DE69431409T2 - MODULAR CONNECTING BLOCK FOR MESSAGE TECHNOLOGY - Google Patents

Abstract

A protected terminal block has a housing (10) having a plurality of test ports (18) and a plurality of electrical contact elements (40), each of which includes a test lead (48) which is accessible through a test port (18). The electrical contact elements are configured in the housing and connected to an exchange wire which is secured to a stub cable. A protection module retainer (140) is secured to a side of the housing (10) proximate the test ports (18) to form a plurality of retaining cups (142) adapted to receive a protection module (100). A grounding strip (150) is secured to ground and retained between the protection module retainer (140) and the housing (10) proximate the test ports (18), the grounding strip (150) having a plurality of integral ground connectors (158). A protection module (100) is provided having a protector (116) which is connected to a pair of terminal block contact elements (102) and a ground connector (160). When inserted into a retaining cup (142), the terminal block contact elements (102) engage a pair of corresponding test leads (48) in test ports and the protection module ground connector (160) engages the grounding strip ground connector (158) to provide surge protection to a pair of conductive paths through the connection of the test leads in the test ports. The protection module may be removed or replaced as needed.

Description

The present invention relates to terminal blocks for connecting line pairs. In particular, the present invention relates to terminal blocks for communications engineering for connecting telephone service lines to telephone connection distribution cables according to the preamble features of claim 1.

Background of the state of the art and related information

Such communication terminal blocks are disclosed in WO 94/18 722, in particular in Fig. 6, and are used to provide suitable electrical connections between telephone customer service lines ("service" side) and telephone connection distribution cables ("exchange" side). These terminal blocks typically connect up to 25 distribution cable line pairs on the exchange side, which may comprise several thousand line pairs, to up to 25 individual service line pairs on the service side.

Terminal blocks are typically designed as standard multi-compartment units that connect either 5, 10 or 25 pairs of wires. In many cases, the number of distribution pairs to be connected may not match the standard number. For example, if seven pairs of wires need to be connected, a ten-pair terminal block, the closest standard terminal block size, must be installed, even if three of the ten pair connections are then not used.

The replacement side wire pairs are difficult to replace because a splice cable that provides the connection from the distribution cable to the replacement side of the terminal block is typically non-removably connected to the terminal block when the splice cable is connected to the terminal block. The permanent connection protects both the splice cable and the replacement side of the terminal block from the environment and ensures a physically secure connection that is designed to withstand repeated establishment and detachment of connections on the service side.

If a connection fails on the replacement side of the terminal block, the entire 5, 10, or 25 pair terminal block must be replaced, requiring a new terminal block and significant installation time and resources. The connection between the splice cable and the failed terminal block must be physically must be severed and the old terminal block discarded, even if only a single connection on the replacement side has failed. In addition, when replacing the terminal block, all existing service side connections must be severed. A new terminal block can then be permanently installed on the splice cable and all service side connections connected to it. This process consumes considerable resources and results in many terminal blocks being discarded because of a single failure.

The service side of terminal blocks is generally subject to the most wear and tear because the service side is used to repeatedly connect and disconnect the telephone service through the terminal block to the distribution cable. Service line pairs are typically connected to the terminal block by some type of connector that is easily connected and disconnected in place, such as a simple terminal clamp where a stripped service line is connected to the terminal clamp and then secured with some type of cap. Another common type of connector is an insulation cover terminal where the service line does not need to be stripped before being connected to the terminal block and the insulation is cut by a knife or other sharp surface when securing the service line to the terminal. Again, with the insulation cover type connector, some type of cap is typically used to secure the service line in place.

While the caps typically used in the terminal or insulation cover terminal provide some protection from the environment, moisture, contaminants, chemicals, dust, and even insects can reach the terminal connection, causing corrosion or other degradation of the contact. This problem is exacerbated by the fact that, in addition to the traditional above-ground location of such terminal blocks, underground and even underwater terminal block locations are increasingly required for telephone distribution purposes. Accordingly, efforts have been made to better isolate the terminal in the terminal block from the environment to prevent such degradation. One such approach has been to use a variety of insulating materials, such as greases or gels, and surround the terminal where the electrical connection is made.

In order to properly test connections and determine whether a problem is related to the exchange side or the service side, it is necessary to turn off one side so that each side can be evaluated independently. In general, the Service side off because it may not be possible to disconnect the replacement side leads. This involves spending extra time disconnecting the service side leads, stripping the lead wires, and connecting the wires to the test bench equipment to evaluate the problem. Once the problem is solved, the test assembly must be removed and the service side leads connected to the terminal block. This process takes a significant amount of time.

Accordingly, there is a present need for an improved communications terminal block for connecting wires from the exchange side to the service side so that individual terminal blocks can be added or removed as needed while maintaining resistance to moisture and other environmental factors which subject the connections therein to degradation over time and limit the applications where such terminal blocks can be reliably used. In addition, there is a present need for an improved communications terminal block which permits testing of the service or exchange side without interrupting the service or exchange side lines.

ESSENCE OF THE INVENTION

The present invention provides a modular terminal block according to claim 1.

In a preferred embodiment, each of the individual terminal blocks of the modular communications terminal block of the present invention utilizes a separate housing molded from a dielectric material. Each individual terminal block is attached to a mounting rail and held in place by, for example, a flexible clamp molded to the housing. Each housing forms a separate container for the insulating fluid that flows during wire connection and disconnection within chambers in the housing.

Connection to the interconnecting cable wires is provided by a interconnecting cable carrier that is movable relative to the housing and formed on a service side of the housing. Connection to services is in turn provided by a service cable carrier that is movable in a chamber within the housing and accessible from an opposite service side of the housing.

In particular, a pair of interconnect line access slots are provided on the housing provided to receive a pair of interconnect cables. Within a chamber in the housing, adjacent the interconnect cable access slots, the interconnect cable carrier is positioned. The interconnect cable carrier is movable between an open position and a closed position and receives each of the interconnect cables in respective interconnect cable conduits. The interconnect cable carrier is held in place in the selected position by a retaining stub which slides into one of two retaining stub slots in the housing corresponding to the selected position, open or closed, of the interconnect cable carrier.

