EP0789939A1 - Soudage de fils distincts pour former un cable ruban monobloc destine a un connecteur performant - Google Patents

Soudage de fils distincts pour former un cable ruban monobloc destine a un connecteur performant

Info

Publication number
EP0789939A1
EP0789939A1 EP95932408A EP95932408A EP0789939A1 EP 0789939 A1 EP0789939 A1 EP 0789939A1 EP 95932408 A EP95932408 A EP 95932408A EP 95932408 A EP95932408 A EP 95932408A EP 0789939 A1 EP0789939 A1 EP 0789939A1
Authority
EP
European Patent Office
Prior art keywords
conductors
bonding
wires
insulation
fixture
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP95932408A
Other languages
German (de)
English (en)
Other versions
EP0789939B1 (fr
Inventor
Jess B. Ferrill
Kevin Hudson Snead
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Whitaker LLC
Original Assignee
Whitaker LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US08/332,218 external-priority patent/US5571035A/en
Priority claimed from US08/334,172 external-priority patent/US5592739A/en
Application filed by Whitaker LLC filed Critical Whitaker LLC
Publication of EP0789939A1 publication Critical patent/EP0789939A1/fr
Application granted granted Critical
Publication of EP0789939B1 publication Critical patent/EP0789939B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/70—Coupling devices
    • H01R12/77—Coupling devices for flexible printed circuits, flat or ribbon cables or like structures
    • H01R12/78—Coupling devices for flexible printed circuits, flat or ribbon cables or like structures connecting to other flexible printed circuits, flat or ribbon cables or like structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H01R24/60—Contacts spaced along planar side wall transverse to longitudinal axis of engagement
    • H01R24/62—Sliding engagements with one side only, e.g. modular jack coupling devices
    • H01R24/64—Sliding engagements with one side only, e.g. modular jack coupling devices for high frequency, e.g. RJ 45
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/50—Fixed connections
    • H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
    • H01R12/61—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures connecting to flexible printed circuits, flat or ribbon cables or like structures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/50—Fixed connections
    • H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
    • H01R12/65—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures characterised by the terminal
    • H01R12/67—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures characterised by the terminal insulation penetrating terminals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/26—Pin or blade contacts for sliding co-operation on one side only

