrically connected with selected conductors 14 of bus 10 thereby programmably interconnecting these electrical conductors together in accordance with an established program.
The terminated sections of branch buses 12 to main bus 10 are preferably encased in housing member 30 to protect the terminations and to provide a strain relief, as well as to secure .he housing members in position to the equipment or within the equipment itself. Housin~3 member 30 comprises hermaphroditic cover members 32 molded from a suitable dielectrical material. Each cover member 32 includes hook members 34 at each corner with slots 36 and latching members 38 adjacent thereto.
Latching members 38 have beveled surfaces 40 and latching surfaces 42.
A rectangular wall 44 extends outwardly from an inside surface of cover member 32 and is spaced inwardly from slots 36 and latching member 38.
Aligning members 46 also extend outwardly from the inner surface of cover members 32 at opposite corners of wall 44 and they are insertable into 9780 -5~
~.2148:~6 holes 47 as cover members 32 are latchably mated together and they serve to align latching members 3% with their respective slots. Bus 10 ancl buses 12 extend through housing member 30 when cover members 32 are latchably secured together with the terminated areas of the buses disposed within the area defined by walls 44.
In operation, a section of branch bus 12 terminated to main bus 10 via electrical connectors 22 is positioned within wall 44 of cover member 32, then another cover member 32 is latchably connected to cover member 32 via latching members 38 positioned in respective slots 36 with latching surfaces 42 engaging the outer surfaces of cover members 32, aligning members 46 and holes 47 aligning respective cover members 32 relative to one another and latching members being aligned relative to respective slots 36 to enable the cover members ~o be latched together so that bus 12 and bus 10 extend through housing member 30 with the terminated areas thereof and electrical connectors being protected and insulated by housing member 30. If desired, screws or bolts 48 engage hook members 34 to secure housing 30 in position as illustrated in Figure 2. Beveled surfaces 40 facilitate movement of latching members 38 outwardly as cover members 32 move to~3ether in a latched condition. Projections 39 are spaced inwardly from respective slots 36 and they serve as a surface against which a screwdriver or the llke is positioned to apply a force against latching members 38 to move them from a latched position.
After branch electrical buses 12 are terminated to main electrical bus 10 at selected locations therealong via electrical connectors 22, main bus 10 can be shielded if desired to provide a shielded electrical harness that will comply with Federal Communications Commission regulations. To shield 97%0 -6-~2148316 main bus 10, a piece of insulating tape 50 is secured onto main bus 10 covering legs 28 of connectors 32 that extend therethrough to insulate them. Thereafter, a sheet of conductlve foil 52 having the same width as bus 10 is adhered to bus 10 thereby supplying a shield therefor.
Conductive foil can also be applied to branch buses 12.
Each housing member 30 can have secured thereto a grounding contact 54 to ground conductive foil 52 at each of housing members 30 or selected ones thereof as desired. Ground contact 54 comprises an elongated member 56 having securing members 58 that are wedgingiy secured in slots 60 located in one side of wall 44. Spring contact fingers 62 are bent back over elongated member 56 for electrical connection with conductive foil 52 when the terminated sections of buses 10, 12 are housed in housing member 30 within the walls 44 as illustrated in Figure 6.
Spring ground contact 64 extends outwardly from elongated member 56 and is positioned along an inside surface 66 of a channel section 68 of cover members 32 with spring ground contact 64 extending between an outer end of an extension 70 of wall 44 which also extencls between the sidewalls of channel section 68. A vertical section 72 of contact 64 extends along extension 70. The free end of contact 64 is almost located coincident with the axis of hole 74. A ground wire 76 is inserted into hole 74 through the beveled entrance thereto and is forced against the inner end of channel section 68 by the spring action of spring ground contact 64 as illustrated in Figure 6 thereby biting into ground wire 76 and securely maintaining ground wire 76 in electrical engagement therewith. Ground wire 76 can then be appropriately connected to a suitable ground. In this ~2~483~
way a number of ground connections can be made for appropriately grounding conductive foil shield 52 at a number of locations.
Figures 7 through 10 illustrate alternative embodiments of electrical connectors for use in conjunction with electrically connecting flat conductors 78 insulatively positioned in a parallel orientation in insulatlng jacket 80 with flat electrical conductors 84 disposed in a parallel orientation in insulatlng jacket 86 of a branch electrical bus 88 flat electricai conductors 78 84 crossing one another. Electrical connector ~0 illustrated in Figures 7 and 8 has a circular body section 92 from which depends legs 94 that are pointed at their outer ends. Triangular shaped members 96 are located centrally of body section 92 and they extend parallel to the axis thereof.
