WO1998015988A1 - Electrical interconnection system and a contact therefor - Google Patents

Electrical interconnection system and a contact therefor Download PDF

Info

Publication number
WO1998015988A1
WO1998015988A1 PCT/IB1997/001135 IB9701135W WO9815988A1 WO 1998015988 A1 WO1998015988 A1 WO 1998015988A1 IB 9701135 W IB9701135 W IB 9701135W WO 9815988 A1 WO9815988 A1 WO 9815988A1
Authority
WO
WIPO (PCT)
Prior art keywords
terminal
contact
conductors
support structure
bus line
Prior art date
Application number
PCT/IB1997/001135
Other languages
French (fr)
Inventor
Jean Claude Joly
Original Assignee
The Whitaker Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by The Whitaker Corporation filed Critical The Whitaker Corporation
Priority to GB9907427A priority Critical patent/GB2333907B/en
Priority to AU41332/97A priority patent/AU4133297A/en
Publication of WO1998015988A1 publication Critical patent/WO1998015988A1/en

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
    • H01R4/2416—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type
    • H01R4/242—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type the contact members being plates having a single slot
    • H01R4/2425—Flat plates, e.g. multi-layered flat plates
    • H01R4/2429—Flat plates, e.g. multi-layered flat plates mounted in an insulating base
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
    • H01R12/50—Fixed connections
    • H01R12/59—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures
    • H01R12/61—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures connecting to flexible printed circuits, flat or ribbon cables or like structures
    • H01R12/613—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures connecting to flexible printed circuits, flat or ribbon cables or like structures by means of interconnecting elements
    • H01R12/616—Fixed connections for flexible printed circuits, flat or ribbon cables or like structures connecting to flexible printed circuits, flat or ribbon cables or like structures by means of interconnecting elements having contacts penetrating insulation for making contact with conductors, e.g. needle points
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/24—Connections using contact members penetrating or cutting insulation or cable strands
    • H01R4/2416—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type
    • H01R4/2445—Connections using contact members penetrating or cutting insulation or cable strands the contact members having insulation-cutting edges, e.g. of tuning fork type the contact members having additional means acting on the insulation or the wire, e.g. additional insulation penetrating means, strain relief means or wire cutting knives