Definitions

  • This invention is directed to a method of bondinr the entry ends of a plurality of discrete wires to fo. ⁇ a unitary ribbon cable for insertion into and termination by an electrical connector, such as a modular plug, and to the enhancement of such connector by the use of a load bar insert to improve performance through a reduction in crosstalk.
  • a current standard or performance level used today is identified as Category 5 products where operating frequencies may be 100 MHz or higher. While the invention has diverse application for the preparation and alignment of wires to be terminated within a connector, it has particular utility with the loading of modular plugs which often must be terminated in the field by technicians, or in small factory operations manually.
  • Modular plugs a relatively inexpensive electrical connector
  • the cable to be terminated in the plug is a bundle of four twisted pair, insulated, multi-colored wires (eight in total) , within a cable jacket or wrap of an insulating sheath.
  • the bundle may optionally include a surrounding shield or a drain wire for use in a shielded plug.
  • the cable jacket is peeled back to expose the various insulated pairs. Thereafter, with the several insulated wires exposed, the wires are untwisted and arranged in the desired order, generally in a side-by-side fashion. The wires are then individually inserted into the connector housing and terminated by an insulation piercing blade, a termination procedure known in the art. Recognizing these cumbersome procedures, load bar inserts were developed to facilitate the loading process. A typical loading bar insert is illustrated in U.S. Patent No. 4,713,023.
  • the invention thereof includes a wire positioning means for holding insulated conductors in an array so that the ends thereof are presented in alignment below terminal receiving cavities when the wire loaded positioning means is in the housing.
  • the positioning means includes cam means formed thereon and adapted to engage a housing strain relief section when it is moved downwardly, whereby the positioning means is moved forwardly in the housing to fully seat the positioning means therein and position the free ends of the insulated conductors below the terminals.
  • the patent teaches the process of preloading wires into a wire holder which locates the leading ends of the wires at the same pitch as passageways in the connector housing.
  • the wire holder, supported by the wires is then inserted into and along a mouth of the housing until it abuts a tapered throat at the entrance to the passageways. Further advance of the bundle feeds the discrete wires through the wire holder into the respective passageways guided by the throat, while the wire holder remains adjacent the tapered throat.
  • the wire organizer is first pushed to the end of the trimmed wires, then inserted into the connector housing.
  • the wires are pushed beyond the wire organizer into a position to be individually terminated, as known in the art.
  • the assembly and termination of the modular plug is very labor intensive. The procedure by which this invention supports the performance and loading of the modular plug of the companion application, and its ability to generally improve the speed in which modular plugs may be factory terminated, will become apparent in the description which follows, particularly when read in conjunction with the accompanying drawings.
  • This invention is directed to the field of electrical connectors, such as a modular plug, where a plurality of insulation jacketed wires are inserted into and terminated within the plug, where one such termination procedure is by insulation piercing.
  • the method of this invention is particularly directed to a procedure for aligning and bonding, such as by heat, adhesive or tape, a plurality of discrete insulation jacketed wires to facilitate the handling and insertion of the wires into a modular plug housing, for example, where they are terminated.
  • the steps in bonding by heat comprise aligning the plural wires in side-by-side fashion on a first fixture, where the fixture includes a plurality of heating elements, with each heating element arranged to contact the insulation jackets of an adjacent pair of the wires.
  • a load bar insert may be provided down stream of the bonded wire ends.
  • a preferred load bar insert is characterized by having an upper surface and a lower surface to space or separate selected pairs of the conductors.
  • the insert or spacing maximizes the separation of the selected pairs and arranges them in plural planes before being realigned upstream into a common plane for bonding and terminating at the conductor terminating end.
  • a first embodiment includes grooves in the upper and lower surfaces of the insert, while a second embodiment is directed to a spacing rod like member, such as may be made of an elastomer, plastic, or plastic-like tube.
  • FIGURE 1 is an exploded perspective view of an electrical connector, such as a modular plug, for example, in which the procedure of the present invention has been practiced, further illustrating the use of a performance enhancing load bar insert.
  • FIGURES 2 to 4 are transverse sectional views illustrating the sequence for bonding discrete wires to form a uniform ribbon cable according to this invention.
  • FIGURES 5 and 6 are lateral sectional views corresponding to the sequences illustrated in Figures 2 and 3, respectively.
  • FIGURE 7 is a lateral sectional view of the assembled modular plug illustrated in Figure 1.
  • FIGURE 8 is a sectional view taken through line 8-8 of Figure 7.
  • FIGURE 9 is a perspective view of the load bar insert of Figure 1, illustrating a pre-loading condition thereof, with the discrete conductors poised for lacing therein.
  • FIGURE 10 is a sectional view of a prior art cable, taken along line 10-10 of Figure 1, showing plural conductors prior to a planar arrangement thereof for entry into the load bar insert of Figure 9.
  • FIGURE 11 is a sectional view of a preferred load bar insert of this invention, taken along line 11-11 of Figure 1.
  • FIGURE 12 is a sectional view, taken along line 12- 12 of Figure 1, showing the realigned conductors in a planar relationship for entry into a modular plug, for example, prior to termination therein.
  • FIGURE 13 is a perspective view of a second embodiment for a load bar insert, where such load bar insert is optionally removable.
  • FIGURE 14 is a perspective view similar to Figure
  • FIGURE 15 is an enlarged, longitudinal sectional view, similar to Figure 7, showing in phantom lines the position of the load bar of Figures 13 and 14.
  • This invention relates to a procedure for bonding plural, discrete, insulated wires to form a unitary ribbon cable, and to the product thereof. More particularly, the invention is directed to a cost effective method for manual factory wiring of a modular plug, for example, and to the optional use of a load bar insert to enhance performance of the modular plug.
  • FIG. 1 illustrates a prime example of how the method of this invention can simplify the loading and termination of a modular plug.
  • a typical electrical connector 10 as shown in Figure 1, comprises an insulating housing 12 formed with an open end 14 for receiving a multi-wire electrical cable 16, a terminating end 18 communicating with a row of cable wire receiving passageways. The passageways further communicate with an internal cavity 20 opening into end
  • the multi-wire electrical cable 16 is characterized as twisted pair cable, where preferably selected pairs of wires are twisted together. That is, a typical cable for an 8- position modular plug will reveal four twisted pairs of insulated wires.
  • a preferred pairing arrangement of conductors or wires for the modular plug terminal numbers is as follows: 1-2, 3-6, 4-5, and 7-8.
  • this invention has utility in the loading of fine wires to electrical connectors, with or without the assistance of a loading bar insert or wire organizer, as hereinafter explained. Nevertheless, the preferred approach lies in the use of this invention with a loading bar insert 22, and illustrated in Figure 1 and later Figures.
  • pairs 3-6 and 7-8 are seated within upper slots 34, while the remaining two pairs are seated within lower slots 36.
  • the upper slot containing pair 3-6 includes an end divider 40, to separate and align the wires into their numerically assigned position for termination.
  • the opposite surface 52 includes means 54 for supplying electric current to the heating elements 48 to effect heating thereof.
  • the heating elements 48 are positioned to lie between adjacent side-by-side wires, and to the outside thereof, see Figure 3. In the illustrations of Figures 2 to 4, if the number of wires is "n”, the number of heating elements is "n + 1". With the respective fixtures positioned in a compressive relationship to the discrete wires, note the direction arrows of Figure 3, electrical current may be applied to the heating elements 48 by means 54 to effect melting and bonding of the insulated wires into a unitary ribbon cable at the end thereof.
  • the respective fixtures 44 are brought together to trap and locate the discrete wires exactly on the preferred 0.040" centerlines, where the heating elements 48, such as nichrome heating wires, are also spaced on 0.040" distances.
  • the heating elements act as miniature "V" blocks.
  • Figures 7 and 8 illustrate an inserted and preterminated unitary member in a modular plug, where the bonded wires are positioned under the plural terminating blades 23.
  • the passageways 32 into which the bonded wires are received are typically a series of circular communicating sections, where the upper and lower surfaces are scalloped 60, and the sections are separated by two spaced apart opposing ribs 62.
  • stubbing can occur.
  • the present invention where the bonded web between adjacent wires has been modified by the newly impressed profile 55, stubbing problems are greatly minimized.
  • a fixture was prepared using a printed circuit board with nine SST wire loops arranged on .040" centerlines, the same spacing as the insulated wires, in parallel fashion.
  • a current of 7 to 10 amps at from 5 to 2 seconds was applied to the SST wire loops to effecting bonding of the insulated wires.
  • the bonded wires were readily inserted into a modular plug. Alternate procedures are available to effect bonding of the wire ends. For example, while the wires are positioned in side-by-side fashion in a suitable fixture, an adhesive or tape may be applied to such ends to present a unitary ribbon cable at least at the end thereof.
  • the load bar insert in its several embodiments, as illustrated in Figures 1,7,9 and 11-15, it should again be noted that this is an optional feature to the wire bonding noted above. However, before continuing with a description of this optional feature, some brief background may be helpful.
  • the multi-wire electrical cable 16, shown in section in Figure 10 is characterized as twisted pair cable, where preferably selected pairs of wires 38 are twisted together. That is, a typical cable for an 8-position modular plug will reveal four twisted pairs of insulated wires.
  • a preferred pairing arrangement of conductors or wires for the modular plug terminal numbers are as follows: 1-2, 3-6, 4-5, and 7-8. This will be discussed in more detail hereinafter.
  • Figure 9 illustrates a first embodiment of a load bar insert 22, adapted to be slidable received through opening 14 within the housing 10.
  • This preferred insert formed from a dielectric material, was described above. Note by providing for the upper and lower slots, separation of the wires is maximized within the housing 10. Further, by providing for the forward or diverging surface 30, the respective wire pairs along the upper surface 24 are in multiple planes before returning to a single plane, as shown in Figure 12. These factors contribute significantly to the improved performance of the plug, since crosstalk is reduced by increasing the wire separation distance.
  • a second embodiment for a load bar insert 64 is illustrated in Figures 13 to 15, with the primary purpose of the insert being to space-apart the wires into multiple planes prior to realignment for purposes of termination, this new insert satisfies well such purpose.
  • the insert 64 comprises a spacing member, which may be an elastomer, styrofoa , or plastic cylinder, where the selected pairs of wires are placed either over the top or under the bottom.
  • the critical pair 3-6 is along the top while the remaining pairs are below the insert.
  • the wire divergence pattern is varied. Howev. , a common feature thereof is the provision that the critical pairs 3-6 and 4-5 are separated.