When the interconnect carrier is in the open position, the interconnect cable conduits can accommodate any interconnect through the interconnect access slots in the housing. The interconnect carrier has two slots for receiving insulation piercing electrical contact blades. The insulation piercing contact blades are molded onto an interconnect contact retained in a slot in the access latch.

The terminal block is easily mounted on the mounting rail by slipping a tab formed next to the service side of the terminal block over one edge of the mounting rail. The replacement side of the terminal block is then slid into place over the other edge of the mounting rail until a flexible clamp holder molded onto the housing snaps into place. This secures each end of the terminal block to the mounting rail.

When the replacement side is slid onto the mounting rail, the connector carrier is pushed upward by the pressure from the mounting rail and moved to the closed position. When the connector carrier is moved to the closed position, the insulation piercing contact blades pierce the insulation of the connectors and come into contact with the conductive portion of the connectors. Consequently, the interconnectors are in conductive contact with the interconnector contact contact in a slot in the access latch.

Once the service lines are installed on the mounting rail, they can be connected to the service side of the terminal block. Immediately thereafter, each service line is in conductive connection with a service line connection contact held within a slot in the access jack. A connection module is plugged into the access jack with two rows of contacts that provide a conductive path between each service line and corresponding connecting line. Any number of contacts can be accessed via "single branch" openings on the top of the connection module.

The interconnect module may include many types of plug-in units, including a bridge module that easily connects the service side to the exchange side. Another embodiment includes a protector module that connects the service and exchange sides when plugged into the access jack and includes a dual gas discharge tube and a ground connection contact. Each end of the dual gas discharge tube is soldered to a number of contacts and the ground connection contact is conductively connected to the center of the gas discharge tube.

The other embodiment of the connection module is the two-way test module. The two-way test module has a row of service line test contacts and a row of connection line test contacts. The cover of the two-way test module has a bayonet contact. The service line and connection line test contacts are each formed with a slot that holds the bayonet contact and connects the service side to the exchange side when the bayonet contact is inserted. The bayonet contact is automatically inserted into the test contacts when the cover of the two-way test module is closed. When the cover is closed, the exchange side is therefore connected to the service side. When the cover is closed, the two-way test module is sealed with a gasket. The gasket provides protection from the environment to the internal parts of the gasket.

When the cover is open, the replacement side is no longer connected to the service side, and the ends of the service line test contacts and the interconnection line test contacts are exposed above the seal so that a crocodile test connector or equivalent test connector can be conveniently connected to either the service line test contacts or the interconnection line test contacts for testing.

Another embodiment of the two-way test module has a protected two-way test module that connects the service and exchange sides when plugged into the access jack and includes a dual gas discharge tube and a ground connection contact. Each end of the dual gas discharge tube is soldered to a series of contacts and the ground connection contact is conductively connected to the center of the gas discharge tube.

If either the protector module or the protected two-way test module is to be used, the earth connection contact must be at zero potential. To achieve this, the mounting rail is grounded during installation. The mounting rail thus provides the necessary ground connection point for each terminal block. When installing the terminal block on the mounting rail, a terminal block ground connector seated in the interconnect carrier is connected to the mounting rail's ground connector. The terminal block ground connector is conductively connected to a ground bonding contact held in the central slot of the access latch. When the protector module is plugged into the access latch, the ground bonding contact therefore penetrates the central slot of the access latch and connects the protector module to ground via the mounting rail. One of the many functions of the GDT and GDT contact connection is in conjunction with the two rows of contacts to divert voltage to ground, for example in the event that there are voltage spikes on the conductive path between the service side and the exchange side.

A chamber is provided in the connecting lead carrier, the chamber containing the service lead carrier and the connection module for the insulating agent such as grease or gel to be injected so as to surround each lead carrier and the number of contacts and fill the cable engagement opening in the carriers. During wire termination, the agent flows around the respective carriers without being forced out of the housing.

The services can be removed and reconnected many times via the service side openings and the service carrier.

The terminal block can be installed and removed from the mounting rail as often as necessary while retaining the insulation material. Removal from the mounting rail is accomplished by lifting the clamp and releasing the terminal block from the mounting rail. No special tools are required. After removal, the interconnection lead carrier can be moved back to the open position to release the interconnection leads. The terminal block can be reused immediately after removal.

A reliable, easily manufactured structure is another feature of the terminal block of the present invention. Other features and advantages of the present invention will be appreciated upon review of the following detailed description of the present invention.

Accordingly, it will be understood that the present invention provides an improved communication terminal block with significantly improved robustness against environmental factors such as moisture, chemicals and other such contaminants while maintaining a relatively simple structure.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of a service side of a preferred embodiment of the modular terminal block system of the present invention.

Figure 2 is a perspective view of a replacement side of a preferred embodiment of a variety of the modular terminal block system of the present invention, showing a pair of replacement side leads connected to a terminal block.

Figure 3 is an exploded view of the basic components of the terminal block housing including a service side lead carrier and a replacement side lead carrier of the present invention.

Figure 4 is an exploded view illustrating the housing and housing insert of a terminal block in accordance with the present invention.

Fig. 5 is a broken away view showing an interior of a terminal block in accordance with the present invention and illustrating a replacement side lead support assembly prior to connection of a connecting lead and a service side lead support assembly prior to connection of a service lead.

Fig. 6 is a broken away view showing an interior of a terminal block in accordance with the present invention and illustrating a replacement side wire carrier assembly after connecting a connection line and a service side wire carrier assembly after connecting a service line.

Figure 7 is a sectional view taken along line 7-7 of Figure 6 and shows a cross section of an actuator and the service side conduit carrier in accordance with the present invention.

Figure 8 is a sectional view taken along line 8-8 of Figure 6 and shows a cross section of the replacement side leadframe in accordance with the present invention.

Fig. 9 shows a perspective view of the detail of a ground connection between a Connection block and the mounting rail.

Fig. 10 shows a detailed view of the ground connection between the terminal block and the mounting rail from below.

Fig. 11 is an exploded view of the basic components of the protector module.

Fig. 12 is an exploded view of the basic components of the two-way test module.

Fig. 13 is a broken away view showing an interior of a two-way test module.