Definitions

  • This invention relates to an electrical contact for interconnecting conducting wires or paths, and a system of interconnection using such contacts.
  • a complex harness and wiring system electrically interconnects various components, and provides electrical power and interconnection to components in various positions in the vehicle. It is typical to provide leads with individual conducting wires having connectors on either end for interconnecting components and provide power to various components individually. Due to the number of interconnections and the complexity, assembly of the wiring harness and interconnection leads to the components of the dash board is often effected manually. It would be desirable to provide an interconnection system that is simpler, in particular that is better adapted for automatic assembly to structures such as a frame or support structure of a dashboard.
  • an electrical interconnection system comprising a support and a harness for interconnecting components on the support, the harness comprising a bus line comprising a plurality of conductors for carrying power and signal currents common to a plurality of components, further comprising tap lines for tapping off the bus line to supply power and signal currents to the components, each pair of conductors comprising a conductor of the tap line and a conductor of the bus line being interconnected by single terminals positioned at the junction of the conductor pair.
  • an electrical terminal comprising a first contact section and a second contact section, the first and second contact sections comprising respectively first and second insulation displacing contact slots adapted to cut through the insulation layer of conducting wires and contact inner conducting strands thereof, the slots provided respectively on first and second walls substantially orthogonal to each other.
  • the interconnection system and contact provide a versatile and flexible means of wiring a support structure such as a dashboard, in particular enabling automatic assembly thereof.
  • the single electrical contact is also particularly cost effective to produce.
  • Figure 1 is an isometric view of a support structure being assembled to an electrical interconnection system by an automated assembly machine
  • Figure 2 is a detailed partial view of part of the support structure with electrical interconnection elements thereon;
  • Figure 3 is a more detailed view of contact elements of the interconnection system interconnecting wire conductors
  • Figure 4 is an isometric view of a contact element
  • Figure 5 is a detailed isometric view of a component connector on the support structure connected to tap lines.
  • an interconnection system 2 comprises a support structure 4 on which is mounted a wiring or conductor harness 6 comprising electrical conductors 8 interconnecting electrical connectors 10,12.
  • the conductors 8 are conducting wires comprising a conductive core surrounded by an insulating layer.
  • Conductors of the wiring and harness are arranged in distribution lines 14,15 (hereinafter called bus lines), and tap lines 16.
  • the bus lines 14,15 are interconnected at one or both ends to bus line connectors 12 which are for connection to complementary connectors of an automotive wiring harness that supply power and signal interconnection to the dashboard 4.
  • the bus lines 14,15 thus serve to distribute signal and power, and interconnect the various tap lines 16 to each other and to an external wiring harness (such as that of an automobile) .
  • the tap lines 16 electrically connect tap line connectors 10 (hereinafter called component connectors) to the bus line 14 conductors. Electrical connection of the tap line 16 conductors to the bus line 14,15 conductors is provided by contacts 18.
  • the conductors 8 of the tap line 16 can be terminated to terminals of the component connector 10 at processing stations 20 of an assembly machine 22 adapted to assemble the harness 6 to the support 4. Termination of the conductors to the component connectors can thus be affected separately from the support 4, the component connectors and tap line conductors then being positioned over the support and bus line conductors mounted thereon for connection thereto.
  • a termination device 24 on a main frame 26 of the machine 22 then interconnects the tap line conductors to the bus line conductors.
  • the termination machine 24 is supplied with the contacts 18 in strip form 19 (i.e. the contacts are interconnected on a carrier strip) .
  • the component connectors 10 may be provided with insulation displacing contacts 28, a mating face of the component connector having plugging contacts (not shown) extending from the IDC contacts 28 for plugging directly onto contacts of an electrical component, for example an electrical component such as a clock, lighting control, tachometer, etc. of an automotive dashboard.
  • the IDC contacts of the component connectors 10 enable rapid automated termination of the wire conductors thereto. Providing and terminating the component connectors 10 separately from assembly of the bus line 14 and bus line connectors 12 to the support structure enables versatile and easy adjustment of the automated assembly procedure for various configurations of component connectors and their positioning on the support structure.
  • the interconnection contact 18 is in this embodiment stamped and formed from sheet metal and comprises a first contact section 30 and a second contact section 32 for contacting respectively a first conducting wire and a second conducting wire disposed transversely thereacross.
  • the contact sections are provided as insulation displacement contact (IDC) slots 34,36 that cut through the outer insulating layer of the conductors and contact the inner conducting strands thereof when the wires are pressed into the slots.
  • IDC slots 34 of the first contacting section 30 are provided on opposed substantially planar parallel walls 38 that are perpendicular to substantially parallel and planar walls 40 in which the second IDC slots 36 are formed.
  • the walls thus form a substantially box shaped contact extending from a top or pressure surface end 42 to an opposed wire receiving end 44 in the direction of insertion or termination T of the contact.
  • the IDC slots 34 of the first contact section are positioned at a different height than the IDC slots 36 of the second section with respect to the insertion direction T, such that as best shown in figure 3, a first conductor can be terminated across the first IDC slots 34, and a second conductor positioned orthogonally thereacross can be terminated in the second IDC slots 36.
  • conducting wires of the tap line 16 can be interconnected to conducting wires of the bus line that extend transversely (in this embodiment orthogonal) thereto.
  • retention members 48 Extending beyond the funnel shaped wire entry guides 46 of the IDC slots are retention members 48 at each corner 49 of the box-shape extending to the wire receiving end 44.
  • the retention members 48 act like spears or darts for insertion into plastic, foam or other supple material from which the surface 50 of the support structure 4 is made.
  • the retention members 48 comprise retention protrusions 52 in the form of barbs that grip in the support structure for retaining the terminal 18 thereto.
  • the retention members 48 can be provided with more pointed tips 53 and what is shown in figure 4 if required.
  • the tap line conductors can thus be interconnected to the bus line conductors by stitching the contact 18 with the termination device 24 directly onto the support structure surface 50.
  • a rapid, simple and automated interconnection means is thus provided.
  • the terminals 18 can be individually stitched at any position across the surface of the support structure 4 for a particularly versatile automated procedure. Stitching is also a particular cost effective means whereby secure retention of the conductors of the harness 6 and of the terminals 18 to the support structure is simultaneously affected by providing the retention members 14 piercing into the support structure surface during termination.
  • the tap line conductors are securely retained within the contact slot 34 as a closed end 35 (see figure 4) thereof is towards the top or pressure surface 42 of the terminal, the other end being closed by the support structure. It would also be conceivable to provide insulative housings that are positioned over the terminals 18, and it would also be possible to pre-mount the terminals 18 within an insulative housing which is then terminated to the tap line and bus line conductors.

