GB2409353A

GB2409353A - A re-useable insulation piercing connector

Info

Publication number: GB2409353A
Application number: GB0330080A
Authority: GB
Inventors: David Watters; Gary Cook; Ian Goulding; Keith Winter; Nick Lewis; Patrick Farmer
Original assignee: Deutsch Ltd
Current assignee: Deutsch Ltd
Priority date: 2003-12-20
Filing date: 2003-12-20
Publication date: 2005-06-22
Also published as: WO2005062429A1; GB0330080D0

Abstract

A cable connector for a cable, the cable including a wire having a conductor and an insulation layer, the cable connector comprising a contacting means for electrically contacting the conductor, which contacting means, in use, perforates the insulation layer in a direction substantially non-parallel to an axis of the wire. Specific embodiments include the use of cable receptacle 214 having wire positioning portions 230 for arranging the individual wires so that spikes 22 perforate the insulating sleeve of the wires and form an electrical bridge between the cables.

Description

A CABLE CONNECTOR

The present invention relates to a cable connector, and particularly, but not exclusively to a robust, reusable cable connector intended for use in harsh environments.

Typically, boats and other sea-going vessels carry a range of electrical and electronic equipment including for example a radio, a GPS (Global Positioning System) device and such devices as fish-finders. The equipment lo always requires connection to a power source and different parts of the equipment often are interconnected. In fact, new regulation has enforced the interconnection of the equipment, in particular of the radio and the GPS device.

Those responsible for the equipment are often reluctant to leave the same unattended aboard a docked vessel for fear of it being stolen, and in other situations desire to replace or to repair the equipment. This entails the frequent disconnection and reconnection of parts of the said equipment from other equipment and from the power source.

The various parts of the equipment generally require different forms of connection, and consequently there is a range of sizes of wire requiring interconnection.

Thus there is demand for a reusable waterproof cable connector which allows the rapid and easy connection and disconnection of a variety of cables.

French Patent Application number FR 2 766 018 discloses a cable so connector which includes a cable receptacle securable to a main connector part. When the cable connector is assembled, the insulation of each wire held in the cable receptacle is sliced on either side of the conductor by a bifurcate contact element, in order to make an electrical connection with the conductor beneath the insulation. Each contact element differs in length, so that each contacts a wire at different moments during the making of a connection, thereby reducing the requisite force. The gap between the two prongs of each contact element is suitably dimensioned for the particular wire diameter which the cable connector is designed to be used with.

lo The insulation of a wire contacted by a bifurcate contact element isdamaged upon even first use of the connector, rendering the same unsuitable for applications which require the frequent and often reuse of a connector.

A significant part of the conductor is left exposed by the making of a connection, leaving the same exposed to the elements and susceptible to damage by the manipulation of the connector.

The conductor beneath the insulation is also severely damaged when a connection is made by the bifurcate contact elements, such that after frequent reuse of the connector, the cable needs to be reduced in length in order for the contact elements to contact an undamaged piece of wire.

As the contact elements need to be staggered in length, the cable connector is necessarily large.

When a wire passes between the prongs of a contact element during the making of a connection, sufficient frictional forces may be generated for welding to occur between the contact element and the conductor of the wire, rendering easy disconnection impossible.

Furthermore, the range of diameters of wire which the connector can accommodate is limited by the gap between the prongs of the contact elements.

According to the present invention, there is provided a cable connector for a cable, the cable including a wire having a conductor and an insulation layer, the cable connector comprising a contacting means for electrically contacting the conductor, which contacting means, in use, perforates the insulation layer in a direction substantially non-parallel to an axis of the i o wire.

The contacting means perforates the insulation rather than slicing it as in the prior art. Thus the cable connector of the invention may be reused frequently with only negligible damage to the insulation or conductor of a wire. In addition, the conductor is not left exposed by the making of a connection, and the cable connector does not require the application of significant force in order for a connection to be made.

The contacting means is small compared to the diameter of the wire, in to contrast to the prior art connectors; the cable connector can thus be small compared thereto. Also, there is no welding effect as may occur with the

prior art connectors.

The diameter of the wire is largely irrelevant to the connection, provided the Is length of the contacting means is greater than the thickness of the insulation of the wire. Thus, use of the cable connector with a variety of cables and wire sizes is possible.

As the contacting means contacts a wire in a direction substantially nonparallel to an axis of the wire, perforating its insulation, the length of the wire is not critical to the function of the cable connector.

The cable connector of the present invention may include any one or more of the following preferred features: The contacting means may be a spike. The cross-sectional width of the spike is less than that of the wire.

A spike which is substantially conical in shape allows wires within a range of diameters to be contacted, while causing negligible damage to the insulation and conductor of a wire. Such a spike is simple to manufacture.

Other shapes of contacting means are equally suitable, for example a hollow cylindrical contacting means or a pyramidal contacting means.

Preferably, the size of the perforation formed by the contacting means is less than half of the diameter of the wire.

If the contacting means comprises a spike of substantially uniform diameter, the diameter of the spike is preferably less than half of the diameter of the wire. When the spike is conical, preferably the maximum diameter of the portion of the spike making contact with the insulation of the wire is less than half of the diameter of the wire.

The cable connector may comprise a cable receptacle including a wirepositioning portion, which wire-positioning portion positions the wire within the cable receptacle.

The wire-positioning portion ensures that a wire is accurately positioned in relation to a respective contacting means.

The wire-positioning portion may include a channel defined by two non parallel and intersecting sides, such that the channel is capable of supporting wires having diameters within a predetermined range.

A wire will rest at the lateral centre of such a channel regardless of the diameter of the wire, within reason. Thus the wire-positioning portion can lo accommodate a range of wire sizes while always positioning a wire accurately in relation to a respective contacting means.

Furthermore, a wire having a large diameter as compared to the lateral width of the channel rests therein with its axis further from the intersection of the two sides than that of a wire having a small diameter as so compared.

Where the contacting means is a conical spike, the diameter of the spike at a point where the same perforates the insulation of a wire is greater with the larger diameter wire than with the smaller diameter wire. Thus, in an embodiment of the invention comprising a conical spike in conjunction with the channel as above-described, the size of the perforation in the insulation of a wire is in proportion to the diameter of the wire.

The cable receptacle may include a wire-collecting portion, for collecting a part of a wire between a point where the contacting means contacts the wire and an end of the wire.

Excess wire not forming part of a circuit is collected in the wirecollecting portion. Thus the length to which the wire is cut is not critical to the function of the cable connector. A wire must, however, be cut to an so approximate length during assembly.

The wire-positioning portion may include a wire-restraining means for restraining a wire in position in the wire-positioning means.

The wire-positioning portion of the cable receptacle may be formed of a resiliently deformable material. A base of the cable receptacle may be formed of a rigid material, in order to transmit force applied onto the base, when assembling the cable connector, onto a wire held in the wirepositioning portion, thereby urging the same against the contacting means.

The resilience of the wire-positioning portion may itself constitute the wire- restraining means, where the wire is restrained by a narrowed part of a wire- positioning portion. In addition, the resilience of the wire-positioning portion may aid in sealing the cable connector against the ingress of moisture.

The cable connector may comprise a main connector part which houses the contacting means and to which the cable receptacle is securable.

so In one embodiment, the cable connector includes two main connector parts, which are connected together when the cable connector is assembled. Each main connector part houses a contacting means and a cable receptacle is securable to each.

In this case, the main connector part may include an electrical connector connected to the contacting means, which electrical connector, when the main connector part is connected to a second main connector part, electrically contacts a corresponding electrical connector of the second main connector part. The cable connector may include means for aligning the so main connector part with the second main connector part so that the electrical connector is aligned with the corresponding electrical connector of the second main connector part.

Alternatively, a single contacting means may constitute the contacting means of both main connector parts by extending wholly through each. The contacting means itself thus constitutes the aligning means. In this case, the contacting means may be fixedly attached to one main connector part or to the other, or may be a separate element attachable to both main connector parts.

In another embodiment, the cable connector includes only a single main connector part to which two cable receptacles are securable.

One cable receptacle may be securable to a first region of the main connector part, which first region includes the contacting means; the main connector part may comprise a further region to which a further cable receptacle is securable and which includes a further contacting means; the further contacting means being electrically connected to the contacting means.

In this way, a single main connector part is used to connect two cables together. The contacting means may again extend wholly through the single main connector part, thereby constituting the contacting means on either side thereof.

The cable receptacle may be securable to the main connector part in a predetermined configuration, such that, in use, the contacting means perforates the insulation layer in a direction substantially coincident with and parallel to a diametric plane of the wire.

Having a predetermined configuration means that the cable connector may be assembled without care as to whether each contacting means is correctly located relative to a respective wire.

s By ensuring that the contacting means perforates the insulation layer in a direction substantially coincident with and parallel to a diametric plane of the wire, a good connection is ensured as the contacting means is always directed towards an axis of the wire.

lo The cable connector may comprise aligning means for so aligning the cable receptacle and the main connector part.

The aligning means may comprise a slot and a key, one of which is included by the cable receptacle and the other by the main connector part.

Alternative forms of aligning means are possible, for example a cable receptacle having a rectangular or other-shaped cross section. The aligning means may also permit of more than one predetermined configuration of the cable receptacle.

A major lateral dimension of the contacting means may be small compared to the width of the channel. Thus the size of the perforation created by the contacting means is small compared to a diameter of a wire held in the channel. 2s

According to the present invention, there is also provided a cable connector including a cable receptacle having a plurality of wirepositioning portions for positioning wires a of a cable, and a main connector part having a plurality of contacting means for electrically contacting wires positioned by so the wire-positioning portion, the cable connector comprising aligning means for aligning the cable receptacle with the main connector part in a predetermined configuration such that each of the contacting means is aligned with a respective wire- positioning portion, and such that in use, the contacting means perforates the insulation layer in a direction substantially coincident with and parallel to a diametric plane of the wire.

The cable connector may include any one or more of the following preferred features: o The aligning means may comprise a slot and a key, one of which is included by the cable receptacle and the other by the main connector part.

Each contacting means, in use, may perforate an insulation layer in a direction substantially non-parallel to an axis of the wire.

Each contacting means may be a spike.

Each wire-positioning portion may include a channel defined by two nonparallel and intersecting sides, such that each channel is capable of supporting wires having diameters within a predetermined range.

The cable receptacle may include a plurality of wire-collecting portions, each for collecting a part of a wire between a point where a respective contacting means contacts a wire and an end of the wire.

Each wire-positioning portion may include a restraining means for restraining a wire in position in the wire-positioning means.

The wire-positioning portion of the cable receptacle may be formed of a so resiliently deformable material. A base of the cable receptacle may be formed of a rigid material, in order to transmit force applied onto the base, when assembling the cable connector, onto a wire held in the wirepositioning portion, thereby urging the same against the contacting means.

The cable receptacle may be securable to a first region of the main connector part, which first region includes the contacting means; the main connector part may comprise a further region to which a further cable receptacle is securable and which includes a further contacting means; the lo further contacting means being electrically connected to the contacting means.

According to the present invention, there is also provided a method of connecting cables comprising the step (D) of perforating an insulation layer Is of a wire of a cable with a contacting means, thereby electrically contacting a conductor of the wire, wherein the contacting means perforates the insulation layer on one side of the wire only and in a direction substantially non-parallel to an axis of the wire.

so The method may include any one or more of the following preferred features: The method may comprise the step (A) of, before step D, using a wire- positioning portion to position the wire in relation to the contacting means as such that the contacting means perforates the insulation layer in a direction substantially coincident with and parallel to a diametric plane of the wire.

The method may comprise the step (B) of, after step A and before step D, aligning a cable receptacle with a main connector part using aligning means, wherein the cable receptacle includes the wire-positioning portion and the main connector part houses the contacting means.

The method may comprise the step (C) of, after step B and before step D, s securing the cable receptacle to the main connector part in a predetermined configuration.

According to the present invention, there is also provided a method of manufacturing a cable connector, for a cable including a wire having a lo conductor and an insulation layer, the method comprising the step of producing a contacting means for electrically contacting the conductor, which contacting means, in use, perforates the insulation layer in a direction substantially non-parallel to an axis of the wire.

The method may include any one or more of the following preferred features: The contacting means may be so produced as to be a spike.

to The method may comprise the step of producing a cable receptacle including a wire-positioning portion, which wire-positioning portion positions the wire within the cable receptacle.

The method may comprise the step of producing the wire-positioning portion to include a channel defined by two non-parallel and intersecting sides, such that the channel is capable of supporting wires having diameters within a predetermined range.

The method may comprise the step of producing the cable receptacle to include a wire-collecting portion, for collecting a part of a wire between a point where the contacting means contacts the wire and an end of the wire.

s The method may comprise the step of producing the wire-positioning portion to include a restraining means for restraining a wire in position in the wire-positioning means.

The method may comprise the step of producing a main connector part lo which houses the contacting means and to which the cable receptacle is securable, the contacting means being electrically connected to an electrical connector presented by the main connector part.

The method may comprise the steps of producing the cable receptacle to be securable to a first region of the main connector part, which first region includes the contacting means; producing the main connector part to comprise a further region to which a further cable receptacle is securable and which includes a further contacting means; producing the further contacting means to be electrically connected to the contacting means.

The method may comprise the step of producing the cable receptacle to be securable to the main connector part in a predetermined configuration such that, in use, the contacting means perforates the insulation layer in a direction substantially coincident with and parallel to a diametric plane of the wire.

The method may comprise the step of producing aligning means for so aligning the cable receptacle and the main connector part.

The method may comprise the step of producing the aligning means to comprise a slot and a key, one of which is included by the cable receptacle and the other by the main connector part.

The method may comprise the step of producing the contacting means so that a major lateral dimension thereof is small compared to the width of the channel.

In order that the present invention may more readily be understood, a lo description is now given, by way of example only, reference being made to the accompanying drawings, in which: Figure 1 is an exploded perspective view of a preferred embodiment of the present invention; Figure 2 is a cross-sectional view through an axis 2-2 of the embodiment of Figure 1; Figure 3 is an exploded perspective view of a second embodiment of the present invention; Figure 4 is an exploded perspective view of a third embodiment of the present invention; so Figure 5 is an exploded perspective view of a fourth embodiment of the present invention; Figure 6 is an exploded perspective view of a fifth embodiment of the present invention.

Cable connector 10 as shown in Figures 1 and 2 generally includes two sides 100, 102, each of which comprises a main connector part 12, a cable receptacle 14 and an end nut 16.

The first side 100 will now be described in detail.

A cylindrical axial bore 18 extends partway through the main connector part 12. The bore 18 terminates with a flat distal face 20, on which is disposed a plurality of conductive contacting means 22, each consisting of a substantially conical spike. The plurality of contacting means 22 is disposed in a circular arrangement on the distal face 20, each contacting means 22 extending outwardly therefrom in a direction parallel with an axis 2 of the main connector part 12. Each contacting means 22 electrically contacts a wire of a cable when the cable connector 10 is fully assembled. However, if there are fewer wires than contacting means 22, one or more contacting lo means 22 will be unused.

Each contacting means 22 is in electrical contact with a corresponding contacting means 22 in the second side 102 of the cable connector 10, which corresponding contacting means 22 is in this embodiment integral with the first contacting means 22.

As shown particularly in Figure 2, the cable connector 10 includes two main connector parts 12, which are attachable together. The main connector part 12 of the first side 100 abuts against a main connector part 12 of the second side 102. In this embodiment, each contacting means 22 extends wholly through each main connector part 12, such that each contacting means 22 may contact wires on either side 100, 102 of the cable connector 10. The contacting means 22 thus aligns the two main connector parts 12 with one another.

:5 The cable receptacle 14 is so dimensioned as to fit closely inside the bore 18 of the main connector part 12. A part of the cable receptacle 14 is made of a resilient material, for example rubber, such that a close fit with the bore 18 seals the same against the ingress of moisture. A base 66 of the cable receptacle 14 may be formed of a rigid material, in order to transmit force so applied onto the base 66, when assembling the cable connector 10, onto a wire held in the wire-positioning portion 30, thereby urging the same against the contacting means 22.

The cable receptacle 14 includes a lateral face 28, which lateral face 28 lies adjacent the distal face 20 of the bore 18 when the cable receptacle 14 is inserted fully into the same. The lateral face 28 includes a number of wire positioning portions 30, each consisting of a radial channel. Each contacting means 22 extends into a respective wire-positioning portion 30 when the cable receptacle 14 is inserted fully into the bore 18 and properly aligned lo therewith.

Each wire-positioning portion 30 includes a wire-restraining means 32 consisting of a narrowed portion of the radial channel. The wirepositioning portion 30 is made of a resilient material. A wire is held in the channel by compressive forces in the narrowed portion, while the resilience of the cable receptacle 14 allows the wire to be easily inserted and removed. The wire is held in such a position that when a respective contacting means 22 perforates the insulation of the wire, it does so in a direction substantially coincident with and parallel to a diametric plane of the wire. Thus the contacting means 22 is always directed substantially towards an axis of the wire.

The cable connector 10 includes an aligning means, consisting of a slot 36, disposed longitudinally on an outer surface of the cable receptacle 14; and a key 38, so disposed on the main connector part 12 as to engage with the slot 36 when the cable receptacle 14 is inserted into the main connector part 12.

The slot 36 and the key 38 are positioned such that, when the cable receptacle 14 is inserted into the main connector part 12, each contacting means 22 is aligned with the lateral centre of a respective wire-positioning so portion 30.

A peripheral seal 62 between the cable receptacle 14 and the main connector part 12 seals the bore 18 against the ingress of moisture. A seal 68, best seen in Figure 2, encloses the wire-positioning portions 30 and s further seals the bore 18.

The cable receptacle 14 also includes a cable-receiving portion 44 consisting of an axial bore 18 extending wholly through it.

lo The end nut 16 includes a thread 58, which thread 58 cooperates with a corresponding thread 60 of the main connector part 12. The end nut 16 also includes a cable-receiving portion 46 consisting of an axial bore extending wholly through it. A seal 64 within the end nut further seals the cable connector 10 against the ingress of moisture.

To assemble one side of the connector, a part of the outer insulation of a cable is first removed, so that a sufficient length of each wire is exposed for it to extend along the wire-positioning portion 30 at least as far as the point where a contacting means 22 will contact the wire. The cable is then so inserted through the cable-receiving portion 44 of the end nut 16, through the seal 64 and finally through the cable- receiving portion 46 of the cable receptacle 14.

The wires of the cable are then spread radially outwardly with each wire Is being inserted into a wire-positioning portion 30 of the cable receptacle 14.

The wires are arranged within the wire-positioning portions 30 according to a particular scheme, such that wires in a cable receptacle 14 of the second side 102 may be arranged according to the same scheme. Connection of a particular wire in the first side 100 to a corresponding wire in the second so side 102 is thereby ensured.

Each wire is then located behind a respective wire-restraining means 32 such that the wires are held in place.

It is not necessary to remove the insulation of the wires, nor must they be cut to an accurate length in order to make a connection. They must, however, be cut to an approximate length during assembly.

The cable receptacle 14 is then inserted into the bore 18 of the main lo connector part 12, using the aligning means to align properly each of the contacting means 22 with a respective wire-positioning portion 30.

The end nut 16 is then screwed onto the main connector part 12. Attachment of the end nut 16 urges each wire held by a wire-positioning portion 30 against a respective contacting means 22.

The insulation of each wire is perforated by a contacting means 22 in a direction substantially perpendicular to an axis of the wire, and moreover in a direction substantially coincident with and parallel to a diametric plane of the wire. Each contacting means 22 perforates wholly the insulation layer of a wire, thereby making electrical contact with the conductor beneath.

The contacting means 22 is of sufficient length for electrical contact to be possible with wires of a predetermined range.

The contacting means 22 creates in the insulation layer a hole which is small compared to a lateral width of a channel in which a wire resides, and thus is small compared to the overall diameter of the wire. Preferably, the hole created is less than half of the diameter of the wire. Thus the wire is substantially undamaged by the making of a connection; the connector can be disassembled and reassembled repeatedly and frequently with substantially no damage to the insulation or the conductor of the wire.

Furthermore, a connection can be made either with wires having a solid conductor or with those having a multi-strand conductor.

Figure 3 shows a cable connector 210, which comprises a second embodiment of the present invention, wherein each feature corresponding to that of the first embodiment is given the same reference number.

The cable receptacle 214 does not include the wire-restraining means 32 of the first-described embodiment. Each wire-positioning portion 230 consists of a radial channel formed by two non-parallel and intersecting sides, such that each channel has a substantially v-shaped cross section. Thus a wire ts positioning portion 230 may hold a wire of a diameter within a predetermined range.

A wire is urged by the sides of a channel always towards the lateral centre thereof. The aligning means causes each contacting means 22, when the so connector is assembled, to be aligned with the lateral centre of a respective channel. Thus, when the cable connector 210is assembled, each contacting means 22 perforates an insulation layer of a wire in a direction substantially coincident with and parallel to a diametric plane of the wire.

The radial channels extend wholly to the periphery of the lateral face 28 of the cable receptacle 214 and continue longitudinally along the side thereof.

The longitudinal channels constitute wire-collecting portions 48, wherein excess wire beyond that necessary to connect electrically to thecontacting means 22 is collected. Thus the length to which the wires are cut is not so critical to the function of the cable connector 210.

Whereas the cable connector 10 of the first-described embodiment includes two main connector parts 12 which are attachable together, the cable connector 210 of the second embodiment includes only one main connector s part 212. The main connector part 212 essentially consists of two main connector parts 12 so formed as to be an integral component.

One cable receptacle 214 is securable to a first region 200 of the main connector part 212, which first region 200 includes the contacting means 0 22. The main connector part 212 includes a further region 202 to which a further cable receptacle 214 is securable and which includes a further contacting means 22. The further contacting means 22 is electrically connected to the contacting means 22, or rather, a single contacting means 22 extends wholly through the main connector part 212.

Figure 4 shows a cable connector 310, which comprises a third embodiment of the present invention, wherein each feature corresponding to that of an above-described embodiment is given the same reference number.

to The cable receptacle 314 includes wire-positioning portions 330, each consisting of a radial channel.

The cable connector 310 includes a wire-restraining means 332 in the form of an attachable disc, including thereon substantially v-shaped protrusions 50. Each v-shaped protrusion 50 is so located as to restrain a respective wire within a wire-positioning portion 330 when the cable connector 310 is assembled. The wire-restraining means 332 includes therein a plurality of apertures 52, disposed such that, when the cable connector 310 is assembled, each is aligned with a respective contacting means 22, the so contacting means 22 passing through each in order to contact a wire. The wire-restraining means 332 also includes adjacent each v-shaped protrusion two radial slots 54, such that each v-shaped protrusion 50 may deflect, owing to the resilience of the material from which the wire- restraining means 332 is formed, under the force applied to the wire- restraining means 332 when the same is attached to the cable receptacle 314. The wire restraining means 332 is attachable to the cable receptacle 314 by means of releasable clips 56.

Figure 5 shows a cable connector 410, which comprises a fourth lo embodiment of the present invention, wherein each feature corresponding to that of an above-described embodiment is given the same reference number.

The cable connector 410 again includes a wire-restraining means consisting of v-shaped protrusions 50, although in this embodiment the v- shaped protrusions 50 protrude from the distal face 20 of the bore 18 rather than from a separate attachable disc. The function performed is identical to that of the wire-restraining means 332 of the third embodiment.

Figure 6 shows a cable connector 510, which comprises a fifth embodiment of the present invention, wherein each feature corresponding to that of an above-described embodiment is given the same reference number.

The contacting means 522 of the cable connector 510 is longer than those of above-described embodiments. The contacting means 522 perforates the insulation of a wire on either side of the same.

The cable receptacle 514 includes therein a plurality of apertures 550, rather than a cable-receiving portion 44 is in above-described embodiments. When assembling the cable connector 510, individual wires of a cable are inserted through the apertures 550 before being positioned in the wire-positioning portions 330.

It will be apparent that a person skilled in the art could make minor s modifications to the invention as described herein, which modifications, although departing from the literal wording of the following claims, are nonetheless within the intended meaning thereof.

Due to the manner in which components of the present invention fit lo together, a connection may be formed using the invention without having to use any specialized tools.

In addition, the present invention is substantially waterproof due to the materials used to form the connector, and to the presence of seals. A Is connector according to the present invention may therefore be submerged in water with little or no damage occurring.

Although the invention has been described primarily in terms of a connector for use in marine environments, it is to be understood that the invention has wide application and may be used in a wide range of domestic and industrial settings.

In addition, although the invention is intended to be used in harsh environments, it could also be used in benign environments. 2s

Claims

1. A cable connector for a cable, the cable including a wire having a conductor and an insulation layer, the cable connector comprising a contacting means for electrically contacting the conductor, which contacting means, in use, perforates the insulation layer in a direction substantially non-parallel to an axis of the wire.

2. The cable connector of Claim 1 wherein the contacting means is a lo spike.

3. The cable connector of any preceding claim comprising a cable receptacle including a wire-positioning portion, which wire- positioning portion positions the wire within the cable receptacle.

4. The cable connector of Claim 3 wherein the wire-positioning portion includes a channel defined by two non parallel and intersecting sides, such that the channel is capable of supporting wires having diameters within a predetermined range.

5. The cable connector of any of Claims 3 to 4 wherein the cable receptacle includes a wire-collecting portion, for collecting a part of a wire between a point where the contacting means contacts the wire and an end of the wire.

6. The cable connector of Claim 3 or 5 wherein the wire-positioning portion includes a wire-restraining means for restraining a wire in position in the wire-positioning means.

so

7. The cable connector of any of Claims 3 to 6 wherein the cable receptacle is formed of a resiliently deformable material.

8. The cable connector of any of Claims 3 to 7 comprising a main connector part which houses the contacting means and to s which the cable receptacle is securable, the contacting means being electrically connected to an electrical connector presented by the main connector part.

9. The cable connector of Claim 8 wherein lo the cable receptacle is securable to a first region of the main connector part, which first region includes the contacting means; the main connector part comprising a further region to which a further cable receptacle is securable and which includes a further contacting means; Is the further contacting means being electrically connected to the contacting means.

10. The cable connector of Claims 8 or 9 wherein the cable receptacle is securable to the main connector part in a predetermined configuration, such to that, in use, the contacting means perforates the insulation layer in a direction substantially coincident with and parallel to a diametric plane of the wire.

11. The cable connector of Claim 9 or 10 comprising aligning means for as so aligning the cable receptacle and the main connector part.

12. The cable connector of Claim 11 wherein the aligning means comprises a slot and a key, one of which is included by the cable receptacle and the other by the main connector part.

13. The cable connector of any Claims 4 to 12 wherein a major lateral dimension of the contacting means is small compared to the width of the channel.

14. A cable connector including a cable receptacle having a plurality of wire-positioning portions for positioning wires a of a cable, and a main connector part having a plurality of contacting means for electrically contacting wires positioned by the wire-positioning portion, the cable connector comprising aligning means for aligning the cable receptacle with lo the main connector part in a predetermined configuration such that each of the contacting means is aligned with a respective wire- positioning portion, and such that in use, the contacting means perforates the insulation layer in a direction substantially coincident with and parallel to a diametric plane of the wire.

15. The cable connector of Claim 14 wherein the aligning means comprises a slot and a key, one of which is included by the cable receptacle and the other by the main connector part.

16. The cable connector of either of Claims 14 or 15 wherein each contacting means, in use, perforates an insulation layer in a direction substantially non-parallel to an axis of the wire.

17. The cable connector of any of Claims 14 to 16 wherein each as contacting means is a spike.

18. The cable connector of any of Claims 14 to 17 wherein each wirepositioning portion includes a channel defined by two non parallel and intersecting sides, such that each channel is capable of so supporting wires having diameters within a predetermined range.

19. The cable connector of any of Claims 14 to 18 wherein the cable receptacle includes a plurality of wire-collecting portions, each for collecting a part of a wire between a point where a respective contacting means contacts a wire and an end of the wire.

20. The cable connector of any of Claims 14 to 19 wherein each wirepositioning portion includes a restraining means for restraining a wire in position in the wire-positioning means.

21. The cable connector of any of Claims 14 to 20 wherein the cable receptacle is formed of a resiliently deformable material.

22. The cable connector of any of Claims 14 to 21 wherein each contacting means is electrically connected to a respective electrical connector presented by the main connector part.

23. The cable connector of any of Claims 14 to 22 wherein the cable receptacle is securable to a first region of the main so connector part, which first region includes the contacting means; the main connector part comprising a further region to which a further cable receptacle is securable and which includes a further contacting means; the further contacting means being electrically connected to the contacting means.

24. A method of connecting cables comprising the step of D. perforating an insulation layer of a wire of a cable with a contacting means, thereby electrically contacting a conductor of the wire, wherein the contacting means perforates the insulation layer and in a direction substantially non-parallel to an axis of the wire.

25. The method of Claim 24 comprising the step of A. before step D, using a wire-positioning portion to position the wire in relation to the contacting means such that the contacting means perforates the insulation layer in a direction substantially coincident with and parallel to a diametric plane of the wire.

lo

26. The method of Claim 25 comprising the step of B. after step A and before step D, aligning a cable receptacle with a main connector part using aligning means, wherein the cable receptacle includes the wirepositioning portion and the main connector part houses the contacting means.

27. The method of Claim 26 comprising the step of C. after step B and before step D, securing the cable receptacle to the main connector part in a predetermined configuration.

so

28. A method of manufacturing a cable connector, for a cable including a wire having a conductor and an insulation layer, the method comprising the step of producing a contacting means for electrically contacting the conductor, which contacting means, in use, perforates the insulation layer in a direction substantially non-parallel to an axis of the wire.

29. The method of Claim 28 wherein the contacting means is so produced as to be a spike.

so

30. The method of either of Claims 28 or 29 comprising the step of producing a cable receptacle including a wire-positioning portion, which wire-positioning portion positions the wire within the cable receptacle.

31. The method of Claim 30 comprising the step of producing the wirepositioning portion to include a channel defined by two non-parallel and intersecting sides, such that the channel is capable of supporting wires having diameters within a predetermined range.

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32. The method of any of Claims 30 to 31 comprising the step of producing the cable receptacle to include a wire-collecting portion, for collecting a part of a wire between a point where the contacting means contacts the wire and an end of the wire.

Is

33. The method of any of Claims 30 to 32 comprising the step of producing the wire-positioning portion to include a restraining means for restraining a wire in position in the wire-positioning means.

34. The method of any of Claims 30 to 33 comprising the step of to producing a main connector part which houses the contacting means and to which the cable receptacle is securable, the contacting means being electrically connected to an electrical connector presented by the main connector part.

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35. The method of Claim 34 comprising the steps of producing the cable receptacle to be securable to a first region of the main connector part, which first region includes the contacting means; producing the main connector part to comprise a further region to which a further cable receptacle is securable and which includes a further so contacting means; producing the further contacting means to be electrically connected to the contacting means.

36. The method of Claim 34 or 35 comprising the step of s producing the cable receptacle to be securable to the main connector part in a predetermined configuration such that, in use, the contacting means perforates the insulation layer in a direction substantially coincident with and parallel to a diametric plane of the wire.

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37. The method of Claim 36 comprising the step of producing aligning means for so aligning the cable receptacle and the main connector part.

38. The method of Claim 37 comprising the step of producing the aligning means to comprise a slot and a key, one of which is included by the cable receptacle and the other by the main connector part.

39. The method of any of Claims 28 to 38 comprising the step of So producing the contacting means so that a major lateral dimension thereof is small compared to the width of the channel.