Electrical connectors 90 have been formed in accordance with conventional metal stamping and forming practices in strip form if desired and legs 94 are inserted through the insulating jackets of overlapping buses 82 88 with conductors 78 84 extending normal to one another so that legs 94 straddle such conductors at a selected point of interconnection so that when electrical connector 90 is moved to a terminating position legs 94 clear the crossed electrical conductors at such terminatlng location with triangu!ar shaped members 96 penetrating through insulatlng jacket 86 into penetrating engagement with conductor 84 and the pointed ends of legs 94 are directed inwardly toward the axis of connector 90 penetrating insulating jacket 80 and penetrating into conductor 78 as illustrated in Figure 8 thereby electrically connecting these conductors together and also breaking down any oxicles therebetween.
~2148,36 Electrical connector 90A of Figures 9 and 10 is identical in configuration to electrical connector 90 of Figures 7 and 8 except that body section 92A is rectangular in configuration rather than circular;
otherwise electrical connector 90A is identical to electrical connector 90 and the termination thereof to terminate conductors 78, 84 is the same as that disclosed in relation to the termination of electrical connector 90 of Figures 7 and 8 except that pointed ends of legs 94A are not directed towards the axis of electrical connector 90A.
Figures 11 and 12 illustrate a harness making operation for making an electrical harness in an automatic manner under prog ram control . As shown in Figure 11, main electrical bus 10 is fed from a reel 98 through a cable length sensing station 100 to sense the length of cable that is to be removed from reel 98. Bus 10 is fed to a terminating station 102 at which is located a table 104 along which bus 10 moves and is held in position thereon by hold-down members 106 that can be actuated by electromagnetic means or air- or fluid-operated meanC.. Branch bus 12 is fed from reel 108 across main bus 10 along table 104 with bus 12 passing by cable length sensing station 110 that senses the length of cable that is desired to be removed from reel 108. A program-controlled terminating device 112 operates through an opening 114 in table 104 to automatically insert electrical connectors 22, 90 or 90A from a strip of connectors 116 fed to terminating device 112 from a supply reel (not shown) thereby interconnecting the conductors of buses 10, 12 in accordance with a programmed termination scheme. Electric motors 118 are operationally connected to terminating device 112 to move the terminating dies thereof to their programmed locations for insertion of the electrical connectors into 9780 _9_ ~Z~83~i the crossed buses electrically connecting selected electrical conductors tog ethe r .
After bus 12 has been terminated to bus 10, bus ~ 2 is cut from its supply and bus l O is moved to insulation applying station 120 at which insulating tape 50 is appiied to bus 10 covering the exposed legs of the connectors. Bus 12 is then moved to shield applying station 122 where conduct~ve foil 52 is adhesively secured to the bottom surface of bus 10 whereafter housing member 30 is positioned onto the terminated sections of buses 10, 12.
After other branch buses 12 have been terminated to main bus 10, insulating tape 50 applied onto bus 10, conductive foil 52 secured thereto, and housing members 30 secured in positlon over the terminated sections of the buses, bus 10 is then cut from supply reel 98 and a completed harness has now been made. If desired, only housing member 30 can be positioned onto the terminated sections of the buses withcut applying insulating tape or conductlve foil. Insulating tape and foil may be applied to both sides of the main and branch cables.
Figure 13 depicts a flow diagram for making a harness in accordance with the equipment illustrated in Figures 11 and 12, and the harness making operation can be under the control of a programmable controller that is microprocessor operated. Insulating tape can be applied onto main bus cable and branch bus cable if concluctive foil is to be aclhesively secured onto both sides of the maln bus cable. If conductlve foil is secured onto the main bus cable, then grounding contact 54 is included in the housing member.
Claims
THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An electrical cable assembly, comprising: main electrical bus means including a multiplicity of electrical conductors iso-lated from one another by insulating jacket means; branch electri-cal bus means including less electrical conductors than said main bus means isolated from one another by insulating jacket means, said branch electrical bus means crossing said main elec-trical bus means; electrical connector means selectively connec-ting electrical conductors of said branch electrical bus means to respective electrical conductors of said main electrical bus means; and dielectric means applied to the terminated section of the electrical connection harness thus formed insulating the electrical connections thereof.
2. An electrical cable assembly as set forth in claim 1 wherein said conductors of said bus means are round and disposed normal to one another, each of said electrical connector means includes opposed slots electrically connected to the electrical conductors of said branch bus means and other opposed slots elec-trically connected to the respective electrical conductors of said main bus means.
3. An electrical cable assembly as set forth in claim 1 wherein said conductors of said bus means are flat and disposed normal to one another, each of said electrical connector means includes triangular-shaped members penetrating through the insul-ating jacket and into the electrical conductor of the branch bus means while leg members extend through the insulating jackets and straddle the crossed electrical conductors of the buses with pointed ends of the leg members penetrating back through the insulating jacket of the main bus into the electrical conductor.