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  • Connection Or Junction Boxes (AREA)

Abstract

An electrical interconnection system for an automotive dashboard (4) comprises a bus line (14) and tap lines (16) interconnecting the bus line to component connectors (10) that plug into electrical components of the dashboard. Interconnection between tap line conductors and bus line conductors is provided by IDC contacts (18) comprising a substantially box-shaped contact having first IDC slots (36) on first sidewalls, and second IDC slots (34) on orthogonal walls for contacting orthogonally disposed pair of conducting wires. The IDC contact has dart like retention members (48) such that the contact can be stitched directly into the plastic (elastomeric or foam) surface of the automotive dashboard.

Description

ELECTRICAL INTERCONNECTION SYSTEM AND A CONTACT
THEREFOR
This invention relates to an electrical contact for interconnecting conducting wires or paths, and a system of interconnection using such contacts.
In applications such as automotive dashboards, a plurality of electrical components are mounted on one or a few support members or frames. A complex harness and wiring system electrically interconnects various components, and provides electrical power and interconnection to components in various positions in the vehicle. It is typical to provide leads with individual conducting wires having connectors on either end for interconnecting components and provide power to various components individually. Due to the number of interconnections and the complexity, assembly of the wiring harness and interconnection leads to the components of the dash board is often effected manually. It would be desirable to provide an interconnection system that is simpler, in particular that is better adapted for automatic assembly to structures such as a frame or support structure of a dashboard.
It is therefore an object of this invention to provide a simple electrical interconnection system for interconnecting components of a structure such as a dashboard. It would be advantageous if such interconnection system is well adapted for automatic assembly to the structure. It would be further advantageous if the automatic assembly of the interconnection system is flexible and versatile, in the sense that various configurations could be easily provided. It would be further advantageous to provide cost effective interconnection means, for example versatile and cost effective electrical contacts used in such interconnection systems.
Objects of this invention have been achieved by providing an electrical interconnection system according to claim 1 and an electrical contact therefor according to claim 2. In particular, an electrical interconnection system is provided comprising a support and a harness for interconnecting components on the support, the harness comprising a bus line comprising a plurality of conductors for carrying power and signal currents common to a plurality of components, further comprising tap lines for tapping off the bus line to supply power and signal currents to the components, each pair of conductors comprising a conductor of the tap line and a conductor of the bus line being interconnected by single terminals positioned at the junction of the conductor pair. Also, objects are achieved by providing an electrical terminal comprising a first contact section and a second contact section, the first and second contact sections comprising respectively first and second insulation displacing contact slots adapted to cut through the insulation layer of conducting wires and contact inner conducting strands thereof, the slots provided respectively on first and second walls substantially orthogonal to each other. Advantageously therefore, the interconnection system and contact provide a versatile and flexible means of wiring a support structure such as a dashboard, in particular enabling automatic assembly thereof. The single electrical contact is also particularly cost effective to produce.
Further objects and advantageous features of the invention will be apparent from the description, drawings and claims . An embodiment of this invention will now be described by way of example with reference to the figures, whereby;
Figure 1 is an isometric view of a support structure being assembled to an electrical interconnection system by an automated assembly machine;
Figure 2 is a detailed partial view of part of the support structure with electrical interconnection elements thereon;
Figure 3 is a more detailed view of contact elements of the interconnection system interconnecting wire conductors;
Figure 4 is an isometric view of a contact element; and
Figure 5 is a detailed isometric view of a component connector on the support structure connected to tap lines.
Referring to figures 1 and 2, an interconnection system 2 comprises a support structure 4 on which is mounted a wiring or conductor harness 6 comprising electrical conductors 8 interconnecting electrical connectors 10,12. In this embodiment, the conductors 8 are conducting wires comprising a conductive core surrounded by an insulating layer. Conductors of the wiring and harness are arranged in distribution lines 14,15 (hereinafter called bus lines), and tap lines 16. The bus lines 14,15 are interconnected at one or both ends to bus line connectors 12 which are for connection to complementary connectors of an automotive wiring harness that supply power and signal interconnection to the dashboard 4. The bus lines 14,15 thus serve to distribute signal and power, and interconnect the various tap lines 16 to each other and to an external wiring harness (such as that of an automobile) .
