GB2342790A

GB2342790A - IDC Connector

Info

Publication number: GB2342790A
Application number: GB9917435A
Authority: GB
Inventors: Bofill Pedro Duran; Esclarin Raul Sanz
Original assignee: Whitaker LLC
Current assignee: Whitaker LLC
Priority date: 1998-07-24
Filing date: 1999-07-23
Publication date: 2000-04-19
Anticipated expiration: 2019-07-23
Also published as: GB9917435D0; GB2342790B

Abstract

A splicing connector (2) comprises a housing (4) having a first housing portion (12) with a wire receiving cavity (28) and a second housing portion (14) with an IDC terminal (6') mounted on the second housing portion (14). The first and second housing portions are interconnected by a deformable web (16') such that the first housing portion with the IDC blade (6') can be depressed and terminated to a wire received in the cavity (28). A cover (9') may be provided in the housing portion (12). The housing portion (12) may have grooves to guide the IDC terminal (6'). The web (16') may fold during movement of the IDC into contact with a wire.

Description

SPLICING CONNECTOR This invention relates to a splicing connector, in particular for splicing electrical wires.

A common type of splicing connector comprises an insulative housing with insulation displacement contact (IDC) terminals mounted in the housing, and a separate cover or hingeably attached cover that is used to close the housing and stuff insulated contacting wires into IDC slots of the terminals. Pairs of wire ends are typically received in respective cavities of the connector housing, or in cavities of the cover, and are \ stuffed into the IDC slots of the IDC terminals when the cover is clipped or latched to the housing by pressing the cover and housing together, for example by hand or with a tool. A particularly rapid and easy splicing connection between wires can thus be effected. Such connectors may also be used for purposes other than splicing, for example to connect wires to electrical or electronic equipment for example on which the connector housing is mounted. The IDC terminals may also interconnected to pluggable contacts for connection to a complementary connector. Splicing connectors of the type described above are widely used in the telecommunication industry for splicing telephone or data transmission wires. Examples of such splicing connectors are described in US 5,120,246 and US 5,071,365.

A further example of a splicing or tapping connector with IDC blades is shown in US 3,899,236.

Although the plastic housing is moulded from one part, the hingeable halves need to latch together to close, each half requiring fairly complicated mould die forms.

The interface between the housing halves is difficult to seal effectively, and the complicated form requires precise and expensive moulding dies. The latch is also exposed and may be damaged during handling which could lead to failure of the electrical connection if the connector halves unlatch during use/operation.

There is a continuous demand to reduce the cost of splicing connectors, in addition to improving the ease of use. It would be desirable in certain applications to improve the sealing of the connection area between wires and IDC contacts, to improve the reliability of the connector in environments where moisture or other agents that couad effect the electrical connection, are present. tt would be desirable to improve the robustness and compactness of splicing connectors.

It is an object of this invention to provide an improved IDC connector, in particular for splicing wires, that is cost-effective and well sealed. It would be further advantageous if the connector is compact and robust.

Objects of this invention have been achieved by providing the IDC connector according to claim 1.

Disclosed herein is an IDC connector comprise a housing and an IDC terminal adapted to displace the insulation layer of an electrical wire and contact the inner conducting strands thereof, the housing comprising a wire receiving cavity extending in the housing in a longitudinal direction, the IDC terminal positionable in the housing in a pre-assembly position where the wire can be inserted into the wire receiving cavity, and movable in a direction transverse to the longitudinal direction from the pre-assembly position to a terminated position where electrical contact between the IDC terminal and wire is effected, wherein the IDC terminal is attached to a second portion of the housing that is movable with respect a second portion of the housing comprising the wire receiving cavity, wherein the first and second housing portions are integrally interconnected by a deformable web surrounding the interface between the first and second housing portions.

Advantageously therefore, the relatively movable housing portions are integrally formed to provide a particularly cost-effective connector to manufacture, and that enables a well sealed connection area to be provided in the event a sealed connector is desired. A further avantage is the reduced handling cost and greater reliability as the connector can be produced as a single inseperable component that is compact and robust compared to connectors with separate or hinged wire receiving housings and stuffer covers. Splice connection to wire conductors is quick and easy to perform.

The IDC terminal is received in a chamber that traverses the wire receiving cavity from the second housing portion to an open end that may be covered by a cover part that is latched or bonded to the first housing portion such that the IDC receiving cavity is securely closed and sealed if required. The cover part can be manufactured by moulding or alternatively by extrusion and subsequently cut to the desired shape for covering the opening. Retention barbs or protrusions may be provided on the IDC terminals for engaging the cover in the terminated position such that the cover is securely retained to the housing.

For a sealed connector, the deformable web is provided around the whole periphery of the first housing portion and extending to a periphery of the second housing portion surrounding the IDC terminal receiving cavity of the housing. If sealing is not required, the web for example may surround the interface between the housings intermittently. The web may be in the form of a thin wall that folds into the IDC terminal receiving cavity of the housing as the first housing portion is moved from the pre-assembly to the terminated position.

The IDC terminal may be provided in the form of a substantially planar IDC blade edge-stamped from sheet metal and comprising an IDC slot for receiving the conducting core of the wire therein. A plurality of IDC blades may be provided integrally stamped from the same piece of, sheet metal for electrical interconnection between a respective plurality of wires inserted in the respective cavities of the connector housing. The invention however could comprise many different IDC terminals which may for example comprise pointed tips that pierce through the wire insulation into the conducting core of the wire, and the terminals may have contact sections for plugging with a complementary connector, and only a single or plurality of terminals may be provided that are not electrically interconnected for applications that are not splicing. In other words, the invention may be implemented in a variety of different connector designs for a variety of different applications that are not related to the splicing of wires, whilst benefiting from the advantages described above.

Embodiments of this invention will now be described by way of example with reference to the accompanying drawings, in which: figures 1 and 2 are perspective views in crosssection of a first embodiment of a connector according to this invention; figures 3 and 4 are perspective views of a housing of the first embodiment; figure 5 is a perspective view of a cover of the first connector embodiment ; figure 6 is a perspective view of an IDC terminal of the first embodiment ; figure 7 is a perspective view of a second connector embodiment according to this invention; figures 8 and 9 are cross-sectional perspective views of the second embodiment in the pre-terminated and terminated positions respectively; figure 10 is a perspective view of a housing of the second embodiment; figures 11 and 12 are views of the cover part of the second embodiment, in the completely manufactured and partially manufactured states respectively ; figure 13 is a perspective view of an IDC terminal of the second embodiment according to this invention.

Referring to the figures, an IDC connector 2,2' comprises an insulative housing 4 that may for example be moulded from a plastic or elastomeric material, an IDC terminal 6,6'and a cover 9,9'. The IDC terminal 6,6'comprises an IDC blade 8,8'that is substantially planar, formed from sheet metal, and comprising an IDC slot 10 for receiving and contacting the inner conducting core of an insulated electrical wire. In both embodiments shown, a pair of IDC blades 8,8'are stamped and formed from an integral piece of sheet metal for electrically interconnecting a pair of conducting wires. The splicing connector 2,2'may however be provided with a plurality of IDC blades adapted to interconnect a corresponding plurality of wires greater than two.

The housing 4 comprises a first housing portion 12 and a second housing portion 14 that is interconnected to the first housing portion via a web 16, 16'that is integral with the first and second housing portions. The IDC terminal 6,6'is attached to the second housing portion 14 by insertion of a mounting end 18 of the IDC terminal in an interference fit in a corresponding groove 20 extending across an inner face 22 of the second housing portion 14. The terminal 6,6'may be mounted to the housing portion 14 in many other ways, for example by overmoulding the housing over a mounting end of the terminal, or by stitching the terminal through a cavity that extends from the outer face 24 to the inner face 22 of the second housing portion 14.

Although in the present embodiments a splicing connector is shown, the terminals may comprise contact portions that project through the outer surface 24 of the second housing portion 14 for plugging connection or any other conventional connection to complementary terminals or contacts. In this regard, the second housing portion 14 may have many different shapes and sizes adapted to the desired application. In the present embodiments, the second housing portion 14 comprises an anvil 26 serving as a pressure surface for pressing the second housing portion 14 towards the first housing portion 12 during termination. The second housing portion moves in a substantially linear termination direction (T) transverse to the longitudinal direction (L) of the wires to be connected.

The first housing portion 12 comprises a wire receiving cavity 28 for each IDC blade 8, the cavity extending in the longitudinal direction (L) from a wire receiving open end 30 to an inner closed end 32, the longitudinal wire receiving cavity 28 traversing an IDC terminal receiving cavity 34 in which the IDC blades 8, 8'are received. In the second embodiment shown in figures 7 to 10, the entry of the cavity portion of the closed end 32 is provided with tapered or funnel shaped guide portion 33 to guide wires into the cavity of the closed end.

The IDC terminal receiving cavity 34 extends from the second housing portion 14 to an open end 36 of the first housing 12, the open end 36 defining an opening that permits manufacture of the cavity 34 and inner surface of the web 16,16'and second housing portion 14, for example by injection moulding of plastic. The cover 9,9'closes the opening 36 of the IDC terminal receiving cavity 34 such that the connection between the IDC blade 8 and the wire may be sealed.

In the first embodiment shown in figures 1-6, the cover 9 is moulded separately from the housing and secured thereto via latches 46 engaging with complementary latches 48 of the housing. The cover has a slot or groove 40 receiving a portion of the IDC blade 8 therein for guiding the blade during termination. The cover has U-shaped channels 43 formed along an inner surface 42 for guiding wires into the end portion 32 of the wire receiving cavities 28, and supporting the wires during termination.

In the second embodiment, the cover 9'is manufactured in a particularly cost-effective manner by extruding a profile 38 as shown in figure 12, which is then cut to the desired profile (which in this embodiment is oval) as shown in figure 11, in order to completely close the opening 36. The extruded profile 38 may comprise a groove 40'across the inner surface 42 that receives tips 44 (see figure 9) of the IDC blades 8 therein when the blades are moved from the pre-assembly position shown in figure 8 to a terminated position shown in figure-9.

The slots or groove 40,40'of the first or second embodiments respectively provide a stable retention of the blade in particular with respect to traction applied on a conducting wire terminated to the blade. The IDC blade 8,'8'may further comprise retention portions in the form of barbs 41,41'that engage in the cover groove 40,40'in an interference fit to further secure the terminal in the terminated position and additionally secure the cover 9,9'to the housing 4. A particularly secure terminated splice connection is thus provided.

The extruded profile 38 may be further provided with a latching portion, for example in the form of a protrusion 46'along side edges 47 that co-operate with complementary groove 48'of the housing to retain the cover 9 to the housing. To improve the sealing of the connection, the IDC receiving cavity 34 may be partially filled with a sealing gel or grease. As the cover is substantially planar or of low profile, it may be provided, slightly protruding, substantially flush, or recessed with respect to the lower surface 37 of the housing or edge 39 of the opening 36 such that it cannot be easily damaged or removed, thus improving the robustness and reliability of the connector. A slightly protruding or flush arrangement is preferred as the cover may then rest against a (planar) surface of a crimping tool used to terminate the connector to wires, to prevent removal thereof.

As best seen in figure 10, side walls 50 of the first housing portion 12 that bound the IDC terminal receiving cavity 34, are provided with guide grooves 52 that receive guide portions 53 at side edges of the IDC terminal 6 (see figure 13) therein for stabilising and guiding the IDC terminal when it is depressed from the pre-assembly to the terminated position. The complementary guide grooves 52 and guide portions 53 also enhances retention of the IDC terminal 6 to the housing n opposition to pulling forces on wires terminated to the IDC blades.

The deformable web 16, 16'that interconnects the first housing portion 12 to the second housing portion 14 is in the form of a thin membrane integrally moulded with the housing portions that is deformable into the cavity 34 as the second housing portion 14 is pressed towards the first housing portion 12. The second housing portion 14 has an outer periphery 54 that is smaller than the inner periphery 56 of the IDC terminal receiving cavity 34 such that the second housing portion 14 fits into the cavity 34 of the first housing portion.

Although in both embodiments the deformable web 16,16' folds into the cavity 34, the second housing portion could also extend over the outer periphery of the first housing portion and the deformable web made to fold over the outside of the first housing portion rather than inside the cavity 34. In other words, various flexible or deformable webs that interconnect the first and second housing portions could be provided to provide the substantially linear termination movement from the preassembly to the terminated position.

In the first embodiment according to figure 1, the deformable web 16 extends around the whole periphery (or interface) joining the first and second housing portions such that the interconnection between first and second housing portions is completely sealed. In applications where sealing is not required, the deformable web 16' may only extend intermittently along the interface between the first and second housing portions as shown in figure 7, where the web 16'of the second embodiment has gaps 17 at corners 19 of the periphery or interface.

The gap 17 facilitate deformation of the web.

Connqction of electrical wires to the connector 2 is thus effected by inserting the one or more wires into corresponding cavities 28 of the first housing portion 12 in the longitudinal direction, until abutment with the closed end 32, and subsequently depressing the second housing portion 14 such that the portion of wire traversing the IDC terminal receiving cavity is stuffed into the IDC slot 10 of the IDC blade 8 such that electrical contact between the blade and inner conducting core of the wire is made. The deformable web 16,16'is folded into the cavity 34 during movement of the first housing portion from the pre-assembly position shown in figures 1 and 8 to the terminated position shown in figure 9.

The deformable web joining the first and second housing portions, the secure reception of the wires in cavities of the first housing portion, and linear movement of an IDC blade from a pre-assembly to a fully terminated position all contribute to provide a particularly reliable, robust, compact and secure termination in a cost-effective manner. In particular, the connector is simple to manufacture and may be provided as a single insertable part that is not easily terminated or disconnected or opened by accident, and that may be well sealed if desired.

Claims

CLAIMS 1. An IDC connector (2,2') comprises a housing (4) and an IDC terminal (6,6') adapted to displace the insulation layer of an electrical wire and contact the inner conducting core thereof, the housing comprising a wire receiving cavity (28) extending in the housing in a longitudinal direction (L), the IDC terminal (6,6') positioned in an IDC receiving cavity (34) of the housing traversing the wire receiving cavities, the IDC terminal movable from a pre-assembly position where the wire can be inserted into the wire receiving cavity (28), to-d terminated position where electrical contact between the IDC terminal and wire is effected, the movement in a direction transverse (T) to the longitudinal direction (L), wherein the IDC terminal (6, 6') is attached to a second portion (14) of the housing that is movable with respect a first portion (12) of the housing comprising the wire receiving cavity (28), and wherein the first and second housing portions (12,14) are integrally interconnected by a deformable web (16, 16') surrounding the interface or periphery between the first and second housing portions and that enables the relative movement of the housing portions in the transverse direction (T).
2. The connector of claim 1 wherein the deformable web (16) extends around the whole periphery (54) of the interconnection between the first and second housing portions (12, 14).
3. The connector of claim 1 wherein the deformable web (16') extends intermittently around periphery (54) of the interconnection between the first and second housing portions (12,14).
4. The connector of claim 1,2 or 3 wherein the connector (2) further comprises a cover (9, 9') positioned over an opening (36) of the first housing portion (12) resulting from forming of the IDC terminal receiving cavity (34).
5. The connector of claim 4 wherein the cover (9') is made from an extruded profile (38).

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6. The connector of claim 4 or 5 wherein the cover comprises a groove (40) for receiving portions of the IDC terminals therein in the terminated position.
7. The connector of claim 4,5 or 6 wherein the cover (8) is arranged approximately flush with respect to an outer edge (39) of the opening (36) to prevent damage or accidental removal thereof.
8. The connector of any one of the preceding claims wherein the first housing portion (12), second housing portion (14), and deformable web (16,16') are integrally injection moulded from a plastic or elastomeric material, the first and second housing portions forming substantially solid indeformable parts relative to the deformable web.
9. The connector of any one of the preceding claims wherein side walls (50) of the IDC terminal receiving cavities (34) are provided with guide grooves (52) extending in the transverse direction (T) for guiding the IDC terminals during depression from the preassembly to the terminated position.
10. The connector of any one of the preceding claims wherein the second housing portion (14) is joined at an outer periphery (54) to the deformable web (16,16'), the outer periphery (54) being smaller than an inner periphery (56) of the IDC terminal receiving cavity (34) such that the deformable web is foldable into the IDC terminal receiving cavity (34) during termination.
11. A connector constructed and arranged substantially as hereinbefore described with reference to the accompanying drawings.