WO2000001037A1

WO2000001037A1 - Multi-conductor cable connector with increased dielectric isolation between adjacent contacts

Info

Publication number: WO2000001037A1
Application number: PCT/US1999/014112
Authority: WO
Inventors: Art Jochen; Roger D. Lang; John A. C. Mcallister
Original assignee: Circuit Assembly Corp.
Priority date: 1998-06-26
Filing date: 1999-06-23
Publication date: 2000-01-06
Also published as: TW457745B; AU4708299A

Abstract

A connector (100) for a high density multi-conductor ribbon cable (122). The connector in one embodiment includes a cover (104) and a base member (102) includes indentations (112, 116) that are adapted to receive the ribbon cable and position the ribbon cable in a desired orientation with respect to openings that communicate with the indentation when the ribbon cable is captured between the cover member and the base member. A plurality of contacts (130) are then connected to the conductors of the captured ribbon cable via the openings that communicate with the indentations. In one embodiment, the openings in the base member include a guide section that is adapted to guide the contacts into the conductors of the ribbon cable during the insertion process. In another embodiment, the connector includes a plurality of contacts where the contacts have at least one indentation that is adapted to increase the distance between the outer surface of the contact and an adjacent conductor when the contact is connected to a conductor of the ribbon cable. The at least one indentation is further adapted to receive displaced insulation surrounding the conductor so as to improve isolation between the contacts and adjacent conductors or contacts and further reduce the stress on the insulation that could result in cold flow of the insulation over time.

Description

MULTI-CONDUCTOR CABLE CONNECTOR WITH INCREASED DIELECTRIC ISOLATION BETWEEN ADJACENT

CONTACTS

Background of the Invention Field of the Invention The present invention relates to connectors configured to connect to multi-conductor ribbon cable and, in particular, concerns a connector that is configured to connect to conductors within a high density multi-conductor ribbon cable in a more efficient and accurate manner. Description of the Related Art

Ribbon cable is a type of cable which has a plurality of conductors positioned adjacent to each other in a single plane. Typically, conductors are encased in a flexible insulating material, such as vinyl, which follows the contours of the parallel, closely spaced conductors in the ribbon cable. Ribbon cable is often used to interconnect computer components. One common example of the use of ribbon cable is to connect motherboards in personal computers to disk drives. Ribbon cable is also often used to interconnect computers to accessory equipment.

Generally, connectors are used to interconnect the cables to various devices. These connectors have a plurality of contacts which are configured to contact the conductors within the ribbon cable and also to provide a pin connection to a mating connector or printed circuit board. Typically, the connector includes a plurality of contacts that have an insulation displacement end that pierces the insulation surrounding the conductor in the ribbon cable and contacts the embedded conductor, and a mating section that provides a connection point for pins of a mating connector or printed circuit board.

The typical connector is generally rectangular in shape and has an opening which receives the ribbon cable so that the connector spans the width of the ribbon cable. The insulation displacement ends of the plurality of contacts are positioned within the connector so that when the connector is closed around the ribbon cable, the insulation displacement end pierces the insulation surrounding the conductors of the ribbon cable and forms an electrical connection with each of the conductors within the ribbon cable. The contacts are preferably exactly positioned within the connector so as to be able to contact and make an electrical connection with the corresponding conductor within the ribbon cable. However, currently available connectors for higher density ribbon cables suffer from several problems. One such problem stems from the relatively small size of the conductors and their relatively close position to each other. The tolerances between the contacts in the connector must be very exact to ensure that each contact is being connected to only its' intended conductor. However, the conductors in the cable are also prone to be slightly misaligned as a result of manufacturing tolerances. This can result in the contacts making inadvertent contact with adjacent conductors or not making adequate contact with the intended conductors. Hence, there is a need for a connector that is capable of correctly orienting the conductors with respect to the contacts to ensure better connection between the contact and the conductor.

Moreover, the contacts in the connectors that are configured to be attached to the higher density ribbon cables are generally smaller in size. One difficulty associated with these smaller contacts is that the insulation displacement ends of the contacts are more likely to bend during the attachment of the connector to the ribbon cable. As the conductors within the high density ribbon cables are closer together, this can result in the contacts making electrical connection to conductors other than the intended conductor. Further, as the conductors are positioned closer together, the tolerances in the connector are much smaller. It is important that the conductors of the ribbon cable be exactly aligned with respect to the connector to ensure that the contacts in the connector make good electrical connections to the contacts. Consequently, the higher density ribbon cable connectors that are currently available are less reliable as accurate connection between the contacts and the conductors is more problematic.

Another problem of prior art connectors is that the manufacturing and assembling cost of these connectors is relatively high. Specifically, these connectors typically use multiple rows of contacts that are positioned within the connector in a position where they can connect to corresponding conductors within the ribbon cable. For example, with the old forty conductor ribbon cable, there would be two rows of 20 contacts positioned in the connector so as to connect to the ribbon cable conductors. With the higher density ribbon cables, there is often three or four rows of contacts positioned within the connector to connect to each of the ribbon cable conductors.

The greater the number of rows of contacts in the connector increases the assembly cost of the connector. Specifically, the contacts that are positioned within the connectors are typically provided in rows that are ganged together. If the connector is configured to have more rows of contacts, then more rows of contacts must be positioned into the corresponding receptacles in the connectors. For example, a single prior art connector that connects to a ribbon cable having sixty-eight conductors spaced on 0.025" centers may have four parallel rows of contacts that are spaced on 0.100" centers so that the four separate rows of contacts make electrical contact with the conductors in the ribbon cable. This requires that the assembler of the device position four separate rows of contacts into receptacles formed in the connector during the assembly process. Moreover, there are typically only two rows of mating sections of the contacts that are positioned within the connector so as to be connected to an external connector or printed circuit board. The assembly of a connector having four rows of insulation displacement ends configured to make electrical connection with the ribbon cable, but only two rows of mating sections greatly complicates the assembly of the connector.