Fig. 14 is a sectional view taken along line 114-14 of Fig. 13 and shows a cross section of a two-way test module.

Fig. 15 is an exploded view of the basic components of the protected two-way test module.

DETAILED DESCRIPTION OF THE INVENTION

Referring to Figure 1, the modular terminal block system of the present invention is illustrated. As shown, in a preferred embodiment of the present invention, a number of individual terminal blocks are used, the number of which may vary from 1 to 25 or more with the specific application. One of the terminal blocks is shown removed from the mounting rail.

Each terminal block 10 of the modular system of the present invention utilizes a separate terminal block housing 12. The service side of the terminal block is shown and has service line opening pairs 14 along one face thereof. As will be discussed in more detail below, the line opening pairs 14 provide service lines access to an interior chamber within the housing 12. The housing 12 is made of a dielectric material suitable for fabrication into the desired shape. For example, any of several commercially available thermoplastics may be readily used because of their relatively low cost and ease of machining. However, other dielectric materials may also be used.

As shown in Figures 1, 3 and 4, a portion of the bottom of the terminal block 10 of the present invention includes a lead carrier 20. The lead carrier 20 is preferably made of a dielectric material, which may be the same as the housing 12. The lead carrier includes further includes a ground connection guide 22 which projects downward from the base of the connection line carrier 20.

The ground connection guide 22, best shown in Figures 3, 4 and 10, supports a ground connection 18 which connects to the mounting rail 24 in a manner as shown in Figures 9 and 10. The terminal block is mounted on a DIN standard mounting rail 24 modified to include the rail ground connection 26 which is connected to "earth" by connecting the conductive mounting rail 24 to ground during installation. The mounting rail 24 may be made of steel or aluminum or any other suitable conductive material. The ground connection 18 supported by the ground connection guide 22 provides the conductive connection to the rail ground connection 26. Fig. 9 provides a perspective view of the detail of the ground connection guide 22 and the ground connection 18 prior to connection to the mounting rail 24 at the rail ground connection 26. Fig. 10 provides a view from below showing the ground connection guide 22 and the ground connection 18 connected to the mounting rail 24 at the rail ground connection 26.

As shown in Figure 1, the terminal block 10 is secured to the mounting rail by a face tab 28 located proximate the service side of the terminal block, a rear clamp retainer 30 located proximate the replacement side of the terminal block, and the ground connection guide 22. The face tab 28 has a protruding inner edge that secures the face of the terminal block by squeezing the mounting rail between itself and the ground structure of the terminal block. The rear clamp retainer 30 provides a protruding inner edge that secures the rear of the terminal block to the mounting rail 24. The terminal block ground connection guide 22 (as shown in Figure 9) and the rail ground connection 26 guide the terminal block onto the mounting rail 24. The terminal block is secured to the mounting rail by first attaching the front clamp 28 to the mounting rail. Once the terminal block ground connection 18 and ground connection guide 22 are properly aligned with the rail ground connection 26, downward pressure is applied to the rear of the terminal block to push the rear clamp 30 over the edge of the mounting rail until the rear clamp engages the mounting rail, firmly clipping the terminal block in place. The ground connection is made when the terminal block is clipped into place.

Depending on the application of the terminal block, the fastening can only be made from the front nose 28 and rear clamp 30 in applications where a ground connection is not required. In addition, the use of alternative fastening devices instead of the clip/nose connection is contemplated, such as fastening the terminal block to the mounting rail using a clip mechanism at both ends of the terminal block; fastening the terminal block by reversing the locations of the clip and nose at the ends of the terminal block; or fastening the terminal block to the mounting rail using an industrial hook and eye fastener such as VELCRO (trademark).

To remove the terminal block 10 of the present invention from the mounting rail 24, any flat-ended tool, such as a screwdriver, may be used to apply force and pry the rear clamp retainer 30 from the mounting rail 24 so that the rear clamp retainer 30 can be disengaged from the mounting rail 24 and the entire terminal block can be released from the mounting rail.

In this manner, any number of terminal blocks can be coupled together along a mounting rail to provide access to additional service lines as needed from a connecting distribution cable secured to a splice cable. In this embodiment, a single terminal block would be provided for each connecting line pair and service line pair. Depending on the design, a single mounting rail can be used, or multiple mounting rails can be used. The terminal blocks can be clipped into place or detached along the mounting rail 24 to change the number of terminal blocks as needed. Additionally, as discussed in more detail below, the replacement side lines of the terminal block and the service side lines of the terminal block can be repeatedly connected and disconnected.

Furthermore, for other types of applications, a single service opening may be used instead of a pair of openings 12 for each terminal block, or additional service openings could be provided in each terminal block if a need arose in a specific application. Accordingly, the design of the service openings and their design on the mounting rail 24 is only an illustrative preferred embodiment and may be varied as needed with the specific application.

Still referring to Fig. 1, the top of each housing 12 includes a terminal actuator 32. As will be discussed in more detail below, the remainder of the actuator 32 extends through the housing 12 into the interior chamber of the service side. As shown in Fig. 1 by the position where the terminal actuator 32 is omitted from the illustration, the actuator 32 protrudes from the interior of the housing 12 through an opening 34 in the housing 12. The terminal actuator 32 is preferably made of a dielectric material, which may be the same as the housing 12. The top of the terminal actuator 32 is preferably shaped such that a hand screwdriver, wrench or other tool can be readily positioned and rotated. Alternatively, the actuator 32 may be designed to be grasped and rotated by a user of the terminal block. Rotating the actuator a fixed amount, preferably indicated by visual markings on the housing and the actuator, will cause the service lines to be connected to the connecting lines in a manner to be discussed in more detail below.

Referring to Figure 2, a replacement side view, a plurality of a preferred embodiment of the terminal block of the present invention is shown. The terminal block 10 of the present invention utilizes a terminal block housing 12 having interconnection lead opening pairs 36 along a rear side thereof. As will be discussed in greater detail below, the interconnection lead opening pairs 36 provide the interconnection leads with access into an interior chamber within the housing 12.