The tap lines 16 electrically connect tap line connectors 10 (hereinafter called component connectors) to the bus line 14 conductors. Electrical connection of the tap line 16 conductors to the bus line 14,15 conductors is provided by contacts 18. The conductors 8 of the tap line 16 can be terminated to terminals of the component connector 10 at processing stations 20 of an assembly machine 22 adapted to assemble the harness 6 to the support 4. Termination of the conductors to the component connectors can thus be affected separately from the support 4, the component connectors and tap line conductors then being positioned over the support and bus line conductors mounted thereon for connection thereto. A termination device 24 on a main frame 26 of the machine 22 then interconnects the tap line conductors to the bus line conductors. The termination machine 24 is supplied with the contacts 18 in strip form 19 (i.e. the contacts are interconnected on a carrier strip) .
The component connectors 10 may be provided with insulation displacing contacts 28, a mating face of the component connector having plugging contacts (not shown) extending from the IDC contacts 28 for plugging directly onto contacts of an electrical component, for example an electrical component such as a clock, lighting control, tachometer, etc. of an automotive dashboard. The IDC contacts of the component connectors 10 enable rapid automated termination of the wire conductors thereto. Providing and terminating the component connectors 10 separately from assembly of the bus line 14 and bus line connectors 12 to the support structure enables versatile and easy adjustment of the automated assembly procedure for various configurations of component connectors and their positioning on the support structure.
Referring to figures 1-4, particularly figure 4, the interconnection contact 18 is in this embodiment stamped and formed from sheet metal and comprises a first contact section 30 and a second contact section 32 for contacting respectively a first conducting wire and a second conducting wire disposed transversely thereacross. The contact sections are provided as insulation displacement contact (IDC) slots 34,36 that cut through the outer insulating layer of the conductors and contact the inner conducting strands thereof when the wires are pressed into the slots. The IDC slots 34 of the first contacting section 30 are provided on opposed substantially planar parallel walls 38 that are perpendicular to substantially parallel and planar walls 40 in which the second IDC slots 36 are formed. The walls thus form a substantially box shaped contact extending from a top or pressure surface end 42 to an opposed wire receiving end 44 in the direction of insertion or termination T of the contact. The IDC slots 34 of the first contact section are positioned at a different height than the IDC slots 36 of the second section with respect to the insertion direction T, such that as best shown in figure 3, a first conductor can be terminated across the first IDC slots 34, and a second conductor positioned orthogonally thereacross can be terminated in the second IDC slots 36. In this manner, conducting wires of the tap line 16 can be interconnected to conducting wires of the bus line that extend transversely (in this embodiment orthogonal) thereto. Extending beyond the funnel shaped wire entry guides 46 of the IDC slots are retention members 48 at each corner 49 of the box-shape extending to the wire receiving end 44. The retention members 48 act like spears or darts for insertion into plastic, foam or other supple material from which the surface 50 of the support structure 4 is made. The retention members 48 comprise retention protrusions 52 in the form of barbs that grip in the support structure for retaining the terminal 18 thereto. The retention members 48 can be provided with more pointed tips 53 and what is shown in figure 4 if required.
The tap line conductors can thus be interconnected to the bus line conductors by stitching the contact 18 with the termination device 24 directly onto the support structure surface 50. A rapid, simple and automated interconnection means is thus provided. Furthermore, by computer controlled positioning of the stitching apparatus, the terminals 18 can be individually stitched at any position across the surface of the support structure 4 for a particularly versatile automated procedure. Stitching is also a particular cost effective means whereby secure retention of the conductors of the harness 6 and of the terminals 18 to the support structure is simultaneously affected by providing the retention members 14 piercing into the support structure surface during termination. Additionally, the tap line conductors are securely retained within the contact slot 34 as a closed end 35 (see figure 4) thereof is towards the top or pressure surface 42 of the terminal, the other end being closed by the support structure. It would also be conceivable to provide insulative housings that are positioned over the terminals 18, and it would also be possible to pre-mount the terminals 18 within an insulative housing which is then terminated to the tap line and bus line conductors.

Claims

1. An electrical interconnection system (2) comprising a support (4) and a harness (6) for interconnecting components on the support, the harness comprising a bus line (14,15) comprising a plurality of conductors (8) for carrying power and signal currents common to a plurality of components, further comprising tap lines (16) for tapping off the bus line to supply power and signal currents to the components, each pair of conductors comprising a conductor of the tap line and a conductor of the bus line conductor interconnected by single terminals (18) positioned at the junction of the conductor pair.
2. An electrical terminal (18) extending in a termination direction (T) from a top end (42) to a wire receiving end
(44) comprising a first contact section (30) and a second contact section (32) , the first and second contact sections comprising respectively first and second insulation displacing contact (IDC) slots (32,34) adapted to cut through an outer insulation layer of conducting wires and contact inner conducting strands thereof, the slots provided respectively on first and second walls (38,40) substantially orthogonal to each other.
3. The terminal of claim 2 wherein the first slot extends from a position proximate the top end (42), and the second lot extends from a position more distant from the top end, towards the terminal receiving end in the termination direction (T) .
4. The terminal of claim 2 or 3 wherein the terminal has a pair of opposed first walls (38) and a pair of opposed second wall (40) orthogonal thereto substantially forming a box-shape .
5. The terminal of any one of claims 2-4 wherein the terminal has one or more retention members (48) for securing the terminal to an insulative support structure.
6. The terminal of claim 5 wherein the retention member comprises an extension projecting beyond the IDC slots towards the wire receiving end (44), the extension having locking protrusions (52) for locking to the support structure.
7. The terminal of claim 6 wherein the locking protrusions are disposed proximate a piercing tip (53) of the retention member arranged at the wire receiving end (44) for piercing and locking into a supple material such that the terminal can be stitched onto a support structure and retained thereto by the protrusions.
8. The interconnection system of claim 1 wherein the terminal interconnecting the bus and tap line conductors is a terminal according to any one of claims 2-7.
9. The interconnection system of claim 8 wherein pairs of bus and tap line conductors are arranged substantially orthogonally at their junctions, and are interconnected together and stitched to the support structure by the terminals (18) .
PCT/IB1997/001135 1996-10-04 1997-09-22 Electrical interconnection system and a contact therefor WO1998015988A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB9907427A GB2333907B (en) 1996-10-04 1997-09-22 Electrical interconnection system and a terminal therefor
AU41332/97A AU4133297A (en) 1996-10-04 1997-09-22 Electrical interconnection system and a contact therefor

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP96402132 1996-10-04
EP96402132.3 1996-10-04

Publications (1)

Publication Number Publication Date
WO1998015988A1 true WO1998015988A1 (en) 1998-04-16

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ID=8225295

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB1997/001135 WO1998015988A1 (en) 1996-10-04 1997-09-22 Electrical interconnection system and a contact therefor

Country Status (3)

Country Link
AU (1) AU4133297A (en)
GB (1) GB2333907B (en)
WO (1) WO1998015988A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10238479A1 (en) * 2002-08-22 2004-03-04 Wieland Electric Gmbh Connection connector and electrical distributor

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2264216A1 (en) * 1972-12-30 1974-07-11 Bbc Brown Boveri & Cie ELECTRICAL INSTALLATION SYSTEM
US4364622A (en) * 1980-05-09 1982-12-21 Minnesota Mining And Manufacturing Company Connector for flat cable
EP0100602A1 (en) * 1982-07-23 1984-02-15 AMP INCORPORATED (a New Jersey corporation) Electrical bus interconnection system
EP0191977A1 (en) * 1985-02-04 1986-08-27 Molex Incorporated Improvements in and relating to multi-row electrical connectors and methods of making same

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2264216A1 (en) * 1972-12-30 1974-07-11 Bbc Brown Boveri & Cie ELECTRICAL INSTALLATION SYSTEM
US4364622A (en) * 1980-05-09 1982-12-21 Minnesota Mining And Manufacturing Company Connector for flat cable
EP0100602A1 (en) * 1982-07-23 1984-02-15 AMP INCORPORATED (a New Jersey corporation) Electrical bus interconnection system
EP0191977A1 (en) * 1985-02-04 1986-08-27 Molex Incorporated Improvements in and relating to multi-row electrical connectors and methods of making same

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10238479A1 (en) * 2002-08-22 2004-03-04 Wieland Electric Gmbh Connection connector and electrical distributor
DE10238479B4 (en) * 2002-08-22 2006-03-23 Wieland Electric Gmbh Electric distributor

Also Published As

Publication number Publication date
GB2333907A (en) 1999-08-04
AU4133297A (en) 1998-05-05
GB2333907B (en) 2000-11-08
GB9907427D0 (en) 1999-05-26

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