Further, the greater number of rows of contacts for each connector also results in a higher manufacturing cost. Specifically, each row of contacts must be plated with a conductive material such as gold. The cost of plating is highly dependent upon linear feet of material to be plated. As each row of contacts have the same length, multiplying the number of rows by four results in a four-fold increase in the plating cost of producing the contacts. Moreover, the overall cost of the connectors is also increased as a result of the greater usage of the base metal forming the contacts.

Moreover, the increasing density of the conductors also results in the insulation displacement ends of contacts being positioned closer to adjacent conductors. Typically, there is an insulation material which surrounds each of the conductors that provides electrical isolation between adjacent conductors. When the connector is installed on the conductors, the insulation displacement ends of each of the contacts preferably displace the insulation away from the conductor that the contact is to connect with but still maintain the insulation between the contact and the adjacent conductors so as to avoid inadvertent electrical connection with those conductors. However, with the increasing density of the conductors, the conductors are separated by smaller and smaller amounts of insulation material. Consequently, when the connectors are installed on higher density cables, the amount of insulation between the insulation displacement end of the contacts and the adjacent conductor is significantly smaller. With the smaller amount of insulation material between adjacent conductors, the conductors are more likely to cold flow as a result of the installation of the contacts into the conductors such that the adjacent conductor may contact the insulation displacement end of the contact thereby shorting two conductors together.

Specifically, with typical prior art connectors for multi-ribbon cables, when the insulation displacement end of the contact is inserted through the insulation surrounding a particular conductor, the conductor is generally urged outward from the plane of the adjacent conductors. The insulation displacement end of the contact is generally inserted in a direction that is normal to the plane of the ribbon cable conductors and the interaction between the insulation surrounding the conductor and the insulation displacement ends of the contact results in the conductor that is to be engaged by the contact being displaced from the plane of the adjacent conductors. The insulation that is positioned between the outer edge of the insulation displacement end of the contact and the adjacent conductor is therefore under strain as a result of the displacement of the conductor from the plane by the insertion of the insulation displacement ends of the contact. This strain can result in the insulation cold flowing over time such that the amount of insulation between the outer edge of the insulation displacement ends of the contact and the adjacent conductor is insufficient to prevent shorting between the contact and the adjacent conductor.

A further difficulty that is experienced with multi-ribbon cable connectors of the prior art is that, with the increasing complexity of electronic devices, the connectors often consume a significant quantity of limited space within the electronic device. The typical prior art multi-ribbon cable connector generally has a base member that houses the contacts so that the insulation displacement ends of the contacts extend out of a first side of the base member and external connection to the contacts can be made via a second side of the base member. A retainer is preferably positioned adjacent the first side of the base member and the retainer is preferably adapted to guide the insulation displacement ends of the contacts into the conductors of the multi-ribbon cable. Hence, the retainer typically has a plurality of openings that receive the insulation displacement ends of the contacts so that the insulation displacement ends of the contacts protrude beyond the outer surface of the retainer. The connector also includes a cover which is adapted to be positioned adjacent the outer surface of the conductor so as to define a multi-ribbon cable retaining space that is adapted to receive the multi-ribbon cable therebetween.

However, oftentimes, connectors of the prior art are too large for particular applications. Some of the dimensions of the connector are dictated by the multi-ribbon cable. In particular, the connectors typically are as wide as the multi-ribbon cable so that a contact can make connection with each of the conductors in the planar multi-ribbon cable. However, the height dimension of the connector often creates difficulties for the designer of electronic devices as the housing and spacing of the boards within the electronic device must be made to accommodate the height of the cover, retainer, and base member collectively. In some applications this results in the electronic devices having to be made larger to accommodate the greater dimensions of the connector or it results in the connector being positioned very closely between surfaces which can result in assembly difficulties or even shorting between adjacent electronic components within the device.

From the foregoing it will be appreciated that there is a need for a connector that is configured to be attached to high density ribbon cables that is less expensive and more reliable than currently available connectors. To this end, there is a need for a connector which is cheaper to manufacture and assemble and is also less likely to be damaged during the installation process in a manner that would result in contacts becoming misconnected to conductors within the high density ribbon cable. Moreover, there is a need for a multi-ribbon cable connector that provides enhanced isolation between contacts and adjacent connectors. Further, there is also a need for connectors having smaller dimensions. Summary of the Invention

The aforementioned needs are satisfied by the connector of the present invention which, in one embodiment, is comprised of a retainer having a plurality of openings formed therein, a cover member that is configured to be positioned adjacent the retainer so that a cable receiving area is defined between the cover member and the retainer, and a plurality of contacts wherein the plurality of contacts have a first end that is attached to a carrier so as to form a single row of first ends of the contacts and a second end which is configured to make electrical connection with the conductors of the high density ribbon cable. The retainer and the cover are configured so that the ribbon cable receiving area is comprised of conductor spaces that receive each of the conductors in the ribbon cable. The retainer and cover are further configured to urge each of the conductors into a fixed orientation in the conductor space and the retainer has an opening for each of the plurality of contacts that guides the contacts into the conductor space so that the contact makes electrical contact with the conductor positioned in the space.

In one embodiment, the mating surfaces of the retainer and the cover have indentations that match the contours of the insulation surrounding each of the conductors forming the ribbon cable. When the retainer and the cover are compressed together, the indentations engage with the contours of insulation surrounding each of the conductors so as to precisely locate the conductors in the conductor spaces. The retainer preferably has openings for each conductor space that receive the contacts and guide the contacts so that the plurality of contacts make electrical contact with all of the conductors in the ribbon cable.

