DE3019688A1 - METHOD AND DEVICE FOR ELECTRICALLY CONNECTING MULTI-WIRE CABLES - Google Patents

Description

γ,

DiPL-ING. HELMUT BERKENFELD

PATENT LAWYER _{AT THE SCHANZ 2 wo}

D 5000 COLOGNE 60

Thoraar, ic Betts Corporation

Γ Ί

NAOHGE. "RS: C1 ^J .T

L J

Method and device for the electrical connection of reversing conductor cables

The invention relates generally to a method and an apparatus for making electrical connections, and relates in particular to the electrical interconnection of flat multi-conductor cables when used under a carpet.

In currently known wiring systems under carpet material, flat multi-conductor cables, which should be connected, either in a corresponding, lengthwise abutting relationship for splicing, or arranged in a corresponding right-angled abutting relationship for branches. In the case of splicing, individual conductors are mutually aligned, creating confusion on how to connect the conductors does not occur. A connector that pushes out / pierces the insulation is simply placed under the rabel

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ίφ Ό221) 76 035 76 ■ cable address! Copat Cologne

brought into alignment rait each pair of conductors to be connected and bent over · the one conductor one cable cannot easily be mistakenly connected to several conductors of the other cable will.

In the case of branch connections, on the other hand, there is the possibility of confusion and error of the Installers very large. Because of the mutual squareness, each conductor of the one cable runs here in the direction of all conductors of the other cable and can be connected to these. A connection of the a conductor of one cable with multiple conductors of the other cable can easily occur.

Such confusion is eliminated from the start by using a single length of connector for each connection to be established. However, this practice requires the provision of as much as five connectors of unique length, i.e. for a three-phase branch with neutral and earth conductors carried continuously, and requires correct installation selection for connectors unique length. Apart from that, this connection practice has the disadvantage that all connections have Except for those of the shortest length, several conductors span one of the cables, reducing the potential There is a risk of creating a short circuit between the phases.

In the wiring system under carpet material, vie it in pending United States patent applications entitled "Multiconductor Cable Arrangement and Electrical Connection "and" Multiconductor Cable "is described,

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verden labels to be connected to each other overlap each other, in contrast to the above noticed mutual collision. Such an overlap creates a matrix of possible connection zones commanded. With a three-wire three- ladder junction, there are nine zones in the overlap area, each zone being a unique pair of ladders for possible connection. Those pairs of conductors that are to be connected are perforated and through the perforation an insulation displacing / piercing connector used and on these cable surfaces outside of the overlap bent over. A connector of common dimensions is used throughout and has, if it is bent over, no expansion, but extends outwards from the connecting zone in question. There is thus no need for different size connectors when installing, and no need for care in the selection of the connector by the installer. There the connections do not span several conductors of a cable, there is the possibility of short circuits, velche of a single connector rises, lowered. However, these advantages are canceled by a loss of advantage, velcher of the use of connectors noted above different size inherent, i.e. a decrease in the possibility of connecting the one Conductor of one cable with a number of conductors of the other cable.

According to the invention, an improved method and an improved apparatus for electrically connecting multi-conductor cables is provided. In particular, according to the invention, a device

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and to provide a method of use in electrically connecting mutually overlapped multi-conductor flat cables.

In order to achieve the foregoing and other objects, the invention provides a practice in which multi-conductor cables are in mutually overlapping relationship are arranged and offer the above connection zone matrix, electrically connected by of these zones only selectively produces which are usable for the actual connection of conductor pairs are. In preferred practice, the invention includes the use of a connection zone other than one individual zone for the connection of a pair of conductors, and at least enforces the connection another pair of conductors with preselected multiple zones, the device for such delimiting the use of the zones, includes a selectively apertured connecting guide, which preferably has the ability to determine the alignment of the overlapped label and the pattern of the To create hole guide.