Furthermore, for other applications, a single interconnect opening may be used instead of a pair of openings 36 for each terminal block, or additional interconnect openings could be provided in each terminal block if a need arose in a specific application. Accordingly, the design of the interconnect openings and their design on the mounting rail 24 is only an illustrative preferred embodiment and may be varied as needed with the specific application.

As further illustrated in Figure 2, the terminal block 10 includes a connection module 16 having a cap 42 with two "one-branch" test ports 44 (as shown in Figure 1). As discussed in greater detail below, the connection module 16 provides the connection between the service side and the replacement side of the terminal block and may be embodied in a number of configurations. Preferably, the Interconnect module has a basic configuration, referred to herein as a bridge module, with contacts (shown in Figure 4) that provide a connection between the service side lines and the exchange side lines. An alternative embodiment of the interconnect module, referred to herein as a protector module, protects the service and interconnect lines from voltage spikes. Both the bridge module and the protector module provide test ports 44 to allow testing of the service and exchange sides without opening the terminal block or breaking the service or exchange side lines.

Referring to Figure 3, there is shown an exploded view of the basic components of a terminal block housing including the replacement side conductive carrier and the service side conductive carrier of the present invention. The terminal block of the present invention includes a path for each of two wire connections between the replacement side and the service side. For simplicity of description and to avoid unnecessary clutter in the drawings, only those components that define a single conductive path through the terminal block are described, although the detailed description applies equally to both conductive paths.

As shown, the interconnect carrier 20 includes an interconnect cable conduit 92 that guides the interconnect after it is inserted into one of the interconnect pair openings 36 (as shown in Figure 2). The interconnect carrier 20 includes a contact blade receiving slot 94 for receiving the interconnect contact blade (as described below) and a ground connection receiving slot 98 that connects to the ground connection guide 22 and receives the ground connection (not shown).

A service line carrier 50 is provided which is bolted to the terminal actuator 32. In particular, the service line carrier 50 has a threaded opening 34 in its upper end for receiving the mating threaded end of the terminal actuator 32. The terminal actuator 32 includes a termination plug 54 which is used to retain the insulating means within the housing 12 as will be described later. The service line carrier 50 also has a line receiving opening 56 for receiving a service line plugged into the housing. The line receiving opening 56 is sealed with a perforated seal 58 which is intended to retain the insulating means within the housing 12 as will be described below.

Each cable receiving opening 56 runs through a flanged extension 60 of the service carrier 50 into the central portion of the carrier 50. A first contact blade receiving slot 62 is provided at a first position along the opening 56 in the carrier, and a second contact blade receiving slot 64 is provided at a second position along the opening 56. The first and second contact blade receiving slots 62, 64 receive first and second insulation cutting contact blades 66, 68, respectively. The service carrier 50, including the first and second insulation cutting contact blades 66, 68, is retained in the terminal block housing insert 70.

A housing insert 70 includes first and second contact blade groove guides 72, 74, respectively, for each row of contact blades. The first and second contact blade groove guides receive first and second insulation cutting contact blades 66, 68. The housing insert 70 also retains the service line connecting contact 76. Each service line connecting contact 76 is molded to the first and second insulation cutting contact blades 66, 68. Therefore, when one of the insulation cutting contact blades 66, 68 is in conductive communication with a service line, it is also in conductive communication with the corresponding service line connecting contact 76.

As shown in Figure 4, in addition to the connection contact 76, the housing insert 70 holds a service line connection contact 80 and a ground connection contact 84. These connection contacts are plugged into the base of the five-pin access jack 120 when the housing insert is placed in the housing 12. Specifically, the service line connection contact 76 is held in the service line connection contact slot 122 and the service line connection contact 80 is held in the service line connection contact slot 124. The ground connection contact 84 is held in the centrally located ground connection contact slot 130.

As shown in Fig. 4, the interconnect carrier 20 is inserted into the housing 12 in a space formed between the housing 12 and the housing insert 70. When inserted, the interconnect contact blade receiving slot 94 receives the interconnect insulation cutting contact blade 170. The insulation cutting contact blade 170 is molded onto the interconnect connection contact 80 and is made of a metallic conductor to provide good electrical contact from the connection contact 80 to the interconnect when the insulation cutting contact blade 170 breaks through the insulation thereof during termination, as described below.

As shown in Fig. 4, the terminal block of the present invention includes the embodiment of the connection module as a bridge module 40. The bridge module 40 includes a path for each of two wire connections between the exchange side and the service side. To simplify the description and to avoid unnecessary clutter in the drawings, only those components that define a single conductive path through the bridge module are described, although the detailed description applies equally to both conductive paths.

The bridge module 40 includes a series of molded bridge contacts 110. Each number of bridge contacts 110 includes a service line connection contact 114 and a service line connection contact 116. The contacts are held in the bridge module with a hard encapsulant, such as a non-conductive epoxy, the top of which is shown as encapsulant 38. The hard encapsulant occupies only a portion of the interior of the bridge module 40. The remainder of the interior of the bridge module 40, which includes approximately the upper third of the interior of the bridge module 40, is filled with an insulating gel. Therefore, a test probe can be inserted into the single branch test opening 44 to make conductive contact with the number of bridge contacts 110.

Figure 4 further illustrates the gasket 118 used to provide a seal between the selected interconnect module and the five-pin access latch 120 of the housing 12. The gasket is made of a resilient material known in the art and capable of serving as an environmental barrier between the five-pin access latch 120 and the external environment. The gasket provides a seal such that no environmental contaminants or moisture can enter the interconnect contact area once the interconnect module is clipped into place over the five-pin access latch 120.

As best shown in Figures 5, 6 and 8, installation of a connecting line on the replacement side is illustrated. Figure 5 is a broken away view showing an interior of the terminal block of the present invention and illustrates the replacement side lead carrier assembly prior to connection of a connecting line. With respect to installation of the replacement side lead, a replacement side interior chamber 160 is preferably formed with the bottom and back of the housing insert 70, the sides and back of the housing 12 and the top of the connecting line carrier 20. The connecting line carrier 20 is held in place in the chamber by the combined action of the connecting line carrier retaining stub 176 (as shown in Figure 3) in correspondence with the first or second connecting line carrier retaining slot 178, 180. The connecting line carrier 20 may be actuated by a connecting line carrier actuator molded onto the connecting line carrier 20. slot 164 can be moved to an open or closed position. The actuator slot 164 can be operated with a simple tool, e.g. screwdriver, to push the interconnect carrier away from the roof of the housing 12 into the open position, as shown in Fig. 5, thus opening the interconnect chamber 160. In the open position, the interconnect carrier is held by the interconnect carrier retaining stub 176 and the interconnect carrier retaining slot 178.