In another embodiment, the retainer has openings that receive an insulation displacement end of each of the contacts. The openings are configured so that the insulation displacement ends of the plurality of contacts are confined within the openings in the retainers so that the insulation displacement ends are directed into the corresponding conductors within the ribbon cable that is positioned within the ribbon cable receiving area. Further, the surface of the retainer and the cover that define the ribbon cable receiving area are preferably contoured so as to match the contours of the insulation surrounding the high density ribbon cable.

When the insulation displacement members are inserted through the retainer into the conductors, the cover and the retainer are preferably compressed so that individual ones of the conductors are centered within the space defined by contours of the cover and the retainer while the insulation displacement ends are simultaneously urged into the space defined by the contours of the cover and the retainer. Specifically, the plurality of contacts are also positioned in a base member which urges each of the contacts so that each insulation displacement end of a contact is directed through an opening in the retainer that opens into one of the contoured spaces. Consequently, the compression of the retainer, the cover and the base results in the conductors being centered in the contoured space while simultaneously driving the insulation displacement ends of the contacts into the conductors. This helps to ensure that the insulation displacement ends of the contacts is directed only into the appropriate corresponding conductor within the high density ribbon cable.

In one embodiment, the ends of the plurality of contacts that are positioned in the retainer so as to make contact with the conductors includes at least one tab that makes contact with the inner surfaces of the openings in the retainer. The tabs on each of the contacts are located and dimensioned so that, when the plurality of contacts are positioned in the retainer, the tabs support and stabilize the retainer during compression the ribbon cable. The tabs are either deformed or driven into the retainer material in response to the cover and the retainer being compressed together, however, the tabs stabilize the retainer during the compression of the cover and the retainer thereby facilitating the urging of the conductors into their respective fixed orientations within the spaces defined by the retainer and cover. In effect, the tabs support the retainer to thereby allow the cover to be urged against the retainer with greater force.

In another embodiment, the plurality of contacts are formed so that when the contacts are attached to the carrier they define two parallel rows of second ends that are configured to be mounted within the retainers for subsequent electrical connection to the conductors within the ribbon cable. It will be appreciated that since the contacts are initially positioned in the carrier they define two parallel rows of second ends configured to make electrical connection with the conductors in the ribbon cable, that the assembly of the connector of the present invention is simplified. In particular, the number of rows of contacts that must be positioned within the retainer or like device is reduced by one-half. Further, since a greater number of individual contacts are positioned on a single carrier, the cost of the base metal as well as the cost of plating the contacts with a conductive material such as gold is thereby reduced. The connector of this embodiment also preferably includes a base that is configured to receive the first ends of the plurality of contacts once the carrier has been removed from the first end of the plurality of contacts.

In another aspect of the present invention, a method of attaching a connector to a high density ribbon cable is provided. In particular, a plurality of contacts, wherein the plurality of contacts has a first end and a second end and is arranged so that the first ends of each of the contacts are aligned in a single row and attached to a carrier and the second ends of the plurality of contacts define two separate parallel rows, is positioned within the retainer so that the two parallel rows of second ends of the plurality of contacts are positioned within openings in the retainer. The carrier attached to the first ends of the plurality of contacts is then removed and the first end of the contacts are then positioned within a base member with the base member being located on a first side of the retainer. The high density ribbon cable is then positioned adjacent a second side of the retainer and a cover is positioned adjacent the other side of the ribbon cable. Subsequently, the cover, retainer and ribbon cable are all compressed together so that the plurality of second ends of the contacts are urged through the openings in the retainer so as to displace the insulation of the conductor in a well known fashion and make electrical contact with the plurality of conductors within the high density ribbon cable.

It will be appreciated that this method of attaching a connector to a multi-conductor cable is simplified in that two rows of second ends of contacts are simultaneously positioned within the retainer as a result of the first ends of the retainers being attached to a carrier so as to be aligned in a single row. In one preferred method of assembly, the retainer and the cover are configured so as to be contoured so that the ribbon cable is compressed therebetween during assembly of the connector. This preferably results in the conductors being precisely located within the spaces between the retainer and the cover to thereby facilitate accurate placement of the second ends of the plurality of contacts into selected conductors within the ribbon cable. In another aspect of the invention, a connector having a base member and a cover assembly is provided. In this aspect of the invention, the base member and the cover define the cable receiving area and preferably the inner surfaces of the base member and the cover are contoured so as to define a contoured space for each of the conductors in the multi- conductor ribbon cable. In this aspect of the invention, the connector also includes a plurality of contacts having insulation displacement ends that are sized so as to be positioned within the base member prior to the connection of the connector to the ribbon cable. In one embodiment, the contacts and the base member are sized so that the insulation displacement end of each of the contacts is captured within the base immediately prior to the compression of the ribbon cable between the contoured surfaces of the base and cover members so that the insulation displacement ends of the contacts are retained in a desired orientation with respect to each of the conductors while the conductors are being located within the contoured spaces during the compression of the cover with the base member. In this embodiment, the base member essentially acts as the retainer in retaining the insulation displacement ends in their proper position with respect to the contoured spaces that are to receive the conductors and thereby facilitate the correct positioning of the insulation displacement ends in the conductors. By selecting the length of the contacts and the height of the base member, the overall height of the connector assembly can therefore be reduced to accommodate different uses in different environments for the connector. In another aspect of the invention, a connector that is adapted to a multi-conductor ribbon cable is provided. In this aspect of the invention, the connector includes a plurality of contacts that have insulation displacement ends that are adapted to displace the insulation surrounding the conductors of the multi-conductor ribbon cable and electrically connect to the embedded conductor. The insulation displacement ends are preferably configured so that when the connector is attached to the multi-ribbon cable conductor and the insulation displacement ends of the contacts are engaged with the conductors of the ribbon cable, a greater amount of insulation is maintained between the outer edges of the insulation displacement ends of the contact and the adjacent conductor in the plane of the conductors comprising the multi-conductor ribbon cable. In this configuration, the insulation displacement ends of the contacts are preferably adapted to reduce the tendency of the insulation to cold flow over time after the connector has been installed on the multi-ribbon cable. In one embodiment, each of the plurality of contacts have an insulation displacement end with two tines. At the outer surfaces of each of the tines, an indentation is formed at a position that will be positioned in the plane of the conductors in the multi-conductor ribbon cable when the connector is installed on the multi-conductor ribbon cable with the insulation displacement ends making contact with the individual conductors. The indentation is preferably sized and contoured so as to increase the amount of insulation between the nearest surface of the outer edge of the insulation displacement ends and the adjacent conductors. This results in less strain being applied to the insulation positioned between the contact and the adjacent conductors in the multi-conductor ribbon cable which further reduces the amount of cold flow of the insulation over time.

