US3909935A

US3909935A - Pre-loaded electrical connectors, assembly apparatus and method

Info

Publication number: US3909935A
Application number: US491893A
Authority: US
Inventors: Lionel Dennis Aldridge; Edward Dennman Bunnell
Original assignee: AMP Inc
Current assignee: TE Connectivity Corp
Priority date: 1973-01-08
Filing date: 1974-07-25
Publication date: 1975-10-07
Anticipated expiration: 1992-10-07

Abstract

A method for mechanically and electrically connecting conductors to multi-contact electrical connectors having rows of aligned terminals. Predetermined conductors can be electrically and mechanically connected to predetermined terminals in each of the separate connector housings positioned beside each other by locating the intermediate portion of each conductor over corresponding aligned terminals in the housings, moving the conductors into the slots of the terminals, and cutting out the section of conductor which extends between the terminals.

Description

Unite States atent 1191 1111 31,9 Aldridge et a1. Oct. 7, 1975 [54] PRE-LOADED ELECTRHCAL 3,438,407 4/1969 Over 29/628 BL PP AT 5 3,617,983 11/1971 Patton 339/98 ASSEM Y A AR U 3,708,779 1/1973 Enright et a1. 339/99 R 3,745,512 7/1973 Johnson et al i 339/101 [75] Inventors: Lionel Dennis Aldridge, Seminole; 3,747,209 7/1973 Chow 29/629 Edward Dennman Bunne" Palm Long et al. Harbor both f 1 3,769,701 11/1973 KlOth 1 29/203 MW 3,800,390 4/1974 Johnston 29/203 J [73] Assignee: AMP Incorporated, Harrisburg, Pa. 3,803,695 4/1974 Tucci 29/203 H [22] Filed: July 1974 Primary ExaminerC. W. Lanham [21] Appl. No.: 491,893 Assistant ExaminerJames R. Duzan Attorney, Agent, or Firm-R.obert W. Pitts; Frederick Related US. Application Data W. Raring; y L. Seitchik [62] Division of Ser. No. 321,505, Jan. 8, 1973, Pat. No.

[57 ABSTRACT [52 us. c1 29/628; 29/203 H A method for mechanically and eiectrically Connect- 51 11111.01. 110m 43/00 ing conductors multi-contact electrical connectors 53 Field of Search 29 2 2 30 R, 630 A having rows of aligned terminals. Predetermined con- 20 R, 203 D, 203 H, 203 HC, 203 J 203 ductors can be electrically and mechanically con- MM, 20 MW, 03 p 203 S 339/47, nected to predetermined terminals in each of the sepa- 43, 49 95, 97, 98, 99 rate connector housings positioned beside each other by locating the intermediate portion of each conduc- 5 References Cited tor over corresponding aligned terminals in the hous- UNITED STATES PATENTS ings, moving the conductors into the slots of the termi- 3 012 219 12/1961 Levin et al 29/629 nals, and cutting out the section of conductor which 3:046:636 7/1962 Albright......... m. IIIIIT29/335 extends between the termmafls' 3,363,309 1/1968 Logan et al 29/628 5 Claims, 12 Drawing Figures Sheet 1 of 6 3,909,935

U.S. Patent Oct. 7,1975

US Patent Oct. 7,1975 Sheet 2 of6 3,909,935

3?? Mag/9T5 4 Qfi US. Patent Oct. 7,1975 Sheet 3 of6 3,909,935

0m. 7,1975 Sheet 4 of 6 3,909,935

US. Patent US. Patent Oct. 7,1975 Sheet5 0f6 3,909,935

US. Patent 00. 7,1975 Sheet 6 of6 3,909,935

FREE-LOADED ELECTRICAL CONNECTORS, ASSEIVIBLY APPARATUS AND METHOD BACKGROUND OF THE INVENTION This is a divisional application of pending prior application Ser. No. 321,505 filed on Jan. 8, 1973 now U.S. Pat. No. 3,842,392.

This invention is a method relating to multi-contact electrical connecting devices such as multi-contact electrical connectors and to the use of apparatus for installing such connectors on conductors. The invention is herein disclosed as used in connection with a pair of mateable hermaphroditic connectors but the method can be used with a wide variety of multi'contact connecting devices.