Once the interconnect carrier 20 is moved to the open position, the interconnect 162 can enter the interconnect opening 36 in the housing 12 and travel into the interconnect receiving opening 166 in the interconnect carrier 20 and finally into the interconnect receiving opening 168 of the housing insert 70 until it is seated at the bottom of the opening. If both conductive paths are to be used, it is preferable to plug both replacement side leads into the replacement side lead carrier before the terminal block is clipped into place on the mounting rail.

Fig. 6 is a broken away view of the interior of the terminal block of the present invention and illustrates the replacement side lead carrier assembly after a lead wire has been connected. Fig. 8 is a second view which is a cross section of the replacement side lead carrier taken along line 8-8 in Fig. 6 after a lead wire has been connected. The lead wire can be connected when the terminal block 10 is clipped into place on the mounting rail 24 as shown. Installation of the terminal block 10 on the mounting rail pushes the lead wire carrier 20 upwardly into the closed position. Sliding the lead wire carrier upwardly pushes the lead wire carrier retaining stub 176 out of the lead wire carrier retaining slot 178 and into the lead wire carrier retaining slot 180. The connecting cable can also be connected by pushing the connecting cable carrier by hand into the closed position and then installing the connection block on the mounting rail.

By closing the connecting line carrier, the connecting line is placed in conductive connection with the connecting line connection contact 80 as follows: The connecting line 162 sits in the connecting line cable channel 92. When the connecting line carrier is pushed up into the closed position, the connecting line insulation cutting contact blade 170 is inserted into the connecting line 162 pressed in and thereby moves into the connecting line contact blade receiving slot 94. The insulation cutting contact blade 170 cuts through the connecting line insulation and makes contact with the metallic conductor of the line. The connecting line connection contact 80 is simultaneously placed in conductive connection with the connecting line because it is in conductive connection with the insulation cutting contact blade 170.

5, 6 and 7 illustrate the installation of a service line on the service side. As best shown in Fig. 5, a broken away view showing an interior of the terminal block of the present invention illustrates the service side line carrier assembly prior to connection of a service line. As shown, a service side interior chamber 150 is preferably molded to the tops and sides of the housing 12 and the top of the housing insert 70. The service line carrier 50 is opened by rotating the terminal actuator 32 until the service line carrier 50 is fully retracted toward the roof of the housing 12. Once the service line carrier 50 is retracted to the open position, the service side line 152 can penetrate the apertured seal 58 and migrate into the service line receiving opening 56 until it is seated at the bottom of the opening. In practice, both service side leads are plugged into the service side lead frames before the terminal actuator 32 is used to connect the lead wires.

Fig. 6 illustrates the service side lead carrier assembly after termination of a service line, and Fig. 7 shows a second view which is a cross-section of the terminal actuator and service side lead carrier taken along line 7-7 in Fig. 6 after termination of a service line. As shown, the first and second contact blade receiving slots 62, 64 receive first and second insulation cutting contact blades 66, 68, respectively, when the service line carrier 50 is in the closed position. The first and second insulation cutting contact blades 66, 68 are each molded onto a service line connection contact 76 and are formed of a metallic conductor to provide good electrical contact from the service line connection contact 76 to the service line when the blades 66, 68 pierce the insulation thereof. Therefore, as soon as an insulation cutting contact blade is in conductive connection with a service line, it is also in conductive connection with the corresponding service line connection contact 76.

Which of the two blades 66, 68 makes electrical contact with the conductor wires is determined by the diameter of the wires. That is, whether the conductor is in the first Whether the wire is inserted into the first slot 62 or the second slot 64 depends on the wire diameter. For example, as shown in Fig. 6, a large fitting wire only goes far enough into the opening 56 to reach the slot 62 and thus makes electrical contact with the blade 66. A smaller fitting wire, in turn, reaches the second slot 64 and makes contact with the second, longer blade 68.

As best shown in Fig. 6, the upper portion of the housing 12 above the chamber 150 is provided with an annular groove 154 around the opening 34. The upper end of the terminal actuator 32 is provided with a mating annular flange 156 which fits into the annular groove 154. This thus prevents a compressive movement of the terminal actuator 32 during rotation thereof, unlike prior art actuator connectors which drill into a container to make contact with a service line.

As best shown in Fig. 4, immediately after the connection and service lines are connected as described in Figs. 5-8, the connection line is conductively connected to the connection line connection contact 80 on the connection line connection contact slot 124 in the five-pin access jack 120. The service line is conductively connected to the service line connection contact 76 on the service line connection contact slot 122 in the five-pin access jack 120. The ground connection 18 is conductively connected to the ground connection contact 84 on the ground connection contact slot 130.

To conductively connect the service side to the exchange side using the bridge module 40, the bridge module 40 is plugged into the five-pin access jack 120. The series of bridge contacts 110 completes the conductive loop between the exchange side and the service side. Immediately after the connection, the single branch test port 44 (as shown in Figure 2) can be used to perform the diagnostic test which can examine the signal provided by the connection.

Alternatively, the bridge module may be removed and replaced with a protector module 140 as shown in Fig. 11. The protector module 140 performs the same function as the bridge module 40 in terms of connecting the service and exchange sides when plugged into the five-pin access jack 120, but further includes a gas discharge tube 142 and a ground connection contact 144. The gas discharge tube 142 has three conductive rings, a ring 146 surrounding the circumference of each end of the tube and a third ring 148 surrounding the center of the tube. Each of the rings is soldered or conductively secured to a contact. Therefore, any number of contacts 110 are conductively connected to the end rings, respectively, and the ground bonding contact 144 is conductively connected to the center ring. Among many other functions, the gas discharge tube 142 and ground bonding contact connection 144 in conjunction with contacts 110 serve to divert voltage to ground, for example in the event of voltage spikes on the conductive path. Thus, once the protector module is plugged into the five-pin access jack 120, the two primary conductive paths between the exchange side and the service side are protected from temporary destructive voltage levels. The use and operation of the gas discharge tube and its use in protecting signal lines in this manner are well known in the art.