The foregoing and other features of the invention will be further apparent from the following detailed Description of preferred embodiments and from the accompanying drawings, in which the same reference symbols denote equivalent parts throughout

Fig. 1 is a plan view showing, in its left part, a multi-conductor cable with a shield thereon and shows, in its right-hand part, a pair of three-core cables in an overlapping relationship;

Fig. 2 is a cross-sectional view, with section

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taken to the left of the welding I3o of FIG. 1;

Pig 3 and 4 are top plan views of pairs of four and five conductor cables in an overlapping relationship;

Fig. 5 is a perspective view of a connector velches in progress the invention is suitable for use;

Figure 6 is a perspective view of a five-wire, three-wire tap with connecting pieces from FIG. 5, in a state which secures the junction, but is not bent over;

Figure 7 is a schematic illustration of a link guide, over a pair of overlapping ones Five-wire cable lies;

Fig. 8 is a top plan view of a preferred embodiment of a connector guide in accordance with the present invention;

Fig. 9 is a perspective view showing the link guide of Fig. 8 in an operational configuration in relation to a base, and shows a pair of overlapped five-conductor cables; and

Fig. 10 is a plan view of a further preferred embodiment of a connecting guide according to the invention.

According to the invention, when connecting flat multi-conductor cables, one cable is brought onto another, to create a matrix of zones in which connections of a conductor of one label ait one

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ff.

Head of the other label can be made · The selection of one zone is made and this is perforated. It becomes an insulation piercing connector through the perforation inserted through and bent over to create an electrical connection between the pair of cable conductors in alignment with the selected zone. The selection of additional zones for perforation and insertion of connecting pieces takes place progressively from those zones which hereby do not have a conductor in alignment that was in alignment with a previously selected zone. The inventive Device for making a preferred communication zone precludes the use of communication zones other than a single zone of communication of a pair of conductors, and forces the use of less selective zones individually for connection corresponding other pairs of conductors, reducing the likelihood of connection errors is reduced.

In Figs. 1 and 2, the cable assembly has 1oo an overhead shield 112 made of electrically conductive sheet material, a multi-conductor cable 114, and an underlying plastic sheet 116. That Cable 114 has an electrically insulating sheath 118 made of opposing plastic sheets, which wrap the flat electrical conductors 12o, 122, 124, 126 and 128. The shield 112 stands with the Earth conductor 122 of the cable 114 in connection, for example by welds 13o, which are located at a mutual distance along the length of the cable, as set out more fully in the United States patent applications noted above. Before fixing the shield 112 on the cable 114, the cable

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BAD ORI GINAL

- ■ / ■ 40-

are reduced by the five-wire cable, which is shown on the left in Fig. 1, on a four-wire cable or on a three-wire cable, as shown on the right in Fig. 1, by severing one or more conductors along lines 132, 134 and 136, respectively.

In the right part of FIG. 1, a tap connection is shown, the conductors 12o, 122 and 124 (further referred to as C ₁ , c "and C ₃ ) under another three-conductor cable with the conductors c. _t C ₅ and c _g lie. The mutual overlap area defines a matrix of nine possible connection zones, each labeled 1 to 9, each such zone being uniquely identified as having a single pair of conductors C ₁ to C _g in alignment therewith. Thus zone 1 only has conductors C ₁ and C- mating, zone 2 only has conductors C ₁ and C ₅ mating, etc.

In this example η objects are available for the combination in χ sentences, where η is the number of conductors (6) and χ is the number of electrical connections to be made (3). Since swaps are inappropriate (zones 1, 5, 9 give the same result as 9, 5, 1 and 5 »1, 9, etc.), they are not considered. The number of possible combinations is n! / xi (nx)} or 2o combinations. Of these 20 possible combinations, only 6 can be used to create compounds from C ₁ - C ₃ to C- - Cg, as in the following table:

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Table 1

combination C ₁ links C. ₂ c ₅ , C. 3 ^C 6 I. ^C 1 C ₄ , c 2 ^C 5 ' C. 3 ^C 4 II ^C 1 ^C 6 ' C. 2 ^C 6 ' C. 3 ^C 5 III ^C 1 ^c ₄ , C. 2 ^C 6 » C. 3 ^C 4 IV ^C 1 ^C 5 ' C. 3 ^C 5 ' C. 2 ^C 4 V C ₁ ^C 6 " C. 2 ^C 4 ' C. 3 ^C 6 VI C ₅ ,

Zones

1-5-9 3-5-7 1-6-8 2-6-7 3-8-4 2-4-9

The remaining 14 possible combinations lead to errors in the electrical connection. For example, the combination of connections C ₁ c., C ₃ C ₄ , C ₅ Cg is obviously not usable and would result in an interphase short circuit.