4. An electrical cable assembly as set forth in claim 1 wherein said dielectric means are housing members which include latching means latchably securing said housing members together.
5. An electrical cable assembly as set forth in claim 1 wherein said dielectric means is insulation means which covers parts of the electrical connectors protruding through said main bus means and conductive foil means is secured to an outer surface of said main bus means, and housing means are secured there-around.
6. An electrical cable assembly as set forth in claim 5 wherein ground contact means are mounted on said housing means in electrical engagement with said conductive foil means.
7. A method of making an electrical cable assembly, com-prising the steps of: feeding a main bus cable to a terminating station; feeding a length of a branch bus cable across said main bus cable; selectively applying electrical connectors to the crossed buses electrically connecting electrical conductors of the main bus cable to respective electrical conductors of the branch bus cable by means of leg members of the connectors pene-trating the insulation jackets of the bus cables at corners of the crossing of the conductors and conductor-engaging means of 13. An electrical connector for electrically connecting insulated flat electrical connectors disposed crosswise of each other, comprising: a body section having inwardly-directed wedge-shaped members for penetrating the insulation of one of the elec-trical conductors and being embeddable into the electrical con-ductors, leg members extending outwardly from the body section and having pointed ends for penetrating through the insulation of the crossed electrical conductors straddling them with the pointed ends being bendable -13a-the connectors engaging the conductors; cutting the branch bus cable; and positioning a dielectric means onto the terminated sections of the buses.
8. A method as set forth in claim 7 wherein said position-ing step comprises applying an insulation tape over exposed sec-tions of the electrical connectors; securing a conductive foil onto at least one surface of the main bus cable and the insula-tion tape; and securing an insulating housing therearound.
9. A method as set forth in claim 8 comprising the further step of interconnecting the conductive foil with a ground contact in said insulating housing.
10. An electrical connector for electrically connecting insulated round electrical conductors disposed crosswise of each other, comprising: a body section having L-shaped legs in cross section, aligned slots between adjacent legs, one of the aligned slots cutting through the insulation covering one of the elec-trical conductors and electrically connecting with the electrical conductor while the other of the aligned slots cuts through the insulation covering the other of the electrical conductors and electrically connecting with the electrical conductor.
11. An electrical connector as set forth in claim 10 where-in said body section is rectangular.
12. An electrical connector as set forth in claim 10 where-in said body section is round.
back through the insulation covering the other conductor and into penetrating engagement with the other electrical conductor.
14. An electrical connector as set forth in claim 13 where-in said body section is rectangular.
15. An electrical connector as set forth in claim 13 where-in said body section is round.
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An electrical cable assembly, comprising: main electrical bus means including a multiplicity of electrical conductors iso-lated from one another by insulating jacket means; branch electri-cal bus means including less electrical conductors than said main bus means isolated from one another by insulating jacket means, said branch electrical bus means crossing said main elec-trical bus means; electrical connector means selectively connec-ting electrical conductors of said branch electrical bus means to respective electrical conductors of said main electrical bus means; and dielectric means applied to the terminated section of the electrical connection harness thus formed insulating the electrical connections thereof.
2. An electrical cable assembly as set forth in claim 1 wherein said conductors of said bus means are round and disposed normal to one another, each of said electrical connector means includes opposed slots electrically connected to the electrical conductors of said branch bus means and other opposed slots elec-trically connected to the respective electrical conductors of said main bus means.
3. An electrical cable assembly as set forth in claim 1 wherein said conductors of said bus means are flat and disposed normal to one another, each of said electrical connector means includes triangular-shaped members penetrating through the insul-ating jacket and into the electrical conductor of the branch bus means while leg members extend through the insulating jackets and straddle the crossed electrical conductors of the buses with pointed ends of the leg members penetrating back through the insulating jacket of the main bus into the electrical conductor.
4. An electrical cable assembly as set forth in claim 1 wherein said dielectric means are housing members which include latching means latchably securing said housing members together.
5. An electrical cable assembly as set forth in claim 1 wherein said dielectric means is insulation means which covers parts of the electrical connectors protruding through said main bus means and conductive foil means is secured to an outer surface of said main bus means, and housing means are secured there-around.
6. An electrical cable assembly as set forth in claim 5 wherein ground contact means are mounted on said housing means in electrical engagement with said conductive foil means.
7. A method of making an electrical cable assembly, com-prising the steps of: feeding a main bus cable to a terminating station; feeding a length of a branch bus cable across said main bus cable; selectively applying electrical connectors to the crossed buses electrically connecting electrical conductors of the main bus cable to respective electrical conductors of the branch bus cable by means of leg members of the connectors pene-trating the insulation jackets of the bus cables at corners of the crossing of the conductors and conductor-engaging means of 13. An electrical connector for electrically connecting insulated flat electrical connectors disposed crosswise of each other, comprising: a body section having inwardly-directed wedge-shaped members for penetrating the insulation of one of the elec-trical conductors and being embeddable into the electrical con-ductors, leg members extending outwardly from the body section and having pointed ends for penetrating through the insulation of the crossed electrical conductors straddling them with the pointed ends being bendable -13a-the connectors engaging the conductors; cutting the branch bus cable; and positioning a dielectric means onto the terminated sections of the buses.