As in the bridge module 40, the contacts 110 and gas discharge tube 142 are retained within the protector module 140 with a hard encapsulant, such as a non-conductive epoxy, in the protector module. The hard encapsulant occupies only a portion of the interior of the protector module 140 as used in the bridge module. The remaining upper third of the interior of the protector module 140 is filled with an insulating material. Therefore, a test probe can be inserted into the single branch test port 44 to make conductive contact with the series of contacts 110 and to perform diagnostic tests on the connection. The bridge module 40 and the protector module 140 can be used interchangeably with the housing 12 and the five-pin access jack 120, depending on the application desired by the user.

Alternatively, the bridge module may be removed and replaced with a two-way test module 200 as shown in Figure 12. The two-way test module performs the same function as the bridge module 40 in terms of connecting the service and exchange sides when plugged into the five-pin access jack 120, but includes a configuration of the contacts that allows testing of either the exchange side or the service side without breaking the exchange side or service side lines. The two-way test module further includes a proprietary embodiment further described below.

The two-way test module 200 has a path for each of two wire connections between the exchange side and the service side. To simplify the description and to avoid unnecessary clutter in the drawings, only those components that define a single conductive path through the two-way test module are described, although the detailed description applies equally to both conductive paths.

The two-way test module 200 includes a housing 202 and a hinged lid 204. The test module housing 202 and lid 204 are preferably made of a dielectric material, which may be the same as the housing 12 (as shown in Figure 1). The hinges 206 are molded onto the lid 204 so that the hinges and lid form a single unit. The hinged lid 204 is pivotally attached to the housing by pins 208 molded onto the housing. The hinged lid 204 includes bayonet contacts 210 mounted perpendicular to the interior of the hinged lid and formed of a metallic conductive material such as brass, although other sufficiently conductive materials would work equally well.

Two arrays of test contacts are mounted within the housing 202. Each array of test contacts includes a service line test contact 214 and a link line test contact 216. Each contact is formed of a metallic conductive material similar to that of the bayonet contact 210. Each contact has a plurality of bends. A plurality of bends provide a surface 218 into which a dual gas discharge tube can be inserted for a proprietary embodiment of the two-way test module (described below). A second plurality of bends 220 are provided in correspondence with a slot 222 in each contact which allows the bayonet contact 210 to be inserted simultaneously into the service line test contact 214 and the link line test contact 216. The upper end of the service line test contact 214 and the interconnect line test contact 216 adjacent the cover 204 terminates in a tab 224 which provides a suitable terminal to which an alligator-type test cable or other similar test cable can be attached for testing either the service side or the replacement side.

Fig. 13 is a broken away view showing an interior of a two-way test module. Fig. 14 is a sectional view taken along line 14-14 in Fig. 13 showing a cross-section of the two-way test module 200. As shown in Fig. 13, the contacts within the two-way test module 200 are maintained with a hard encapsulant, such as a non-conductive epoxy, the top of which is shown as encapsulant 230. The hard encapsulant occupies a portion of the interior of the two-way test module 200. The remainder of the interior of the two-way test module 200 is sealed by a gasket 232. The gasket is secured to the top edge of the housing 202. When the cover 204 is closed, the seal 232 provides a seal between the cover 204 and the housing 202 so that a Environmental seal is formed that protects the contents of the two-way test module from the environment. In particular, the seal 232 provides an environmental shield that protects the connection transition between the service line test contact 214, the interconnect line test contact 216, and the bayonet contact 210. Therefore, the connection between the service side and the exchange side that is formed when the cover is closed and the bayonet contact is inserted into the slot 222 provided in the service line test contact 214 and the interconnect line test contact 216 is protected from the environment by the seal. Preferably, the space between the encapsulant and the seal is filled with an insulating agent that also protects the connection transition from the environment.

As shown in Fig. 13, the cover 204 can be pried open using any flat tool, such as a screwdriver. When opened, a tab 224 placed on the top of each contact is exposed above the seal 232 so that an alligator test connector or equivalent test connector can be conveniently connected to either the service line test contact 214 or the connecting line test contact 216 for testing. Even when the two-way test module is in the open position, the contents of the module beneath the seal are largely protected from the environment because only the two slots normally filled with the bayonet contacts are open.

The cover may be provided with a single-branch test opening 44. Therefore, a test probe can be inserted into the single-branch test opening 44 to make a conductive contact with the service and exchange sides once they are connected by the bayonet contact, without opening the cover of the two-way test module.

Alternatively, the two-way test module 200 may be removed and replaced with a protected two-way test module 240 as shown in Fig. 15. The protected two-way test module 240 performs the same function as the two-way test module 200 with respect to connecting the service and exchange sides when plugged into the five-pin access jack 120, but further includes a gas discharge tube 142 and a ground connection contact 144 which operate largely as described in connection with Fig. 11.

The gas discharge tube 142 includes three conductive rings, a ring 146 surrounding the periphery of each of the ends of the tube and a third ring 148 surrounding the center of the tube. Each of the rings is soldered or conductively secured to a contact. Thus, in one embodiment, the interconnect test contacts 216 are each conductively connected to the end rings and the ground connection contact 144 is connected to the center ring 148. conductively connected. Alternatively, the service line test contacts 214 are each conductively connected to the end rings and the ground bonding contact 144 is conductively connected to the center ring. Therefore, once the protected two-way test module is plugged into the five-pin access jack 120 and the cover 204 is in the closed position, the two main conductive paths between the exchange side and the service side are protected from temporary destructive voltage levels. The use and operation of the gas discharge tube and its use in protecting signal lines in this manner are well known in the art.

When the cover of the protected two-way test module is in the open position, the tab 224 located on the top of each contact is exposed above the seal 232 so that an alligator test connector or equivalent test connector can be suitably connected to either the service line test contact 214 or the trunk line test contact 216 for testing.