From the foregoing, it will be appreciated that the connector of the present invention facilitates the attachment of the connector to high density ribbon cable by more accurately locating the conductors to receive the contacts. Further, the connector of this embodiment offers greater support to the ends of the plurality of contacts that are to be connected to the conductors thereby reducing the likelihood that the second ends will be deformed during installation of the connector resulting in inaccurate connection. The connector also reduces the costs of manufacturing and assembling the connector. Moreover, the connectors of the illustrated embodiments can also be adapted so as to have smaller dimensions but still allow for reliable connection to the conductors of the multi-conductor ribbon cable. Further, one embodiment of the connector is adapted to provide enhanced insulation between the contacts and adjacent conductors within the multi- conductor ribbon cable. These and other objects and advantages of the present invention will become more fully apparent from the following description taken in conjunction with the accompanying drawings.

Brief Description of the Drawings Figure 1 is a partially cut-away perspective view of one embodiment of a connector;

Figure 2 is a perspective view of a cover of the connector of Figure 1; Figure 3 is a perspective view of a retainer that is used in the connector of Figure 1; Figure 4 is a perspective view of a base member of the connector of Figure 1;

Figures 5A-5C are isometric illustrations of a plurality of contacts positioned within a carrier member that comprise a portion of the connector of Figure 1;

Figures 6A-6C are isometric views further illustrating one of the plurality of contacts shown in Figures 5A-5C; Figures 7A-7C are isometric illustrations illustrating the attachment of the connector of Figure 1 to a ribbon cable;

Figure 8A is a sectional view of the connector of Figure 1 illustrating the attachment of the plurality of contacts to the conductors of the high density ribbon cable;

Figure 8B is a sectional view of the connector of Figure 1, illustrating one preferred configuration of the contacts of Figures 5A-5C during attachment of the connector to the multi-conductor ribbon cable;

Figure 9 is an isometric view illustrating the configuration of the plurality of contacts as it is positioned within the base and the retainer of the connector of Figure 1; Figures 10A-10D are isometric illustrations of another embodiment of a connector of the present invention illustrating this embodiment of the connector in an assembled and disassembled state;

Figures 11A-11 C are isometric illustrations illustrating the configuration of a second embodiment of a plurality of contacts that are adapted to be used with the connector of either Figure 1 or Figures 10A-10D; Figures 12A- 12D are isometric illustrations further illustrating the contacts of Figures 11 A- 11 C; and

Figures 13A and 13B are sectional views of the contacts of Figures 11A-11C as positioned within a base member and connected to conductors of a multi-ribbon cable conductor assembly.

Detailed Description of the Preferred Embodiments

Reference will now be made to the drawings wherein like numerals refer to like parts throughout. Referring initially to Figure 1, the connector 100 incorporates a base member 102 that is attached to a cover 104, in a manner that will be described herein below, and a retainer 106 that is interposed between the base member 102 and the cover 104.

The cover 104 has an inner surface 110 that has a plurality of indentations 112 that are configured to receive ridges 121 of insulation surrounding each individual conductor 124 within the ribbon cable 122. Similarly, the retainer 106 also includes an inner surface 114 that has a plurality of indentations 116 that are also configured to receive the ridges 121 of the insulation surrounding the individual conductors of the ribbon cable 122. Collectively, the inner surface 110 of the cover 104 and the inner surface 114 of the retainer 106 define a receiving area 120 for the ribbon cable 122.

As will be described in greater detail below, the ribbon cable 122 is positioned within the receiving area 120 and the indentations 112 and 116 are configured to urge the ribbon cable 122 into a fixed orientation with respect to the inner surface 110 of the cover 104 and the inner surface 114 of the retainer 106. Specifically, the indentations 112 and 116 are configured so as to center each conductor 124 within a space 126 between the indentations 112 and 116.

Consequently, when the ribbon cable 122 is captured between the covers 104 and the retainer 106, each of the conductors 124 within the ribbon cable 120 is fixed in the precise location with respect to the cover 104 and the retainer 106.