Landscapes

  • Multi-Conductor Connections (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)
  • Details Of Connecting Devices For Male And Female Coupling (AREA)
  • Connector Housings Or Holding Contact Members (AREA)
  • Connections By Means Of Piercing Elements, Nuts, Or Screws (AREA)
  • Communication Cables (AREA)
  • Insulated Conductors (AREA)

Abstract

Procédé et support permettant d'aligner et de souder une pluralité de conducteurs distincts sous gaine isolante afin d'en faciliter la manipulation et l'insertion dans un boîtier de connecteur électrique où ils seront raccordés électriquement. Ce procédé consiste à sélectionner plusieurs conducteurs distincts sous gaine isolante disposés dans au moins deux plans différents, à disposer et aligner les extrémités des conducteurs de manière juxtaposée dans un plan commun sur un support, et à souder les gaines isolantes des extrémités de fils adjacentes pour former un câble ruban monobloc qui facilite la manipulation et le raccordement. Un processus de soudage préféré consiste à appliquer une chaleur localisée aux extrémités des fils pour faire fondre et souder les gaines isolantes. Un pièce rapportée en forme de barre de charge améliorant les performances peut éventuellement être incorporée entre les conducteurs en aval des extrémités des fils, ce qui permet de séparer les conducteurs et de réduire la diaphonie.
EP95932408A 1994-10-31 1995-09-08 Connecteur électrique du type fiche Expired - Lifetime EP0789939B1 (fr)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US08/332,218 US5571035A (en) 1994-10-31 1994-10-31 Divergent load bar
US334172 1994-10-31
US332218 1994-10-31
US08/334,172 US5592739A (en) 1994-10-31 1994-10-31 Bonding discrete wires to form unitary ribbon cable
PCT/US1995/011270 WO1996013878A1 (fr) 1994-10-31 1995-09-08 Soudage de fils distincts pour former un cable ruban monobloc destine a un connecteur performant