In Fig. 3 has a branch from a four-wire to a four-wire, the conductors d <j to dg. The connection zone matrix has 16 matching zones, ie zones 1o to 25. With η now 8 and χ now 4, the number of possible combinations for connection is 8ί> / 4ί (8-4) ί, respectively. 70. Of these, only 24 can be used to create connections from d ₁ - d ₄ to d ₅ - d ₉ .

In Fig. 4 has a branch line Ftinfleiter to five-wire, the conductors ej to e, -. The connection zone matrix has 25 mating zones, ie zones 26 to 5o. With η now 1o and χ now 5, the possible combination number is 1oi / 5i (1ο-5) ί, or 252. 9o of these are useful for connecting e., - e- to e _g - e., _Q .

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As can be seen from the previous discussion of FIGS 3, an installer of flat cables, which overlap, faces a variety of possible Connections and, accordingly, a high risk of incorrect installation. The present invention seeks to create methods of selecting connection patterns from among those available standing in order to reduce the risk of errors and the installer the cable installation Veniger to make decisions uncertain.

One of such methods is a selection made at the beginning of an original location for a pattern. For example, in the case of a four-wire to four-wire branch from d ₁ to dg (FIG. 3), the zone 1o can be made the original location and the conductors d ₁ and d_ are provided here with perforations that match one another. A second connection point is now selected from those connection points which include all zones and do not match a conductor that matches the original point, ie in the example

3, zones 15-17, 19-21, and 23-25. For purposes of discussion, zone 15 is selected and conductors d ₂ and d _g are provided with mating perforations. The selection of a third connection point is now made from those connection points which all do not match a conductor that matches the original and the second point, ie in the example of FIG. 3 the zones 2o, 21, 24 and 25. If the zone 2o is selected then zone 25 is the fourth junction. If the zone 21 is selected as a third junction, then zone 24 is the fourth comparison

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ORIGfNAL

binding parts. Assuming that the zones were 2o and 25 selected perforations are carried out in zone 2o d- through the conductor and d_, and in zone 25 through the circuit "and d _Q d. It will

4 8

now through the perforations in the selected connection points, connecting pieces inserted and bent over on the outer surfaces of the cables.

In Fig. 5, a connector 14o is shown in the open position, which partially around the axis 142 is bent, thereby defining the parts 144 and 146, each part of which is the insulation having piercing teeth 148. The geometry of the connection point selected in this example in FIG. 4 is the diagonal 15ο, and the perforations are elongated slots 152 along the diagonals 150. The part 144 or 146 is inserted into the slot, until the bending axis 142 is within the slot. The connector will then rotated about its bending axis so that the teeth 148 are in face-to-face relationship with the outer surfaces the cables come. All connecting pieces can be brought into position without bending, until a final check of the branch connection is made. The connectors will then bent over in place, the teeth 148 in electrical communication with the underlying ones Ladders come and be mechanically fastened in place.

Methods

The / for three-wire-three-wire, four-wire-four-wire, and five-wire-five-wire line branches are equally applicable to create correct branches between cables with a different one Number of ladders. Again by reference

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on Pig. 4, a three- _{core cable 154 with conductors e ß} , e_ and e "is to be branched off from the cable with conductors e ^ to e". The transition is made from ej as the neutral conductor of a three-phase power line, e ₂ as an earth conductor, and e ₃ to e _? than phases A, B and C. In the corresponding sequence, ie when the cable 154 is polarized at the transition ej, the point of origin is selected as the point 26, whereby e _{g is} the neutral conductor of the cable 154. From the connection point group which is available for remaining connections, ie zones 32, 33, 37, 38, 42, 43, 47 and 48, zone 32 is selected for connecting conductor e ~ to earth conductor e _g .

The installer or designer of the system can now choose for the purpose of load compensation or the load phases of the remaining available connection zones 38, 43 and 48, i.e. those zones which do not match any of the conductors e ^, e ₂ , e ^ and e "have. Whichever zone is chosen, no further connection zones remain available since the conductor e «is in alignment with all of the zones 38, 43 and 48, which precludes these unselected zones from further use. Where either of the zones 43 or 48 is chosen, the geometry of the connection pattern deviates from the full diagonal. Fig. 6 shows the arrangement achieved by selecting zone 43 with the non-bent connectors in place.