The typical high density ribbon cable has a plurality of conductors or wires 124 that are arranged so as to be spaced parallel to each other and surrounded by insulation. The insulation is typically a vinyl insulation that is contoured around each conductor 124 thereby forming the ridges 121 shown in Figure 1. The insulation further provides electrical insulation between each of the conductors 124. In the illustrated embodiment, the connector 100 is configured to receive high density ribbon cable which incorporates a plurality of conductors (in this example, sixty-eight) that are spaced on approximately 0.025" centers. As is also shown in the partial cut-away section of Figure 1, a plurality of contacts 130 are mounted within the base 102 in an orientation so that the contacts 130 make electrical contact with the conductors 124 and the ribbon cable 122. in this embodiment, the contacts 130 are arranged so that there are four parallel rows of insulation displacement ends that make contact with the conductors 124 and the ribbon cable 122. However, as will be described in greater detail below in reference to Figure 9, the contacts 130 are arranged so that there are two parallel rows of mating sections 140 that are positioned within the base 102 of the connector 100.

Figure 1 also illustrates the basic configuration of the contacts 130. The configuration of the contacts 130 will be described in greater detail below, however, Figure 1 illustrates that the contacts 130 have an insulation displacement end 134 and a mating section 140. The insulation displacement end 134 is essentially comprised of two blades 136. The two blades 136 are configured to displace, in a well-known manner, the insulation 121 surrounding the conductors 124 in the ribbon cable 122 so that the inner surfaces of the two blades 136 make contact with the conductor 124 that is captured in the space 126. In Figure 1, the insulation 121 surrounding the conductors 124 has been stripped away for illustration purposes, however, it will be appreciated that the contacts 130 displace the insulation to make contact with the conductor 124 in a well known manner. Further, the mating section 140 of each of the contacts 130 extend into the base 102 of the connector 100 and is configured to be connected to a pin on an external mating connector or a printed circuit board. Specifically, as shown in Figure 1, the mating section 140 is exposed via an opening 142 (See, Figure 9) so that pins or pin contact members can be positioned within the opening 142 to make electrical contact with the contacts 130. The exact configuration of the contacts 130 will be described in greater detail hereinbelow. Figure 2 illustrates the cover member 104 in greater detail. As shown in Figure 1, the ribbon cable 122 is positioned along the length of the cover member 104 so that the conductors 124 within the ribbon cable 122 are preferably centered within the indentations 114 on the inner surface 110 of the cover 104.

As is shown in Figure 2, a plurality of openings 144 are preferably formed through the cover member 104. The openings 144 are spaced to receive the blades 136 of the insulation displacement end 134 of the contacts 130. Specifically, after the blades 136 have penetrated through the insulation surrounding the conductors 124 within the ribbon cable 122, the blades 136 preferably extend into the openings 144 in the manner shown in Figure 1. Hence, the openings 144 preferably capture the blades 136 in a space defined by the openings 144 so that the blades 136 on adjacent contacts 130 are less likely to be bent during insertion of the contacts, or by subsequent manipulation of the connector 100, to contact adjacent contacts 130. Consequently, there are four rows of openings 144 in the cover that are configured to receive the blades 136 of the insulation displacement ends 134 of the contacts 130.

At both ends 147a and 147b of the cover 104, there are two blocks 148a and 148b which extend outward from the inner surface 110 of the cover 104. The two blocks 148a and 148b are used to secure the cover 104 to the retainer 106 and the base member 102 in a manner that will be described in greater detail below.

Figure 3 illustrates the retainer 106 in greater detail. Figure 3 illustrates the inner surface 114 of the retainer 106 with the indentations 116. Specifically, there are sixty-eight indentations 116 formed on the inner surface 114 of the retainer 106 in this embodiment. The retainer 106 is dimensioned so as to sit adjacent the inner surface 110 of the cover 104 in the manner that is shown in Figure 1. As is also shown in Figure 3, there is a plurality of openings 154 extending through the retainer 106 so that each indentation 116 has a single opening 154 formed therein. The openings 154 in the retainer 106 have the same patterns as the openings 144 in the cover member 104. Specifically, the openings 154 are configured to receive the insulation displacement ends 134 of the contacts 130 and to guide the insulation ends 134 into the appropriate space 126 to thereby make an electrical connection to an appropriate conductor 124 in the ribbon cable 122. As shown in Figure 3, there is one opening 154 per indentation 116 on the inner surface 114 of the retainer 106. Further, the openings 154 are preferably spaced in each row 0.010" apart on center. The overall pattern of openings 154 is configured so that adjacent openings 154 in each row correspond to every fourth conductor 124 in the ribbon cable 122.

The retainer 106 ensures that the insulation displacement ends 134 of the contacts 130 are retained in their desired orientation such that the blades 136 are respectively positioned in the appropriate spaces 126 defined by the indentations 112 and 116 in the manner that is shown in Figure 1. It will be appreciated that forcing the blades 132 through the insulation 121 on the ribbon cable 122 so as to contact each of the conductors 124 within the ribbon cable 122 requires that there be a significant amount of force exerted on the plurality of contacts 130 by the base 102. This force can result in the contacts 130 being bent so that the insulation displacement ends 134 of the contacts 130 do not make electrical contact with the corresponding conductors 124 in the space 126 but may, in fact, make unintended contact with adjacent conductors. However, the retainer 106 is configured to guide the blades 136 into the appropriate conductors 124 in the manner that will be described in greater detail in reference to Figures 7A-7C. As is also shown in Figure 3, two posts 162a and 162b extend from the ends 161a and 161b of an outer surface

160 of the retainer 106. The posts 162a and 162b are used to secure the retainer to the base 102 with the cover 104 secured to the retainer 106 in the manner that will be described in greater detail below in reference to Figures 7A-7C.