It is common practice in the electrical connector art to produce multi-contact electrical connectors by first cutting electrical leads from a coil of wire, stripping insulation from the ends of the leads, crimping electrical contact terminals onto the stripped ends, and finally inserting the terminals into the cavities of an electrical connector housing. Frequently, and particularly in the manufacture of electrical harnesses, the terminals cannot be inserted indiscriminately into the cavities but must be inserted into specific predetermined cavities in the housings since the leads or wires in a harness are not necessarily of the same length and each lead must be connected to a predetermined lead in a mating harness when the harness is put to use. This method of installing connectors on conductors is time consuming and inefficient and has several comparative disadvantages which can result in the production of defective harnesses. For example, during the interval between crimping of the terminals onto the conductors and insertion of the terminals into the cavities of the connector housing, the electrical leads must be repeatedly handled and transported from one work location to another. The terminals are subject to damage during this interval and if one or more terminals in a finished harness is found to be damaged, it must be replaced or the harness discarded. Furthermore, the fact that predetermined terminals must be inserted into predetermined cavities in the connector housing gives rise to the possibility of a terminal being inserted into the wrong cavity and the production of a defective harness. The present invention is generally addressed to the solution of some of these manufacturing problems.

The method employed here insures that the apparatus inserts the proper conductor into its appropriate terminal on each of the connecting devices. The essential aspect of this method is that a single conductor is aligned with corresponding terminals in more than one connector. Apparatus for inserting conductors into multi-contact connectors are disclosed in U.S. Pat. Nos. 3,758,935, 3,769,701, 3,800,390 and 3,803,695. None of these patents involve the application of a single conductor to corresponding terminals of mateable electrical connectors. Although not limited to utilization with mateable connectors, the instant method is particularly useful in that respect.

It is accordingly an object of the invention to facilitate the use of a pair of mateable preloaded electrical connectors having contact terminals therein to which predetermined conductors can be connected in a manner which will reduce the possibility of wiring errors as regards the electrical connections between the conductors and the terminals in the connectors. A further object is to provide an improved method and apparatus for connecting conductors to the terminals in a pair of preloaded electrical connectors, whether or not the connectors are mateable.

These and other objects of the invention are achieved in a preferred embodiments thereof which are briefly described in the foregoing abstract, which are described in detail below and which are shown in the accompanying drawing in which:

FIG. 1 is a perspective view of a hermaphroditic electrical connector assembly in accordance with the invention, the two connector parts being coupled to each other thereby to connect the wires extending into each connector part.

FIG. 2 is a perspective view of a hermaphroditic electrical connector housing in accordance with the invention showing a contact terminal exploded from one of the contact receiving cavities of the housing.

FIG. 3 is a plan view of the housing of FIG. 2.

FIGS. 4 and 5 are views taken along the

lines

44 and 55 of FIG. 3.

FIG. 6 is a view taken along the lines 6-6 of FIG. 3 but showing contact terminals and conductors installed in the contact receiving cavities of the housing.

FIG. 7 is a view taken along the lines 77 of FIG. 1.

FIG. 8 is a sectional view, on an enlarged scale, of the contact portions of two mateable contact terminals of the type shown in FIG. two, this view showing the contact portions separated from each other.

FIG. 9 is a view similar to FIG. 8 but showing the contact portions in engagement with each other.

FIG. 10 is a fragmentary cross-sectional view showing two connector parts positioned side-by-side in a connector holding jig preparatory to the formation of electrical connections between terminals in the connector parts and a conductor.

FIG. 11 is a view similar to FIG. 10 but showing the positions of the parts at the conclusion of the connection operation.

FIG. 12 is a perspective view of one form of assembly apparatus for connecting conductors to terminals in connectors in accordance with the invention.

As shown in FIG. 1, a multi-contact electrical connector assembly 2 in accordance with the invention comprises a pair of connector parts 4, 4' which can be coupled to, and decoupled from, each other to connect and disconnect the conductors 6 and 6'. The connector part 4 and the contact terminals 14 which are con tained in this connector part are identical to the con nector part 4' and the terminals 14'. Accordingly, a description of the connector part 4 and a description of one of the contact terminals 14 will suffice for both connector parts. The same reference numerals, differ entiated by prime marks will be used to identify corresponding structural features of the two connector parts.