The cable 156 of FIG. 4 has four conductors e _fi to e «and can be connected to the cable of the conductors e.

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vie follows connected verden. Where polarization or a pole connection is desired, connections are again established in zones 26 and 32 for e ^, eg and e «, e_, with 6 zones, 38, 39, 43, 44, 48 and 49 for the production of the both phase connections remain. Assuming that zone 48 is selected for conductor eg, ie phase C, only zones 39 and 44 remain for conductor e _g for appropriate selection of phase A or phase B. Again, no connection zones remain with the above method if once this last-noted selection has been made.

The preferred practice increases the installer's assistance over that which is general is offered by the above methods of plaguing a predetermined geometry for manufacture of connections. In this practice, the polarization is adjacent to a first and second Connection of any set of connections placed, and such adjacent connections are invariably established. The above general method is limited to those compounds and the choice of further connections is predetermined or forced through the use of a connection guide in the form of a template with openings or slits in a predetermined pattern, like this shown in Fig. 7.

In FIG. 7, a template or plate 158 is placed over cables e ^ to e_ and e ₆ to e., _Q which are arranged at right angles to one another. The slot 160 is aligned with the zone 26 along the axis 15o. When an installer arranges the template and outlines an anticipated cable opening using the slot 16o,

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thus he excludes the possible connection of conductors e ^ and e, with any other conductors. The slot 162, adjacent to the slot 16o along the axis 15o, is in registration with the zone 32. When an installer outlines a cable connection using the slot 162, he forces the connection of cables e ₂ and e _? and excludes the connection of these two conductors with any other conductors. I ¹ Ur the conductor e «, the template 158 allows only a single connection, ie with the conductor βο. This arrangement drives the distribution of phase A through the conductors e ₃ and e _g . Since the slots are not in Zusammenpassung with the zones 39 and 4o, erroneous, unnecessary phase - A compounds excluded. On the other hand, by including slots 17o and 172 to mate with zones 43 and 48, the template allows phase B or phase C to be routed to conductor e _Q.

In the case of conductor e ^, template 158 does not include a slot in mating with zone 45, which has slot 17o in mating with zone 43 and slot 166 in mating with zone 44. The template thus directs the distribution of phase B either to conductor e _Q , as noted above, or to conductor e_, and accordingly reduces the possibility of erroneous, superfluous connection to conductor e. by such port case of zone 45.

By including slots 172, 174 and 168 in mating register with zones 48, 49 and 50, template 158 allows phase C to be distributed from conductor e ₅ to any of conductors e «» β «and e., _O · Die Pattern geometry, which is shown in Fig. 7

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is such that all slots 16o - 168 are aligned along axis 15o, which is the diagonal of the interconnection matrix that connects the two Multi-core cables are straight. The slots I70 and 174 are parallel to the axis along a first axis 150 aligned and the slot is along one second axis aligned parallel to axis 1 5o.

The limited erroneous connectivity inherent in template 158 of FIG. 7 is further diminished by the reliance on identifying markings on both the cables and the template as developed in the apparatus shown in FIGS. In FIG. 8, a plate 176 has slots 160-174 in a pattern identical to that of the template 158 in FIG. Fitting holes I78 and I80 are provided at ends of the plate 176 and the plate has distinctive markings 182 in the shape of a star, 184 in the shape of a triangle, 186 in the shape of a square, 188 in the shape of a hexagon, and 19o in the shape of a circle. The conductors ej to e, - and the conductors e _g to e _1o (FIG. 7) have corresponding markings. In addition, the plate 176 bears letter designations in the vicinity of various slots. The term "SPLICE ¹¹ includes slots 164, 166 and 168, and the slots bear the terms" 3 WIRE "," 4 WIRE "and" 5 WIRE "respectively Plate the text "TAP 3-4-5 WIRE". The vertical column with the slots 166 and 174 carries the text "TAP 4-5 WIRE". Below the slot 168 is the text "TAP 5 WIRE" Loches I80 there is the text "TAP: USW ONE PER COLUMN MATCH SYMBOLS ON CABLE" (junction: use one pass symbol per column on cable).