The base 102 of the connector 100 is illustrated in Figures 4 and 7A-7C. Specifically referring to Figure 4, an inner surface 166 of the base of the connector 100 is shown. There are two parallel rows of openings 143 that are formed on the inner surface 166 of the base 102. The openings 143 in this embodiment are generally rectangular in shape and are configured to receive the mating sections 140 of each of the contacts 130. Specifically, the mating sections 140 of the contacts 130 extend upward into the openings 143 into the interior of the base 102 and are preferably configured to receive pin contacts from mating connectors, mating printed circuit boards, or any other device that is used to interconnect the ribbon cable connectors via the opening 142 (Figure 9) on the outer surface 107 of the base 102. As is shown in Figure 4, there are two rows of thirty-four openings that provide access to the mating sections 140 of the sixty-eight contacts

130. It will be appreciated, however, that the exact configuration and placement of the openings 143 can vary depending upon the implementation of the connector 100.

As is also shown in Figure 4, both ends 168a and 168b of the base member 102 of the connector 100 include a coupling groove 170 and a latching member 172 that is positioned the sides of the base member 102. The coupling groove 170 is configured to receive the posts 162a and 162b of the retainer 106 to retain the retainer 106 so that the surface

160 of the retainer 106 is positioned adjacent the surface 166 of the base 102 in a well-known manner. Similarly, the outwardly extending members 172a and 172b are also configured to mate with the blocks 148a and 148b of the cover 104 so as to retain the inner surface 110 of the cover 104 adjacent the inner surface 114 of the retainer 106 in a well- known manner. It will be understood that the exact mechanism for securing the base 102, the cover 104 and the retainer 106 together in the manner shown in Figure 1 can be any of a number of well-known methods of securing components of connectors together without departing from the spirit of the present invention.

Figures 5A-5C and Figures 6A-6C illustrate the configuration of the plurality of contacts 130 in greater detail. As shown in Figure 5A, the plurality of contacts 130 are initially attached to a carrier 180. Specifically, a first end 182 of the mating sections 140 of each of the plurality of contacts 130 is connected to the carrier 180. The connection between the carrier 180 and the first end 182 of the mating section 140 is preferably perforated to allow for easy removal of the carrier 180 from the plurality of contacts 130 in the manner that will be described in greater detail below. The plurality of contacts 130 are preferably formed out of a conductive material using well known techniques and are also preferably coated with a conductive material, such as gold, in a well known manner. The mating section 140 is elongate and is configured so as to extend inward into the base 102 of the connector

100 so as to be accessible by external contacts in a manner that will be described hereinbelow in reference to Figure 9. in this embodiment, the mating section 140 includes a bent section 185 that is interposed between the first end 182 and the second end 184 of the mating section 140. A second end 184 of the mating section 140 of the each of the contacts 130 is connected to a central section 186 on each of the contacts 130. The central section 186 is wider than the second end 184 of the mating section 140 so that a lip 190 is defined at the interface between the mating section 140 and the central section 186 of the contact 130.

The central section 186 includes the lower neck portion 156 and an upper neck portion 192 that is separated by a chamfer 194. The chamfer 194 extends outward from the lateral edges of the central section 186 so as to be wider than lower and upper neck portions 156 and 192. The edges 195a, 195b of the chamfer 194 adjacent the neck portions 156 are preferably angled to thereby facilitate positioning of the chamfer 194 into appropriate openings in the retainer 106 and the base 102. The chamfer 194 is used to securely position the central section 186 of the contact 130 in both the retainer 106 and the base 102 in a manner that will be described in greater detail below.

The two blades 136 extend out from the lower neck portion 156 of the central section 186 in the manner that is shown in Figure 5A. The two blades 136 are spaced apart so as to define a space 138 that is preferably sized so that when a conductor 124 in the ribbon cable 122 is positioned between the two blades 136 in the manner shown in Figure 1, the inner edges of both of the blades 136 make physical contact with the conductor 124. The outer tips 139 of the blades 136 are preferably tapered so thereby facilitate positioning of the conductor 124 in the space 138.

Figure 5A also illustrates that a lateral tab 197 is formed on the outer edges of the two blades 136 of each of the contacts 130. The lateral tabs 197 extend outward from the outer edge of the two blades 136 a distance that is slightly less than the distance that the chamfer 194 extends outward from the edges of the central section 186 of the contact 130. The lateral tabs 197 are used to stabilize the retainer 106 during attachment of the cover 104 and compression of the multi-conductor cable 122 in a manner that will be described in greater detail below in reference to Figure 8B. Figures 5B and 5C illustrate one particularly unique aspect of the plurality of contacts 130.

Specifically, in a single row of contacts 130, the insulation displacement ends 134 of adjacent contacts 130a and 130b are offset from an axis that is defined by the carrier 180 to form two parallel rows of insulation displacement ends 134a and 134b. Specifically, referring to Figure 5B, the insulation displacement end 134a of one contact 130a is positioned below the axis defined by the carrier 180 and the insulation displacement end 134b of the next adjacent contact 130b is positioned above the axis that is defined by the carrier 180. However, the mating sections 140 of each of the contacts 130 are connected to the carrier 180 so that the mating sections 140 are arranged in a single parallel row as shown in

Figures 5B and 5C. In this embodiment, there are two parallel rows of seventeen insulation displacement ends 134 of the contacts 130 and a single row of thirty-four mating sections 140 attached to a single carrier 180. This configuration of the plurality of contacts 130 simplifies the assembly of the connector 100 of this embodiment as will be described hereinbelow. Figures 5C and 6A-6C illustrate the configuration of each individual contact 130 of the plurality of contacts in greater detail. Specifically, as shown in Figure 5C, the first end 182 of the mating section 140 of the contact 130 bend in a first direction at the attachment point to the carrier 180 to define a contact face 183. The contact face 183 preferably is the portion of the contact 130 to which an external connector will interface to make electrical connection to the conductor 124 in the ribbon cable 122. The mating section 140 is then angled in a second direction until it reaches the bent section 185 of the contact 130. As will be described in greater detail below, this results in the first end 182 which defines the contact face 183 being biased inward, into the opening 142 in the base 102 that is to receive the pins or connectors from an external connector.