As with the two-way test module 200, the service line and link line test contacts 214 and 216, the ground connection contact 144, and the gas discharge tube 142 are retained with a hard encapsulant, such as a non-conductive epoxy, in the protected two-way test module 240. As with the two-way test module 200, the hard encapsulant occupies only a portion of the interior of the protected two-way test module 240. The remainder of the interior of the two-way test module 240 is sealed by the gasket 232. The seal 232 protects the connection transition between the service line test contact 214, the connecting line test contact 216 and the bayonet contact 210. Therefore, the connection between the service side and the exchange side, which is formed when the cover is closed and the bayonet contact is inserted into the slot 222 provided in the service line test contact 214 and the connecting line test contact 216, is protected from the environment by the seal 232. Preferably, the space between the encapsulant and the seal is filled with an insulating agent which also protects the connection transition from the environment.

In addition, a test probe can be inserted into the single-branch test port 44 when the cover is in the closed position to perform diagnostic tests on the connection between the service side and the replacement side while maintaining the conductive connection between the two sides. The two-way test module 200 and the protected two-way test module 240 can be used interchangeably with the housing 12 and the five-pin access jack 120, depending on the user's desired use.

Referring to Figure 5, prior to using the terminal block of the present invention for interconnect and service line connection, and preferably during manufacture or assembly of the terminal block, a suitable insulating material is injected into the chambers 150 and 160 and over the hard encapsulant within the bridge module 40 and the protector module 140 to fill all of the voids and the line openings in the terminal block. In addition, the voids in the two-way test module 200 or the protected two-way test module 240 may also be filled in a similar manner. Depending on the specific requirements of the application, any of a wide variety of well-known, commercially available greases, gels and other insulating materials may be used.

The viscosity and adhesive qualities of the fluid should be such that lead wires can be inserted and removed from the openings 56, 166 and 44 without excessively sticking to the fluid. The fluid should be fluid enough to flow around the connecting lead carrier 20 and the service lead carrier 50 as they move therethrough. The fluid can be injected into the chamber 150 through a central bore in the terminal actuator 32. This central bore in the terminal actuator 32 is then secured with a stopper plug 54 to ensure that the fluid 28 remains within the chamber once the chamber is filled. Similarly, the perforated seal 58 helps prevent the fluid from flowing out through the service lead receiving openings 56. The agent is further injected into the test port 44 to fill the bridge module 40 and the protector module 140 and through the interconnect receiving port 166 into the chamber 160. The agent is further injected through the seal 232 to fill the two-way test module 200 and the protected two-way test module 240. Injection of the agent may be performed after assembly of the terminal block. Furthermore, in the case of a curable medium such as gel, the agent may be pumped in outside the block after pre-curing or injected in an uncured state and then allowed to cure.

In use, the desired connecting wires to be connected to the terminal block are inserted into openings 166 with the connecting wire carrier 20 in a first open position, shown in Fig. 5. In this position, the lead wires can be easily inserted into the interior of the connecting wire carrier 20, displacing only a very moderate amount of insulating material.

As will be understood from Fig. 5, in the open position the diameter of the lead blocks the opening 166 and prevents the escape of insulation. Once the lead wires are inserted into the lead openings 166, the installer simply pushes the lead carriers 20 into the closed position. This can also be done in conjunction with clipping the carrier into place on the mounting rail 24 as shown in Fig. 6. This movement propels the lead carrier 20 upward. In this position the lead wires are pressed into contact with the lead insulation cutting contact blades 170. The insulation cutting blades 170 cut through the insulation on the lead wires and provide good electrical contact with the conductive inner core of each lead. When the interconnect carrier moves from the open to the closed position, the insulating medium is simply displaced from the chamber 160 to an opening 166 due to the flowable nature of the medium during closure. In this way, the volume of insulating medium in the chamber 160 remains substantially constant despite the upward displacement of the interconnect carrier 20 and the lead wires connected thereto, thereby avoiding the leakage of medium and/or the creation of any voids that could allow the ingress of moisture or contaminants from the environment.

The medium is also retained within the chamber 150 during connection and disconnection of the services in use. The desired services to be connected to the terminal block are inserted through the perforated seal 58 into the openings 56 with the service carrier 50 formed in a first position, shown in Fig. 5. In this position, the lead wires can be readily inserted into the interior of the carrier 50, displacing only a very moderate amount of insulating medium. As will be understood from Fig. 5, in the first position, the flanged extension 60 with the perforated seal 58 of the carrier 50 blocks the portion of the wire access slots 14 below the openings 56 and prevents the escape of insulating medium. Once the lead wires are inserted into the openings 56, the user of the terminal block rotates the terminal actuator 32, which in turn drives the service carrier 50 downwards because of the screw connection of the actuator 32 and the carrier. The end plug 54 prevents the fluid from escaping through the center portion of the actuator. The actuator 32 is rotated until the carrier 50 is driven downwards to the second position shown in Fig. 6. In this position, the leads are pressed into contact with the insulation cutting blades 64, 66. The insulation cutting blades 64, 66 cut through the insulation on the service line and provide good electrical contact with the conductive inner core of the line.

During the downward movement of the service carrier 50 from the first position shown in Fig. 5 to the second position shown in Fig. 6, the insulating medium inside the chamber 150 flows around the sides of the service carrier 50 so that it is displaced from the lower to the upper part of the chamber 150. In this regard, vertical channels (most clearly seen in Fig. 3) can be provided on the service carrier 50 to facilitate the flow of the insulating medium around the carrier element when it is driven from the first to the second position by rotating the actuating element 32. In this way, the volume of insulating medium in the chamber 150 remains substantially constant despite the depression of the service carrier 50 and the connected lead wires, thereby avoiding leakage of medium and/or the creation of any voids that could allow the ingress of moisture or contaminants from the environment.

Unlike conventional terminal blocks, once installed, the terminal block can be removed from the mounting rail and the replacement side leads can be removed and replaced as needed while the insulating material in the terminal block remains intact.

As best shown in Figure 2, to remove the terminal block 10 from the mounting rail 24, a tool, such as a screwdriver, can be used to apply force to push the rear clamp holder 30 away from the mounting rail so that the rear clamp holder 30 can be released from the mounting rail 24 and the entire terminal block can be lifted off the mounting rail.

As best shown in Figure 5, the replacement side leads can be removed and/or replaced once the terminal block is removed from the mounting rail. To remove the replacement side leads, downward force is applied to the interconnect carrier 20 by inserting a flat head tool, such as a screwdriver, into the interconnect carrier actuator slot 164. The downward pressure pushes the interconnect carrier 20 into the open position and releases the interconnect leads from the interconnect insulation cutting contact blades 170. Once the interconnect leads are free, they can be removed from the terminal block. Additionally, new interconnect leads can be plugged into the interconnect carrier for installation if necessary. Consequently, the Terminal block can be used repeatedly in the same or another installation, thus providing maximum flexibility.

The service side leads can be removed by reversing the movement of the terminal actuator. Counter-rotation of the terminal actuator pushes the service lead carrier upward and releases the service leads from the engagement of the first and second insulation cutting contact blades 64, 66. Immediately after separation, the lead can be pulled out of the terminal block housing. In this manner, services in the same terminal block can be connected, removed and replaced as needed.

Accordingly, it will be appreciated that the terminal block of the present invention provides significantly improved environmental protection and enables multiple connection and disconnection of connecting lines and service lines and the terminal block without significant loss of insulation and consequent loss of environmental protection capability. Furthermore, the present invention provides a terminal block that is easy to use and mechanically simple and is not susceptible to failure even after repeated connections and disconnections. In addition, the terminal block provides a bridge module or protector module for appropriate and secure connection of the replacement and service sides and a five-pin access jack for use by additional modules as desired.

Referring to Figures 3 and 4, an exploded side view of the present invention is shown, demonstrating the ease of manufacture of the present invention. As shown, each of the components of the terminal block is moved into position within the housing 12 and is retained by the housing insert 70 and the housing 12. Thus, it will be appreciated that in addition to providing the features described above, the present invention can also be manufactured cost effectively and readily compatible with existing fabrication technologies.

Although the foregoing description is a presently preferred embodiment of the present invention, it should be understood that the terminal block of the present invention may be modified in many ways while still remaining within the scope of the present invention. For example, the specific configurations of the housing, housing insert, interconnect carrier, ground connection to the mounting rail, and service carrier may all be changed due to specific manufacturing considerations or for other reasons without departing from the scope of the present invention. Although the present invention is still intended to be a terminal block suitable for use with insulated exchange and service side wires, the present invention may equally well be used with bare connection or service line wires. Those skilled in the art will appreciate that additional variations and modifications to the preferred embodiment described above may also be made and, accordingly, the above description of the present invention is merely illustrative in nature.

Claims (9)

1. Modular connection block (10) suitable for removable attachment to a mounting element (24), comprising: - a housing (12) with an access latch (120); - means for connecting a service line (152) within the housing (12), wherein the service line connection means includes a service line contact element (66, 68) accessible via the access latch (120); - Fastening means (28, 30) for removably fastening the connection block (10) to the mounting element (24); - connecting line connection means with a connecting line contact element (170) accessible via the access latch (120); and - means (16) adapted to cooperate with the access latch (120) to connect the service line contact element (66, 68) and the connection line contact element (170) so that an electrically conductive path is formed therebetween, marked by Interconnection line connection means (162) responsive to activation of the mounting rail (24) when the modular connection block is clipped into place on the mounting rail (24). 2. The terminal block of claim 1, wherein the connection device (16) includes a test lead feedthrough (44) for providing access to the electrically conductive path formed between the service line (152) and the connection line (162). 3. The terminal block of claim 1, wherein the connection device (16) includes a module (40) with a number of molded contacts (110), including a service line connection contact (114) and a connection line connection contact (116), such that when the module (40) is plugged into the access jack (120), a conduction path is formed between the service line (152) and the connection line (162) via the number of molded contacts (110). 4. Terminal block according to claim 3, wherein the mounting rail (24) is electrically grounded and the connecting device (16) further includes: - a gas discharge tube (142) having a first end electrically connected to the plurality of molded contacts (110) and having a second end is electrically connected to a ground connection contact (84) to provide grounding; and - Means (18) for creating a conductive connection between the ground connection contact (84) and the electrically grounded mounting rail (24), so that if overvoltage occurs on the number of molded contacts (110), the overvoltage is diverted to ground through the gas discharge tube (142). 5. Terminal block according to claim 1, wherein the connection line connection device comprises: - a connecting line carrier (20) through which a connecting line cable duct (92) passes; and - a slot (94) in the conductor carrier (20) extending over the cable duct (92), wherein the connecting conductor contact element (170) is a metal element formed in the access latch (120), wherein a section with a slotted insulation cutting blade (170) extends into the connecting conductor carrier (20) and extends towards the slot (94) in the cable duct (92). 6. Terminal block according to claim 5, wherein the connecting line connection device can be brought into a closed position by the mounting rail (24) when the terminal block (10) is installed on the mounting rail (24). 7. A terminal block according to claim 1, wherein the fastening device comprises: - a frontal lug (28) adjacent the service connection device, which secures a front side of the connection block (10) to the mounting rail (24); and - a rear clamp holder (30) placed next to the connecting line connection means and securing a rear side of the connection block (10) to the mounting rail (24), the connecting line connection means being brought into the closed position when the rear side of the connection block (10) is installed on the mounting rail (24). 8. The terminal block of claim 7, wherein the fastening device further comprises: - an earth connection guide (22) which is molded onto the connecting line carrier (20); - a ground connection (18) disposed within the ground connection guide (22) and molded to a ground-to-ground connection contact disposed in the access latch (120); - a mounting rail (24) which is electrically grounded and has a slot (26) for receiving the ground connection guide (22), the ground connection (18) being guided from the ground connection guide (22) into the mounting rail slot (26) and grounded when the rear of the terminal block (10) is installed on the mounting rail (24). 9. The terminal block of claim 1, wherein the means for connecting a service line (152) includes a first chamber (150), wherein the means for connecting a connecting line (162) includes a second chamber (160), and wherein the connecting means (16) includes a third chamber (38; 230), wherein the first, second and third chambers (150, 160, 38; 230) are filled with a flowable electrical insulating medium.