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As noted above, cable markings are made immutable by slots 16o and 162. In case of a Splicing, i.e. a connection of two longitudinally aligned and overlapping cables, is the Slots 164-168 are used, depending on the number of wires in the conductors.

In the case of a junction, i.e. a connection between two Cables in overlapping and right-angled relationship, all slots can be used. Make correct connections and maintain polarity ensured by simply recognizing the markings. Each marker is clearly colored to continue making proper connections easier. Table 2 shows the various connection options that can be achieved

Table 2

Slots

Connections made

16o, 162 and 164 3 core cable splice

Three-core cable (phase A)

16o, 162, 164 and 166

Three-core cable on three-, four- or five-core cable branch (Phase A).

Splicing four-core cable to four-core cable (phases A and B)

Four-core cable on four-core or five-core cable branch (phases A and B)

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16ο, 162, 164, splice five-conductor cable to Ftinf-166 and 168 conductor cable (three phases)

Five-wire cable to five-wire cable branch (three phases)

16o, 162 and three-core cable to four or five JP-170 conductor cable branch (phase B)

I60, 162 and three-core cable to Ftinfleiterkabel-172 junction (phase C)

I60, 162, 170 four-wire cable to five-wire cable and 174 junction (phases B and C)

I60, 162, 164 four-core cable to five-core cable and 174 junction (phases A and C)

In Figure 9, the plate 176 is shown with structure cooperating therewith to provide an installation tool. For the sake of convenience, the letter texts and markings are omitted, but could be included in the device. The base 192 consists of upwardly extending cable guides 194 and 196, which accommodate cables 198 and 2oo and Place the cables in proper orientation with respect to the slot pattern in plate 176. The cables will thus mutually aligned at right angles, and slots 160 to 168 fit together with a line that goes between edge corners 194a and 196a of guides 194 and 196 extend. The guide 194 has a threaded hole 194b for receiving the pin 2o2, which has a threaded end 2o2a and a shoulder 2o2b. The pin 2o4 can be fixed the guide 196 be attached to as a linkage to

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To serve movement of the plate 176 in the working position, after which the pin 2o2 is screwed into the guide 194.

With the arrangement of FIG. 9, base 192 operates preferably as a die and has slits in its top surface in one pattern and one Configuration conforming to slots 16o-174 of plate 176. To perforate the Cables can be punched into the guide holes in the plate 176 in the positions which the right perforations for the ones to be made Deliver connections. The exertion of an appropriate force or forces on the punch or the punch then creates the desired perforation pattern in the cables. The base 192 preferably has a removable bottom for collecting the material punched from the cables. Connectors of the type shown in Fig. 6 can then be inserted and bent over to to complete the connection.

In a preferred practice, the stencil markings are colored as follows: 182 white; 184 green; 186 black; 188 red; and 19o orange. The cable insulation above the conductors are colored accordingly, for example for a five-wire cable: neutral - white; Grounding - green; Phase A - black; Phase B - red; and phase C - orange.

The arrangement of Fig. 1o has a connecting guide 2o6 which has a slit pattern modified from that of Fig. 8 by omitting of slot 174 and by omitting any instructing markings other than slots 16o and

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162 are adjacent. The skipped Shiita has sole use in a four-wire-five-wire branch and such capability remains through slots 170 and I72. The selection plate 2o8 lies over the guide 2o6 and has lateral notches 21 o to 218, the notch 216 in one another with the locking 22o of the guide 2o6. The plate 2o8 has openings 222, 224, 226 and 228 for making accessible only selectively to the connection guide openings. While the plate is shown as being transparent, it can also be opaque if desired be.

As in the case of FIG. 8, slots 160 and 162 are shared used in all connections of the cables. Only phase A is in the position shown for plate 2o8 available, excluding the use of slots other than slots 160, 162 and 164 are because such other slots do not mate with any of the openings 222 to 228 are located. On the other hand, when the plate 2o8 is oriented so that it engages the notch 218 with Lock 22o brings, the plate and the guide are still in right-angled relationship, so is now only the slot 170 is exposed by plate 208. Phase B is thus made available for a three-wire branch. The distinctive distance i.e. the distance between the tips of adjacent notches is the distance d (Fig. 10) which is passed through the slot pattern is given in leadership 2o6. The extent and location of the openings 222 to 228 are preselected for creation the desired variety of connections. The following table is also explanatory for the marking of the Plate 2o8.