Connector part 4 comprises a housing 4 of insulating material having an upper or mating face 8 and an un derside or rearward face 10. A plurality of contact receiving cavities 12 extend into the housing from the mating face 8, and are arranged in a row which extends between the

ends

32, 42 of the housing. Each cavity has a central transversely extending rib 13 (FIGS. 3 and 5) which serves to support and locate a contact terminal mounted therein as will be explained below. Openings 16 are provided in the side 18 which extends between the

ends

32, 42 and communicate with the cavities 12 for the accomodation of the conductors 6 as shown in FIG. 1. The side 20 which faces in the opposite direction from the side 18 is centrally offset or stepped as shown at 22 and three

upstanding teeth

24, 26, 28 project from the mating face 8 adjacent to side 20 of the housing. The tooth 28 is immediately adjacent to the portion 23 of the side 20 so that when the connector 4 is mated with the connector 4 the

teeth

28, 28 will be against the portions 21, 21' of the sides 20, 20' as indicated in FIG. 3. An elongated recess 30 extends inwardly on the mating face 8 in alignment with the

teeth

24, 26 which are set back from the portion 21 of the side 20. When the two housings are mated, the recess 30 will receive the teeth 24', 26' of the housing 4 and the recess 30 will similarly receive the

teeth

24, 26 of the housing 4. It will be apparent from FIG. 2 that the

teeth

24, 26, 28 are located on the mating face 8 such that wires or conductors extending between the teeth will extend over cavities l2 and will be above and in alignment with the contact terminals contained in these cavities. As will be explained below, these teeth serve to locate the conductors when the connector is installed on a plurality of conductors.

A partial hood 34 extends upwardly, as viewed in FIG. 2, from the righthand end 32 of the housing 4 and partially surrounds the mating face 8. An opening 36 (see FIG. 3) extends through the housing adjacent to the end 32 from the mating face to the lower or rearward face 10, this opening being generally rectangular and having a central inwardly extending boss 38 which defines a downwardly facing shoulder 40. The upper side 39 of base 38 is inclined downwardly toward the rearward face 40 in order to facilitate the flexing of the latch arm 50 of the connector part 4 during coupling as will be described below.

An additional pair of spaced apart

teeth

44, 46 extend from the mating face 8 adjacent to the end 42, these teeth having a thickness which is substantially equal to, and slightly less than, the width of the opening 36 so that the

teeth

44, 46 of the connector part 4 can enter the opening 36' of the connector part 4' as shown in FIG. 7. The

teeth

44, 46 are inwardly spaced from the side 42 so that ledges 48 are provided adjacent to the teeth at their fixed ends. A flexible latch arm 50 extends from the lefthand end of the mating face 8 between the

teeth

44, 46 and has a pointed upper end 52 and a downwardly facing shoulder 54 adjacent to its upper end. An opening 56 extends through the housing from the rearward face thereof and has one side which merges with the outwardly facing side 47 of the latch arm to permit access to the end of the latch arm for decoupling purposes when the connector part 4 is coupled to the part 4'.

It will be apparent from the foregoing that the housing can be coupled to the housing 4 by locating the housings in face-to-face relationship and in end-to-end inverted relationship (end 32 of housing 4 in alignment with end 42 of housing 4') and moving the housings towards each other. During such movement, the latch arm 50 will move against the boss 38 and be flexed inwardly until the shoulder 54 is against the shoulder 40' of the housing 4 as shown in FIG. 7. The

teeth

24, 26 will enter the recess 30, and the tooth 28 moves across the side portion 21 of side as discussed above. The relationship of the housing 4' to the housing 4 is, of course, the same as that of the housing 4 to the housing 4'. It should be noted (FIG. 7) that when the housings are coupled, the mating faces are against each other and portions of the ledges 48 are against the side portions of the boss 38.

The two housings can be disengaged from each other by inserting thin blades through the openings 56, 56' and disengaging the ends of the latch arms from the shoulders 40, 40'. Advantageously,

projections

55, 57 are provided at the ends of the housings to permit manual gripping of the two parts during separation.

Each of the electrical contact terminals 14 has a central conductor receiving portion made up of a pair of parallel plate-

like members

58, 60 which are connected at their upper or free ends by spaced-apart straps 62. Conductor receiving slots 64 extend into these plate sections from their upper ends so that a conductor can be moved downwardly between the plate sections and into the slots. The slots are of a width such that they will penetrate the insulation of the conductor and de form the metallic core thereof so that the edges of the slots will be brought into intimate electrical contact with the metallic cores of the conductors as shown in FIG. 7. Advantageously, the slot in the plate section 60 is relatively narrower than the slot in the plate section 58 so that the slot in the former plate section will drastically deform the metallic core of a conductor 6 and establish good electrical contact therewith while the slot in the plate section 58 will penetrate the insulation of the wire but will not drastically deform the metallic core. This arrangement provides good electrical contact in combination with a mechanical strain relief for the wire as explained in U.S. Pat. No. 3,617,983. A flange 66 extends normally outwardly from the plate section and arms 68 extend upwardly from the end of this flange. These arms are adapted to be crimped into embracing relationship with a conductor to provide a strain relief therefor.

An additional flange or plate section 70 extends from the plate section 60 and has

contact arms

72, 74 extending upwardly from its side edges. As shown best in FIG. 8, the contact arms 72 is relatively long and its upper end 78 is above the upper ends of the

plate sections

58, 60 of the terminal. The upper end of arm 72 is formed inwardly to provide an inclined surface and a boss 82. The shorter contact arm 74 extends generally parallel to arm 72 and is formed inwardly to provide a spherical surface 76 on its inner side. When two contact terminals are inverted and moved towards each other, the contact arms engage each other as shown in FIG. 9. The boss 76' slides over the surface 80 and flexes the arm 72 inwardly until boss 76 is moved past the contact boss 82. As is apparent from FIG. 9, redundant contacts are achieved at four separate locations and the long and

flexible arms

72, 72 are flexed inwardly by the short and stiff arms 74, 74' to provide the continuing contact pressure required for a low resistance and stable electrical connection.

A shearing plate 84 extends normally of the flange or plate section 70 and parallel to the

plate sections

58, 60. The upper edge 126 of this shearing plate cooperates with an insertion apparatus to sever the conductor being inserted into the slot 64 as will be described below.

The contact terminals 14 are assembled to the housing 4 by merely moving them into the cavities 12 as indicated in FIG. 2. Ears 67, which extend laterally from flange 66, dig into the walls of the cavity as do the laterally extending barbs 86 at each side of the shearing plate 84 so that the contacts will be securely anchored in their respective cavities. The ribs 13 of the cavities are received between the

plate sections

58, 60 ,at the lower ends thereof and support these plate sections against buckling during installation of the connector on conductors. i v

Referring now to FIGS. -12, the conductors 6, 6' are connected to the terminals ,14, 14 by means of an apparatus 101 which has insertion punches 110 (FIG. 11) for pushing the conductors into the conductor receiving portions of aligned terminals in two connector parts. The two connector parts 4, 4' are positioned on a holding jig 88 having a base 90 and a pair of spaced apart L-shaped locating clamps 92, 92. These plates have aligned

recesses

94, 94 which are spaced apart by distances corresponding to the spacing between adjacent cavities 12 in the jconnector parts. Theconnector parts 4 4' are located in side by side relationship between the locating

plates

92, 92" with Their sides against each other with corresponding contact terminals in the two part inalignment with each other, and with the vertical legs 94 of the clamps against the

sides

18, 18. The base 90 has rails 96 on its underside so that it can be slid in grooves 98 on the sides of a fixed rail 100 mounted on the base section 102 of the apparatus 101. The apparatus has a generally U-shaped head frame 104 on which there is provided a forwardly extending arm 106. A ram 108 is mounted in suitable bushings in arms 106 and is resiliently biased upwardly by suitable springs (not specifically shown) against one end 130 of a bell crank 128. A plurality of wire cutting and inserting punches 110 are mounted on the lower end of ram 108, one punch being provided for each pair of aligned terminals 14, 14' in the connector parts. Each insertionand cutting punch 110 has a central recess 112 and depending legs 114,114 on each side of this recess, these legs being substantially identical and mirror images of each other. The leg 114 has a central relatively shallow recess 116 which is adapted to receive the spaced apart plates 158, 160 of the conductor receiving section of the terminal 14 and has on the righthand side of this recess forming or die surfaces 122 on its lower end for curling the arms 68 of the terminal onto the conductor 6. On the lefthand side of recess 116, the leg 114 has an edge 124 which cooperates with upper edge 126 of the previously identified shearing plate 84 of the terminal 114. The

lower edge portions

118, 120 of the leg 1 14 immediately adjacent to the recess l 16 are adapted to engage the conductor and push it downwardly into the conductor receiving slots 64 of the terminal.

The insertion punches on the lower end of the ram are moved downwardly by means of a linkage comprising the previously identified bell crank 128 which is pivoted at 132 between ears 133 extending from the upper surface of the arm 106. Bell crank 128 is pivotally connected by parallel links 134 to a lever arm 136 which in turn has its end pivoted at 138 between additional ears 139 which are integral with the head frame 104. It will be apparent that the ram 108 and therefore the insertion punches 110 can be moved downwardly as viewed in FIG. 12 by merely swinging the lever 136 downwardly from its position as shown.

When conductors are to be attached to terminals in the

connector parts

4, 4, the two connector parts are first positioned on the jig 88. Elongated conductors 6a are then located in each aligned pair of openings 93, 93 in the vertical legs 94, 94' of the locating plates 92,

. V 6 H 92. Conductors located in aligned pairs of slots 93, 93 will extend between the

teeth

24, 26,24, 26 between the

teeth

26, 28, 2'6, 28', and between the

teeth

28, 28

and partial hoods 34, 34.; This operation will locate one conductor above each'aligned pair of

terminals

14, 14 in the two connector parts.

The jig 88 is then slid along the rail until it is against a suitable stop (not specifically shown) and is located beneath the ram 108 withan insertion punch 112 above each conductor 6a. The handle 136 is then swung downwardly to drive thep'unches against the conductors and push the conductors downwardly into the aligned terminals in the connectors. During such downward movement of the punches 110, the conductors are severed by the

edges

126, 124 and 126, 124 of the punches 110 and the shear plates 84, 84'. This severing operation produces a short section 6b of scrap conductor which extends between the aligned terminals and results in the joining of the

conductors

6, 6 to the terminals in the two connector parts. Thereaf ter, the ram is returned to its normal position, the connector parts are removed from the jig 88 and they can be coupled to each other as shown in FIG. 1.

The practice of the invention results in several advantages and economies in the manufacture of electrical harnesses and in the installation of connectors on conductors. A significant advantage is that predetermined conductors are connected to specifically predeter mined terminals in, the connector housings when the conductors are laced through the jig and inserted and trimmed as illustrated in FIGS. 10 and 11. It follows that the possibility of the commission of errors is virtually eliminated with regard to the positions of the wires in the connectors. In other words, after a given conductor 6 has been located in alignment with a predetermined aligned pair of

terminals

14, 14 it is inevitable that the resulting conductors 6,. 6' will be connected to each other when the two connector parts are mated with each other. There can be no errors of the type discussed above of misplacement of conductors in either of the connector housings.

A further advantage of the invention is that there can be no damage to the terminals since they are contained in and protected by the housing. Finally, the time required for location of the conductors 6a in the jig is substantially less than the time required inserting individual terminals into predetermined cavities of a housing in accordance with prior art practice. This is be cause the operation of locating a given one of the conductors 6a above a given pair 14, 14' of terminals actually determines the identity of the conductors which in the completed connector assembly will be connected to the same predetermined pair of terminals. The location of a single conductor 6a thus results in the determination of the locations of two

separate conductors

6, 6 in the housings.

Modifications of the invention within the scope of the appended claims will be apparent to those skilled in the art. For example, the principles of the invention are not necessarily apparent all only to hermaphroditic connectors and terminals although hermaphroditic terminals are advantageous under many circumstances.

We claim:

1. A method of connecting predetermined conductors to predetermined terminals in each of two mateable electrical connectors said connectors having a row of contact terminals therein, each terminal occupying a distinct position in said row in one connector and corresponding to the terminal in the same position in the other connector, each contact terminal having a contact portion and a conductor-receiving portion which is adapted to receive a conductor upon movement of said conductor laterally of its axis towards said conductor receiving portion, said method comprising the steps of:

positioning said connectors adjacent to each other with said row of terminals in each connector extending substantially parallel to the row of terminals in the other connector, and with the said contact portion of each row proximate to the contact portion of the said terminals in the other row and the said wire-receiving portions remote from each other, locating intermediate portions of said conductors across said rows with the axes of each conductor in alignment with the said conductor-receiving portions of two corresponding terminals in each of said rows, said connectors being positioned so that each pair of corresponding terminals is in alignment,

moving said conductors laterally of their axes towards said terminals and securing each conductor to the conductor-receiving portions of two opposed corresponding terminals, and

cutting out the portion of each conductor which extends betwcen each pair of corresponding terminals.

2. The method set forth in claim 1 in which said portion of each conductor is cut out concomitantly with movement of each conductor into said conductorreceiving portions of two corresponding terminals.

3. A method of connecting predetermined conductors to terminals in each of two multi-contact electrical connectors or the like, said connectors being of the type comprising an insulating housing having said contact terminals therein, each of said terminals having a conductor receiving portion which is adapted to receive a conductor upon movement of said conductor laterally of its axis and into said conductor receiving portion, said conductor receiving portions in each of said connectors being arranged in side-by-side relationship in a row, said method comprising the steps of:

positioning said two connectors in side-by-side relationship with said rows of conductor receiving portions extending parallel to each other and with corresponding conductor-receiving portions in said two rows in alignment,

locating said conductors in parallel side-by-side relationship with the axes of said conductors extending normally, and across, said rows and with the spacing between adjacent conductors being equal to the spacing between adjacent conductor-receiving portions in said rows,

severing said conductors along at least one severing line which extends between said rows, and moving said conductors laterally of their axes and into said conductor-receiving portions.

4. The method set forth in claims 3, said rows being spaced apart by a predetermined distance, said severing step being carried out by severing said conductors along two parallel severing lines, each of said severing lines being between said rows and being adjacent to one of said rows.

5. The method set forth in claim 3 in which said portion of each conductor is severed concomitantly with movement of each conductor into said conductorreceiving portions of two corresponding terminals.

l I l

Claims

1. A method of connecting predetermined conductors to predetermined terminals in each of two mateable electrical connectors said connectors having a row of contact terminals therein, each terminal occupying a distinct position in said row in one connector and corresponding to the terminal in the same position in the other connector, each contact terminal having a contact portion and a conductor-receiving portion which is adapted to receive a conductor upon movement of said conductor laterally of its axis towards said conductor receiving portion, said method comprising the steps of: positioning said connectors adjacent to each other with said row of terminals in each connector extending substantially parallel to the row of terminals in the other connector, and with the said contact portion of each row proximate to the contact portion of the said terminals in the other row and the said wire-receiving portions remote from each other, locating intermediate portions of said conductors across said rows with the axes of each conductor in alignment with the said conductor-receiving portions of two corresponding terminals in each of said rows, said connectors being positioned so that each pair of corresponding terminals is in alignment, moving said conductors laterally of their axes towards said terminals and securing each conduCtor to the conductorreceiving portions of two opposed corresponding terminals, and cutting out the portion of each conductor which extends between each pair of corresponding terminals.

2. The method set forth in claim 1 in which said portion of each conductor is cut out concomitantly with movement of each conductor into said conductor-receiving portions of two corresponding terminals.

3. A method of connecting predetermined conductors to terminals in each of two multi-contact electrical connectors or the like, said connectors being of the type comprising an insulating housing having said contact terminals therein, each of said terminals having a conductor receiving portion which is adapted to receive a conductor upon movement of said conductor laterally of its axis and into said conductor receiving portion, said conductor receiving portions in each of said connectors being arranged in side-by-side relationship in a row, said method comprising the steps of: positioning said two connectors in side-by-side relationship with said rows of conductor receiving portions extending parallel to each other and with corresponding conductor-receiving portions in said two rows in alignment, locating said conductors in parallel side-by-side relationship with the axes of said conductors extending normally, and across, said rows and with the spacing between adjacent conductors being equal to the spacing between adjacent conductor-receiving portions in said rows, severing said conductors along at least one severing line which extends between said rows, and moving said conductors laterally of their axes and into said conductor-receiving portions.

5. The method set forth in claim 3 in which said portion of each conductor is severed concomitantly with movement of each conductor into said conductor-receiving portions of two corresponding terminals.