Each of the contacts 130 have the above described contact face 183 configuration, central section 186 configuration and insulation displacement end 134 configuration. However, the second end 184a and 184b of the mating sections 140 of the contacts 130a and 130b are configured differently to position the insulation displacement ends 134a and 134b in the two separate parallel rows shown in Figure 5B. In particular, the second end 184 of the mating section 140 of the contact 130 has two configurations as shown in Figures 5C, 6B and 6C.

Referring to Figure 6B, the second end 184b of the contact 130b is bent slightly in the first direction and is then mated to the central section 186 of the contact 130. The first direction, in this embodiment, is in the direction away from the face 183 of the mating section 140 of the contact 130. In contrast, as shown in Figure 6C, the configuration of the second end 184a on the contact 130a is bent in the opposite second direction towards the face 183 so that the contact 130a is spaced apart from the contact 130b in the manner shown in Figure 5C. The configuration of the central sections 186 of the contact 130 is substantially the same regardless of the configuration of the second end 184 of the mating section 140 of the contact 130. The two configurations of the second end 184a, 184b of the mating section 140 of the contact 130 results in the central section 186 of the contacts 130 being positionable into the two adjacent parallel rows of openings 154 in the retainer 106 (See, Figure 3). Hence, the configuration of the plurality of pins 130, when attached to the carriers 180, results in a single row of mating sections 140 and two spaced rows of insulation displacement ends 134. The two rows of insulation displacement ends 134 can be positioned into two rows of spaced apart openings 154 in the retainer 106 to thereby allow the insulation displacement ends 134 to make electrical connection to the conductors 124 of the ribbon cable 122.

Referring to Figures 7A-7C, the assembly of the connector 100 of this embodiment will be described in greater detail. In particular, referring to Figure 7A, a first plurality of contacts 130 that are connected to a carrier 180 are initially positioned so that seventeen of the contacts 130 are positioned within the first row of openings 154 in the retainer 106

(Figure 3) and a second row of seventeen contacts 130 are positioned within a second row of seventeen openings 154 in the retainer 106. A second plurality of thirty-four contacts 130 (not shown in Figure 7A) attached to a carrier 180 which are substantially identical to the first plurality are also positioned within the other two rows of openings 154 in the retainer 106. Preferably, the central sections 186 of each of the contacts 130 are positioned within the openings 154 so that the insulation displacement ends 134 are positioned substantially adjacent the inner surface 114 of the retainer 106 in the manner shown in Figure 7A and 7B.

The carrier 180 is then removed from the first end 182 of the contact end 140 of each of the plurality of conductors 130. As described above, the interface between the carrier 180 and the mating section 140 is preferably scored or otherwise weakened to allow the carrier 180 to be easily removed from the ends 182 of the mating section 140 of the contacts 130. The mating sections 140 of the plurality of contacts 130 are then positioned within the openings

143 in the face 166 of the base 102. As shown in Figure 4, there are two parallel rows of thirty-four openings 143 each of which are configured to receive the mating sections 140 of the plurality of contacts 130. As shown in Figure 7B, the openings 143 in the base 102 are preferably configured so that the central section 186 of each of the plurality of contacts is positioned within the openings 166 so that the chamfer 194 is contacting an upper surface 200 of the openings 143. The configuration and purpose of the surface 200 will be described in greater detail in reference to Figures 8A and 8B below.

Once the contact ends 140 are positioned within the base 102, the ribbon cable 122 is then positioned adjacent the inner surface 114 of the retainer 106 and the cover 104 is positioned adjacent the ribbon cable 122 in the manner that is shown in Figures 7B and 7C. In particular, each of the indentations 112 on the inner surface 110 of the cover 104 and the indentations 116 on the inner surface 114 of the retainer 106 align when the cover 104 is positioned on the retainer

106 so as to center each of the conductors 124 within the conductor space 126 defined by the indentations 112 and 116. Specifically, the insulation 121 surrounding each of the conductors 124 is preferably made of a material such as vinyl which is somewhat flexible. Compression of the retainer 106 against the cover 104 results in the indentations 112, 116 moving each conductor 124 with respect to its neighbor so that each conductor 124 is preferably centered within the spaces 126 when the retainer 106 and the cover 104 are positioned together. It will be appreciated that the cover 104 and the retainer 106 are precisely dimensioned so that the indentations 112 and 116 form circular conductor spaces 126 to center the insulation coated conductors.

The compression of the retainer 106 and the cover 104 and the base 102 together also results in the base 102 exerting force against the lip 190 of the central section 186 of the contacts 130 and also against the chamfer 194 of the contacts 130 to thereby urge the contacts into the space 126. Consequently, the blades 136 are preferably guided by the openings 154 into the conductor spaces 126 by this compression so that the conductor 124 can be captured in the space 138 between the blades 136 in the manner that is shown in Figure 7C. The configuration of the base 102 and its interaction with the plurality of contacts 130 will be described in greater detail in reference to Figures 8A and 8B. Since the upper neck section 156 of the contacts 130 is captured within the openings 154 of the retainer 106 during the compression process, the tendency of the insulation displacement end 134 to bend as a result of the compression and insertion into the insulation 121 of the ribbon cable 122 is reduced. Hence, the connector 100 is simultaneously centering the ribbon cable 122 in the space 126 while urging the insulation displacement ends 134 into the space 126. Figure 8A illustrates the positioning of the plurality of contacts 130 in the base member 102, the retainer 106 and the cover 104 in greater detail. Specifically, the insulation displacement ends 134 extend outward from the inner surface 114 of the retainer 106 so as to make electrical contact with the conductors 124 and the ribbon cable 122. The blades 136 extend through the insulation 121 into the openings 144 that are formed in the cover 104. This helps to ensure that the blades 136 do not become bent as a result of the insulation displacement process or subsequent movement of the connector so as to make unwanted contact with adjacent conductors 124 or contacts 130. The upper neck portion 156 of the central section 186 of the contacts 130 are each positioned within the openings 154 of the retainer 106. As discussed above, this helps to ensure that the insulation displacement end 134 of each contact is correctly positioned into the opening 126 defined by the indentations 112 and 116 on the inner surface of the cover 104 and retainer 106, respectively. As shown in Figure 8B, the opening 154 in the retainer 106 has a flanged section 211 at an outer surface 155.