8. A method as set forth in claim 7 wherein said position-ing step comprises applying an insulation tape over exposed sec-tions of the electrical connectors; securing a conductive foil onto at least one surface of the main bus cable and the insula-tion tape; and securing an insulating housing therearound.
9. A method as set forth in claim 8 comprising the further step of interconnecting the conductive foil with a ground contact in said insulating housing.
10. An electrical connector for electrically connecting insulated round electrical conductors disposed crosswise of each other, comprising: a body section having L-shaped legs in cross section, aligned slots between adjacent legs, one of the aligned slots cutting through the insulation covering one of the elec-trical conductors and electrically connecting with the electrical conductor while the other of the aligned slots cuts through the insulation covering the other of the electrical conductors and electrically connecting with the electrical conductor.
11. An electrical connector as set forth in claim 10 where-in said body section is rectangular.
12. An electrical connector as set forth in claim 10 where-in said body section is round.
back through the insulation covering the other conductor and into penetrating engagement with the other electrical conductor.
14. An electrical connector as set forth in claim 13 where-in said body section is rectangular.
15. An electrical connector as set forth in claim 13 where-in said body section is round.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US40119782A | 1982-07-23 | 1982-07-23 | |
| US401,197 | 1982-07-23 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1214836A true CA1214836A (en) | 1986-12-02 |
Family
ID=23586757
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000430928A Expired CA1214836A (en) | 1982-07-23 | 1983-06-22 | Electrical interconnection system |
Country Status (4)
| Country | Link |
|---|---|
| EP (1) | EP0100602B1 (en) |
| JP (1) | JPS5946776A (en) |
| CA (1) | CA1214836A (en) |
| DE (1) | DE3367052D1 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2187049A (en) * | 1986-02-21 | 1987-08-26 | Allied Corp | Insulation displacement connector for joining flat cables |
| DK115493D0 (en) * | 1993-10-15 | 1993-10-15 | Lk As | SCANNING SYSTEM |
| US5611709A (en) * | 1995-08-10 | 1997-03-18 | Valleylab Inc | Method and assembly of member and terminal |
| WO1998015988A1 (en) * | 1996-10-04 | 1998-04-16 | The Whitaker Corporation | Electrical interconnection system and a contact therefor |
| JP4532133B2 (en) * | 2000-12-15 | 2010-08-25 | 古河電気工業株式会社 | Method and apparatus for conducting connection by crimping flat cable |
| CN105762733B (en) * | 2016-03-25 | 2018-04-03 | 河南省高压电器研究所 | A kind of pipe bus connecting device |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE2031215B2 (en) * | 1970-06-19 | 1974-03-28 | Juergen Dipl.-Ing. 3300 Braunschweig Ernsting | Junction box |
| GB1372401A (en) * | 1972-03-30 | 1974-10-30 | Pressac Ltd | Method of and means for permanently electrically connecting overlapp ing conductor tracks on flexible electric circuit strips or tapes |
| DE2254395A1 (en) * | 1972-11-07 | 1974-05-16 | Bbc Brown Boveri & Cie | BRANCH OR DISTRIBUTION BOX |
| DE2264216B2 (en) * | 1972-12-30 | 1976-05-26 | Brown, Boveri & Cie Ag, 6800 Mannheim | ELECTRICAL INSTALLATION SYSTEM |
| JPS51119991A (en) * | 1975-04-15 | 1976-10-20 | Daiichi Denshi Kogyo Kk | Connecting end |
| ZA774638B (en) * | 1976-09-07 | 1978-06-28 | Amp Inc | Electrical connector |
| US4315662A (en) * | 1979-05-25 | 1982-02-16 | Thomas & Betts Corporation | Undercarpet wiring system installation kit |
-
1983
- 1983-06-22 CA CA000430928A patent/CA1214836A/en not_active Expired
- 1983-07-01 EP EP83303834A patent/EP0100602B1/en not_active Expired
- 1983-07-01 DE DE8383303834T patent/DE3367052D1/en not_active Expired
- 1983-07-22 JP JP58132985A patent/JPS5946776A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0414475B2 (en) | 1992-03-12 |
| DE3367052D1 (en) | 1986-11-20 |
| EP0100602B1 (en) | 1986-10-15 |
| EP0100602A1 (en) | 1984-02-15 |
| JPS5946776A (en) | 1984-03-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |