JPH0414475B2 - - Google Patents

Abstract

An electrical cable assembly comprises a main electrical bus (10, 82) to which branch electrical buses (12, 88) are electrical connected. The main bus and branch buses include a plurality of insulated electrical conductors (14, 18, 78, 84) extending crosswise to one another with electrical connectors (22, 22A, 90, 90A) electrically connecting selected electrical conductors of the buses together. The electrical connectors penetrate the insulation of the buses and make electrical connection with the electrical conductors. The terminated sections of the buses can be housed in housing members (32) providing strain relief and insulation. Shielding (52) can be applied onto the main bus (10, 82) and ground connections (54, 76) can be effected at the housing members (32).

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an electrical cable assembly that selectively connects electrical conductors of a plurality of insulated flat cables, and a connector used therein.

Electrical wiring harnesses are typically assembled by manually placing individual wires in preselected locations and then bundling them together. Machines that automatically assemble harnesses have also been developed, but in either case the wiring harness assembly is time consuming and expensive.

The electrical interconnection scheme according to the invention includes a main electrical bus to which branch electrical buses are electrically connected. The main bus and the branch buses each include a plurality of insulated electrical conductors extending across each other and selected electrical conductors of both buses are electrically connected by electrical connectors. The electrical connector penetrates the insulation of the bus to make an electrical connection with the electrical conductor. The terminating parts of the bus can be housed in a housing member that serves for stress relief and insulation. A shield can be attached to the main bus and a ground connection can be made using the housing member.

That is, in accordance with the present invention, an electrical cable assembly for interconnecting selected conductors of a main electrical bus and a branch electrical bus including a plurality of parallel electrical conductors each separated from one another by an insulating jacket comprises: A plurality of legs having a shape of a main body part and four legs having relatively sharp tips extending from one end of the main body part and press-fitted from one side into the main electric bus and the branch electric bus which are overlapped and intersected with each other. an electrical connector, and an insulating member covering both sides of the intersection area of the main electrical bus and the branch electrical bus, and each electrical connector is press-fitted so that the four legs connect to the main and branch electrical bus. and press-fit two locations on both sides of the intersection of the selected pair of conductors of the main electrical bus and the branch electrical bus between the opposing slots between the legs to electrically connect them to each other. An electrical cable assembly is provided.

Further in accordance with the present invention, an electrical conductor comprising a plurality of parallel electrical conductors, each separated from one another by an insulating jacket, interconnects selected conductors of a main electrical bus and a branch electrical bus superimposed on each other. In the cable assembly, a plurality of generally plate-shaped portions each having at least one wedge-shaped portion cut and raised approximately at the center and a plurality of leg portions each having a relatively sharp tip protruding from the peripheral edge in one direction. electrical connectors, and an insulating member covering both sides of the interconnects of the superimposed main electrical bus and branch electrical buses, the legs of each of the electrical connectors being connected to the superimposed main electrical bus and branch electrical buses; The wedge extends through the electrical bus and the free end is bent into contact with selected conductors of said main or branch electrical bus, said wedge being in contact with selected conductors of said branch or main electrical bus and interconnecting. An electrical cable assembly is provided that features connecting.

In another aspect, the invention provides a method of manufacturing an electrical interconnect system, the method comprising: crossing a branch electrical bus with a main electrical bus; and inserting electrical connectors into the crossing bus at selected locations. The method includes the steps of electrically interconnecting specific electrical conductors of the buses and attaching insulating housings to the intersecting interconnected buses. Among the intersecting buses, the main bus can be equipped with an insulator to cover the exposed portion of the electrical connector, and a conductive shield material is attached to one side of the main berth.

The present invention will be described below with reference to embodiments shown in the drawings.

1-6 illustrate an electrical interconnection scheme for electrically connecting a branch electrical bus 12 to a main electrical bus 10 to form an electrical harness for electronically controlled equipment or the like. The main electrical bus 10 is a multiconductor cable whose electrical conductors 14 are arranged parallel to each other and insulated from each other within an insulating jacket 16. These electrical conductors 14 are typically sized to carry electronic signals in both directions and may be stranded or solid wire. Branch electrical bus 12 is of the same construction, with its electrical conductors 18 covered by an insulating jacket 20. The number of conductors of branch bus 12 may be different from that of main bus 10.

Some of the electrical conductors of main electrical bus 10 and branch electrical bus 12 may be increased in size for purposes of powering electronic devices, if desired.

3 and 4 illustrate an electrical connector 22 for electrically connecting electrical conductors 18 of branch bus 12 to electrical conductors 14 of main bus 10. FIG. The electrical connector 22 is stamped into a strip from a suitable metal strip and is formed as a rectangular body portion 23 having a notch 24 on opposite sides and a notch 26 on the other opposite side. The entrances of the cuts 24 and 26 are obliquely cut. The legs 28 are L-shaped in cross section and are located at the four corners of the electrical connector 22. Electrical connector 22 may be circular (22A) as shown in FIG. 4A if desired.

When it is desired to electrically connect selected ones of the electrical conductors 18 of the branch bus 12 with the electrical conductors 14 of the main bus 10, the legs 28 of the electrical connector 22
is penetrated into the insulating jacket 20 such that on each side of the selected intersection location the notch 24 displaces the insulation surrounding the electrical conductor 18 and the notch 26 displaces the insulation surrounding the electrical conductor 14 to be connected to the electrical conductor 18. Push objects away to electrically connect selected conductors. Therefore, the main bus 1 to be interconnected
By selecting the electrical conductors of 0 and the branch bus 12 by electrical connectors 22, a programmable interconnection according to the needs of the electronic device can be obtained between the buses. Branch bus 12 is electrically connected to the electronic devices via suitable electrical connectors (not shown) terminating its conductors.

The electrical connector strip 22 can be inserted into the termination position by a programmable applicator of the type shown in FIGS. 20, 16 through each electrical conductor 1
8 and 14, the notch 24 pushes away the insulation covering the conductor 18 to make an electrical connection with the conductor, and the notch 26 pushes away the insulation covering the electrical conductor 14 and makes an electrical connection with the conductor. 4th thing to do
As illustrated in the figure. In this manner, selected conductors of bus 12 are electrically connected to selected conductors of bus 10, and these electrical conductors are interconnected in a predetermined program.

The terminal connection of the branch bus 12 to the main bus 10 is preferably housed in an insulating member or housing 30 that protects the terminal connection and provides stress relief, the housing member being in place relative to the device. Alternatively, the device itself may be installed at a predetermined location. Housing member 30 includes hermaphroditic cover members 32 molded from a suitable dielectric material. Each cover member 32 has a hook member 3 at each corner.
4 and the adjacent notch 36 and latch member 38
has. Latch member 38 has a beveled surface 40 and a latching surface 42. Projecting from the inner surface of cover member 32 is a square wall 44 spaced inwardly from notch 36 and latch member 38. Also, centering members 46 protrude from the inner surface of the cover member 32 at opposite corners of the wall 44, and are inserted into holes 47 when the cover members 32 are latched together, so that the latch members 38 are inserted into the respective notches. It serves to align with 36. When the cover member 32 is latched, the bus 1
0 and 12 both pass through this housing member 30.

During work, connect the electrical connector 22 of the branch bus 12.
The portions terminating to the main bus 10 by the plurality of cover members 32 are installed in the wall 44 of one cover member 32 and the other cover member 32 is then inserted into the first notch 36 of the latch member 38. The cover member 32 is latched. Latch member 38
The latching surfaces 42 of the cover members 32 engage the outer surface of the cover members 32, and the centering members 46 and holes 47 center the respective cover members 32 with respect to each other to align the latch members 38 with the notches 36 and lock the cover members together. Enables binding. This latch engagement causes the bus 12
The bus 10 passes through the housing member 30 with its termination areas and electrical connectors protected and insulated by the housing member 30. If desired, screws or bolts 48 are engaged with hook members 34 to secure housing 30 in place, as shown in FIG. Beveled surface 40 facilitates outward movement of latch member 38 when cover member 32 is latched. Protrusion 39
are spaced inwardly from each notch 36;
This serves as a receiving surface for a screwdriver or the like to apply force to the latch member 38 to remove it from the latched state.

Branch electrical bus(s) 12 to electrical connectors 22
After terminating the main electrical bus 10 at a selected longitudinal location by means of a wire, the main bus 10 can be optionally shielded to provide a shielded electrical harness in accordance with FCC (Federal Communications Commission) regulations. can.
To shield the main bus 10, attach a piece of insulating tape 50 (FIG. 1) to it to cover and insulate the legs 28 of the connector 22 protruding from the main bus 10, and then attach a piece of insulating tape 50 (FIG. 1) to the main bus 10 to insulate it. A conductive foil 52 is attached to the bus 10 to serve as its shield.

Each housing member 30 may be provided with a ground contact member 54 for grounding the conductive foil 52 at the location of the housing member 30 or at selected locations of the housing member 30 as required (FIG. 1, Figure 5). The earth contact member 54 is connected to the wall 44
A long member 5 having a mounting member 58 attached in a wedge shape to a notch 60 provided on one side.
Includes 6. The spring contact piece 62 is connected to the elongated member 56
The terminal connection areas of the buses 10, 12 are folded back upwards, as shown in FIG.
When housed inside the wall 44 of 0, it is electrically connected to the conductive foil 52.

A spring grounding contact piece 64 extends from the elongated member 56 and is located along the inner surface 66 of the channel portion 68 of the cover member 32 .
6 and the side wall of the channel section 68 .
and the distal end of the extension part 70. A vertical portion 72 of contact piece 64 runs along extension portion 70 .
The free end of the contact piece 64 is substantially aligned with the axis of the hole 74. A ground wire 76 is inserted into the hole 74 through its obliquely cut entrance, and is pressed against the inner end of the channel portion 68 by the spring action of the spring ground contact piece 64, as shown in FIG. 64 bites into the ground wire 76 to maintain reliable electrical engagement with the contact piece 64 of the ground wire 76.
Ground wire 76 can then be connected to a suitable ground as appropriate. By making a number of such ground connections, the conductive foil shield 52 can be grounded at several locations.

A modified electrical connector, shown as another embodiment in FIGS. 7-10, connects flat conductors 78 insulated parallel to each other in an insulating jacket 80 to each other in an insulating jacket 86 of a branch electrical bus 88. It is used to electrically connect with the flat electrical conductors 84 arranged in parallel. Flat electrical conductors 78 and 84 cross each other. The electrical connector 90 shown in FIGS. 7 and 8 has a circular body portion 92 with a pointed outer leg 94 depending therefrom. A triangular member 96 is centrally located in the body portion 92 and extends parallel to its axis.

Electrical connector 90 is formed in strip form, if desired, by conventional metal stamping processes, and its legs 94 are formed into overlapping buses 82, 88 with conductors 78, 84 crossing each other at right angles. The conductor 78 is inserted into the insulating jacket and at the selected interconnection point.
Triangular member 96 extends through insulating jacket 86 and engages conductor 84, clearing the electrical conductors that cross it when electrical connector 90 is moved to the termination position. The tips of the legs 94 are bent inward toward the axis of the connector 90, penetrate the insulating jacket 80, and bite into the conductor 78, as shown in FIG. The connection is made and the oxide between them is destroyed.

The electrical connector 90A shown in FIGS. 9 and 10 has the same configuration as the electrical connector 90 shown in FIGS. 7 and 8, but the shape of the main body portion 92A is square rather than circular. Otherwise electrical connector 90A
is the same as electrical connector 90, and conductors 78, 8
The circumstances for terminating 4 are also the same as described above for electrical connector 90 of FIGS. 7 and 8. However, the tip of the leg 94A is the electrical connector 90.
It cannot be directed towards the axis of A.

11 and 12 illustrate a harness manufacturing operation for automatically manufacturing electrical harnesses under program control. As shown in FIG. 11, the main electrical bus 10 is fed from the reel 98 through a cable length sensing station 100 that senses the length of cable to be drawn from the reel 98. The bus 10 is fed to a termination station 102 where a table 104 is installed.
a hold-down member 10 that advances along the
6 in place on the table 104. The branch bus 12 is fed from the reel 108 along the table 104 across the main bus 10 through a cable length sensing station 110 that senses the length of cable to be drawn from the reel 108. A program controlled termination connector 112 operates through an aperture 114 in table 104 and connects electrical connectors 22, 90 or 9 from a strip of connectors 116 fed from a supply reel (not shown).
bus 10 by automatically inserting 0A,
12 conductors are interconnected according to the programmed termination plan. The electric motor 118 is connected to the terminal connector 11
2 and its terminating die is moved to a programmed position to insert the electrical connector into the intersecting bus and electrically connect the selected electrical conductors.

Once bus 12 is terminated to bus 10, bus 12 is disconnected from its supply and bus 10 is advanced to an equipment station 120 where electrical tape 50 is applied to bus 10 to cover the exposed legs of the connector. cover. Bus 12 is then advanced to shield installation station 122 where bus 1
After the conductive foil 52 is adhered to the bottom surface of bus 1
A housing 30 is attached to the terminal connection portions 0 and 12.

Another branch bus 12 was terminated to the main bus 10, an insulating tape 50 was applied to the bus 10, a conductive foil 52 was attached to the bus 10, and a housing member 30 was fixed in place on the terminating portion of the bus. By the way, if the main bus 10 is separated from the supply reel 98, a completed harness is obtained. If necessary, the housing member 30 can be simply attached to the terminal connection portion of the bus without attaching any insulating tape or conductive foil.

FIG. 13 is a flow chart of harness manufacturing using the apparatus shown in FIGS. 11 and 12,
The harness manufacturing operation can be controlled by a microprocessor operated programmable controller. If it is desired to adhere conductive foil to both sides of the main bus cable, insulating tape can be attached to the main bus cable and the branch bus cable. If the conductive foil is attached to the main bus cable, an earth contact member 54 is incorporated into the housing member.

As explained above, in the electrical connector of the present invention and the connector assembly used therein, a plurality of legs are arranged adjacently in the same direction and a notch is formed between the legs. The main electrical bus and the branch electrical bus are substantially superimposed and the conductors of the main electrical bus are pressed into one of the adjacent notches of the electrical connector and the conductors of the branch electrical bus are pressed into the other, i.e. in one notch, for example. When the conductors of the main electric bus are press-fitted, the conductors of the branch electric buses are press-fitted into adjacent notches.

Therefore, the height of the electrical connector can be reduced, resulting in a low-profile electrical connector. Electrical cable assemblies also utilize low-profile electrical connectors to press-fit the substantially overlapping intersection areas of the main electrical bus and branch electrical buses, resulting in an extremely low-profile electrical cable assembly that allows for tight spaces. It can also be applied inside.

In addition, since interconnection can be made with only a single electrical connector, no other members are required, and the number of parts is small and the cost can be reduced.

The electrical connector is robust and easy to work with since it penetrates both electrical buses from one side. Also, since the electrical cables are essentially overlapped, it is easy to see where to select conductors.

[Brief explanation of drawings]

FIG. 1 is an exploded perspective view of the main electrical bus, the branch electrical buses, the connectors interconnecting the electrical conductors of these buses, and the housing members containing the interconnecting portions of the buses; FIG. 2 shows the elements of FIG. 1; Fig. 3 is a perspective view of a part of the intersecting bus and the electrical connector separated from it; Fig. 4 shows one of the connectors in the terminal connection state and the other connector in the semi-terminal connection state. A similar view to FIG. 3 and FIG. 4A are perspective views of a modified version of the electrical connector. FIG. 5 is a partially cutaway view of the housing member showing the bus and another housing member interconnected remotely from the housing member. FIG. 6 is a view similar to FIG. 5 showing an assembled state. 7 is a perspective view of another variant of the electrical connector shown away from the intersecting bus; FIG. 8 is a cross-sectional view of the electrical connector of FIG. 7 in termination with the electrical conductors of the intersecting bus; FIG. The figure also shows a perspective view of another modified electrical connector separated from the intersecting bus; FIG.
11 is a perspective view of a harness fabrication operation electrically interconnecting a branch electrical bus to the main electrical bus; FIG. 12 is an enlarged perspective view of the programmable termination device of FIG. 11. 13 are flowcharts of the harness manufacturing operations shown in FIGS. 11 and 12. 10... Main electric bus, 12... Branch electric bus,
14, 18, 78, 84... Electric conductor, 16, 2
0, 80, 86...Insulating jacket, 22, 22
A, 90, 90A...Electrical connector, 23, 9
2,92A...Body part, 24,26...Notch, 28,94,94A...Leg, 30,32...
Housing and its cover member, 96...wedge-shaped portion.

Claims (1)

Claims: 1. An electrical cable assembly interconnecting selected conductors of a main electrical bus and a branch electrical bus comprising a plurality of parallel electrical conductors each separated from one another by an insulating jacket, comprising: A plurality of legs having a shape of a main body part and four legs having relatively sharp tips extending from one end of the main body part and press-fitted from one side into the main electric bus and the branch electric bus which are overlapped and intersected with each other. an electrical connector, and an insulating member covering both sides of the intersection area of the main electrical bus and the branch electrical bus, and each electrical connector is press-fitted so that the four legs connect to the main and branch electrical bus. and press-fit two locations on both sides of the intersection of the selected pair of conductors of the main electrical bus and the branch electrical bus between the opposing slots between the legs to electrically connect them to each other. An electrical cable assembly characterized by: 2. In an electrical cable assembly comprising a plurality of parallel electrical conductors, each separated from one another by an insulating jacket, and interconnecting selected conductors of a main electrical bus and a branch electrical bus superimposed on each other, approximately at the center; a plurality of electrical connectors each having a substantially plate-shaped portion having at least one wedge-shaped portion formed by cutting and raising the portion, and a plurality of leg portions having relatively sharp tips protruding from the peripheral edge in one direction; an insulating member covering both sides of the interconnects of the superimposed main electrical bus and branch electrical buses, the legs of each electrical connector passing through the superimposed main electrical bus and branch electrical buses; The free end is bent to contact selected conductors of the main or branch electrical bus, and the wedge-shaped portion contacts and interconnects selected conductors of the branch or main electrical bus. electrical cable assembly.