Publications (2)

Publication Number Publication Date
EP0789939A1 true EP0789939A1 (fr) 1997-08-20
EP0789939B1 EP0789939B1 (fr) 1999-06-23

Family

ID=26988113

Family Applications (1)

Application Number Title Priority Date Filing Date
EP95932408A Expired - Lifetime EP0789939B1 (fr) 1994-10-31 1995-09-08 Connecteur électrique du type fiche

Country Status (8)

Country Link
EP (1) EP0789939B1 (fr)
JP (1) JP4070805B2 (fr)
KR (1) KR970707607A (fr)
CN (2) CN1161864C (fr)
AU (1) AU688593B2 (fr)
DE (1) DE69510464T2 (fr)
ES (1) ES2135088T3 (fr)
WO (1) WO1996013878A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BG64720B1 (bg) * 1999-12-10 2005-12-30 Krone Gmbh Съединителен кабел с електрическо щепселно съединение

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WO1999017406A1 (fr) * 1997-09-26 1999-04-08 The Whitaker Corporation Fiche modulaire comportant une barre de charge pour la reduction de la diaphonie
US5967801A (en) * 1997-11-26 1999-10-19 The Whitaker Corporation Modular plug having compensating insert
US6080007A (en) * 1998-11-30 2000-06-27 Hubbell Incorporated Communication connector with wire holding sled
AU2564300A (en) * 1999-02-19 2000-09-04 Richard Weatherley Plug assembly for data transmission and method of wiring same
US6447326B1 (en) 2000-08-09 2002-09-10 Panduit Corp. Patch cord connector
EP1171933B1 (fr) * 1999-08-10 2007-12-12 Panduit Corp. Connecteur a cordon de connexion
JP2004342563A (ja) * 2003-05-19 2004-12-02 Nec Corp モジュラプラグ
JP2006351424A (ja) * 2005-06-17 2006-12-28 Swcc Showa Device Technology Co Ltd 差動信号伝送ケーブル
DE102010055851A1 (de) * 2010-12-22 2012-06-28 Harting Electronics Gmbh & Co. Kg Steckverbinder für hohe Datenübertragungsraten
CN103794272B (zh) * 2013-12-17 2016-10-05 国家电网公司 图数模一体化的电网数据管理平台专用线缆
JP6330587B2 (ja) * 2014-09-04 2018-05-30 株式会社オートネットワーク技術研究所 通信用コネクタ
JP6332087B2 (ja) * 2014-09-04 2018-05-30 株式会社オートネットワーク技術研究所 通信用コネクタ
CN105449419B (zh) * 2015-10-21 2018-02-06 贵州航天凯山石油仪器有限公司 一种验封短节与测调短节的连接方法及结构
JP6524372B1 (ja) * 2018-08-27 2019-06-05 三菱電機株式会社 ケーブル用コネクタ

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FR2266430A1 (en) * 1974-03-29 1975-10-24 Rists Wires & Cables Ltd Make-up jig for automobile cable harness - has weld current paths between electrode contact points
FR2523774A1 (fr) * 1982-03-17 1983-09-23 Thomas & Betts Corp Dispositif d'interconnexion telephonique
CA1281090C (fr) * 1985-11-18 1991-03-05 Albert Ray Cox Cable plat a connexion a la masse
GB8606654D0 (en) * 1986-03-18 1986-04-23 Molex Inc Multiconductor connector
DE3826741C1 (fr) * 1987-11-12 1990-02-22 Nixdorf Computer Ag, 4790 Paderborn, De
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BG64720B1 (bg) * 1999-12-10 2005-12-30 Krone Gmbh Съединителен кабел с електрическо щепселно съединение

Also Published As

Publication number Publication date
JPH10508146A (ja) 1998-08-04
WO1996013878A1 (fr) 1996-05-09
EP0789939B1 (fr) 1999-06-23
AU688593B2 (en) 1998-03-12
AU3546195A (en) 1996-05-23
DE69510464D1 (de) 1999-07-29
CN1171172A (zh) 1998-01-21
JP4070805B2 (ja) 2008-04-02
DE69510464T2 (de) 2000-02-24
CN1312601A (zh) 2001-09-12
CN1161864C (zh) 2004-08-11
ES2135088T3 (es) 1999-10-16
CN1076891C (zh) 2001-12-26
KR970707607A (ko) 1997-12-01

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