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Table 3 Slots 162
162
162
162
162 to the use marked rub 16o,
16o,
16o _f
16o,
16o, and 172
, 164 and 166
, 164, 166 and 168
and 164
and 17o 21ο
212
214
216
218

The joints achieved with the indicated slots are noted in Table 2 above.

As can be seen, in practice, neutral and earth connections lead in corresponding individual connection zones of the matrix of the connection zones, for the repeated selection of neutral and earth connection zones, i.e. identical geometry in separate connections of a first pair and a second The pair of cables thus carries the polarization in the entire installed system. This practice can are limited to the connection of a single pair of conductors to a specifically repeating one Zone, for example an outermost conductor of each cable. Albeit mutual perpendicularity If the cable is preferred, other orientations are within the scope of the Invention. The zone selection pattern can also be different being as a diagonal of the matrix; as noted in Table 1 for a three-three matrix.

In the aspect of the above description, where connection guidance takes place by template or the like., are far less useful than all the connecting zones of the matrix. The connection at least one Pair of conductors is effected by excluding the

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3.

Use of zones other than a single zone are. In this case, the connection guide has an opening in a fit with one another single zone and a continuous surface extent extends in directions mutually perpendicular to such opening. The connection of at least one other pair of conductors is forced to less than all of the zones with which such conductors are in registration. In this case the connection guide has a number of openings in mating with a common conductor of a cable, i.e. along an axis parallel to the Ladders of one cable and perpendicular to the conductors of the other cable where the routing of the cables is arranged in a mutually square relationship.

The invention is not specifically geared towards the embodiments shown here by way of example. Rather, various modifications are readily available to the person skilled in the art within the scope of the invention.

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Claims (7)

Claims A method for connecting a first electrical flat cable, which has first conductors, the are at a mutual distance within electrical insulation, with a second electrical Flat cable, which second conductor at a mutual distance within electrical Having insulation, characterized in that: (a) making conductor identifying markings on the cables; (b) the first cable is brought into overlying relationship with the second cable to define a Matrix of connection zones, with each zone having a unique pair of cable ladders in alignment hereby owns; (c) the zones identifying markings that identify these conductors Correspond to markings, identify a selected number of these connection zones, which are less than all of these; (d) perforations are made in such zones identified in step (c) through the first and second Creates ladder inside from opposite side edges; and (e) electrically connects these cables together at the perforations. 2. The method according to claim 1, characterized in that that step (e) is carried out by introducing an electrically conductive structure into each such perforation, and bending of such a structure onto the cable insulation. T 39/155 030087/0619
ORIGINAL INSPECTED 3. The method according to claim 2, characterized in that step (e) is carried out by selecting such an expansion of the electrically conductive structure that it is in such a bent state lies within the side edges of the first and second conductor, may have such a perforation. 4. The method according to claim 3, characterized in that step (e) is further carried out by selecting such an electrically conductive structure, which has the ability to isolate cables to pierce in the process of bending over. 5. The method according to claim 1, characterized in that that the cables are elongated and the perforations extend along an axis which cut the side edges of the first and second conductors. 6. The method according to claim 5, characterized in that each perforation extends along an axis, which forms an angle of 45 ° with the side edges of the first and second conductor 7. Device for performing the method according to claim 1 to 6, characterized by connecting guides which have access to the selected number of connecting zones, and which provide access to all other zones of the matrix, the connection guides identifying the zones Wear markings. 8ο device according to claim 7, characterized in that the connecting guide consists of a plate which has openings through it in 03QÖI7 / 0619 T 39/155 Having matched up with such selected connection zones and which are continuous Expansion into one another with such others Zones of the matrix. 9 · Device according to claim 8, characterized in that the markings identifying the conductors and the markings identifying the zone are color markings or markings of geometric shape. 1o. Device according to claim 8, characterized in that that the connection guide also includes selection devices which are variably settable with respect to the plate for delivery accessible predetermined zones of these selected connection zones. 030067/0819