The tabs 197 engage with inner surface of the flanged section 211, in the manner shown in Figure 8B to stabilize the retainer 106 during the insertion process. Specifically, the tabs 197 engage with the inner surface of each of the flanged sections 211 of the openings 154 in the retainer 106 once the retainer 106 has been positioned on the contacts 130 in the manner that is shown in Figures 7A and 7B above. As the tabs 197 are positioned on the same location on each contact 130, the tabs 197 serve to correctly orient the retainer 106 during the insertion process.

Subsequently, when the cover 104 is positioned on the retainer 106 and the ribbon cable 122 is compressed therebetween, the tabs 197 provide some resistance against the compression of the cover 104 against the ribbon cable 122 to increase the compressive forces against the ribbon cable 122 to thereby better urge the conductors 124 within the ribbon cable 122 into the desired orientation within the spaces 126 defined by the inner surfaces of the cover 104 and the retainer 106. The tabs 197 are configured to either deform or be forced into the material forming the retainer 106 as the compression continues to allow the contacts 130 to be inserted through the openings 154 in the retainer 106 and make electrical contact with the conductors 124 of the ribbon cable in the manner that is shown in Figure 7C and is described in greater detail below. Further, as is also shown in Figure 8A, the flanged section 211 of the openings 154 is also configured to receive the portion of the chamfer 194 on the plurality of contacts that are adjacent the neck 156 of the contact 130. This helps to ensure that the contacts 130 are not over inserted into the conductors 124 of the high density ribbon cable 122. The openings 143 on the inner surface 166 of the base 102 also have a flanged section 212 that is adapted to receive the portion of the chamfer 194 on the contacts 130 that is positioned adjacent the upper neck section 192 of the central section 186.

The openings 142 in the base 102 also have a protrusion which extends laterally into the openings 143 so as to form a stop 202 in each of the openings 143 that engages the lip 190 on the contact 130. Hence, once the mating sections 140 of the contacts 130 are positioned within the openings 143 of the base 102, compression of the base 102 towards the cover 104, with the retainer 106 and the ribbon cable 122 interposed therebetween, results in the lip 200 and the stop 202 urging the insulation displacement end 134 of the contact 130 into the space 126. It will be appreciated that a relatively significant amount of force is typically required to force the insulation displacement ends 134 of each of the contacts 130 into the conductors 124 in a high density ribbon cable 122 especially in light of the resistance provided by the tabs 197 engaging with the inner surfaces of the flanged section 211 of the openings 154 in the retainer 106. The lip 200 and the stop 202 provide the surfaces that force the contacts 130 through the insulation 121 surrounding the conductors 124 to thereby make good electrical contact with the conductors 124. Hence, the base 102 is configured, during compression of the base 102 and the cover 104, to urge the plurality of contacts 130 in a first direction that is normal to the plane of the inner surface 166 of the base 102. The base 102 therefore urges the plurality of contacts 130 through the openings 154 in the retainer 106 while the retainer 106 ensures that the plurality of contacts 130 are urged in the first direction into the conductors 124 centered within the spaces 126.

Figure 8A illustrates that the blocks 148 on the cover 104 engage with the posts 162 of the retainer 106 and the lip 172 of the base 102 to thereby secure the cover 104 to the base 102 with the retainer 106 and the high density ribbon cable 122 captured therebetween. It will be appreciated that securing the cover 104 to the base 102 after attachment of the connector 100 to the ribbon cable 122 can be accomplished in any of a number of manners that are well known in the ribbon cable connector industry without departing from the present invention.

Figure 9 further illustrates the plurality of contacts 130 as they are positioned in the base 102. In particular, Figure 9 illustrates that the insulation displacement ends 134 of the plurality of contacts 130 are positioned within the openings 142 so as to extend out from the inner surface 166 of the base 102. Four adjacent contacts 130 are shown in Figure 9 to illustrate that the insulation displacement ends 134 of adjacent contacts 130 are offset from each other in the above-described manner.

The mating sections 140 of the plurality of contacts 130 extend into the opening 143 so as to be able engage with an external printed circuit board or mating connector that is inserted into the opening 142. Specifically, the mating sections 140 are respectively positioned within grooves 221 formed in the inner walls of the base 102 so that the contact surface 183 faces into the opening 142. The upper end 187 of the mating section 140 preferably engages with a lip 223 formed adjacent the outer surface 167 of the base 102 so that the mating sections 140 are captured within the grooves 221. As discussed above, the mating sections 140 are preferably bent so as to extend into the opening 143 to thereby be biased inward to ensure that the contact face 183 makes good electrical contact with the mating connector or printed circuit board. It will be appreciated that the connector 100 of this embodiment is simpler to assemble as the contacts 130 are arranged so that a single carrier 180 attached to a single row of mating sections 140 of the contacts 130 is connected to two offset rows of insulation displacement ends 134. Hence, the assembly step of positioning the plurality of contacts 130 into the retainer 106 is simplified as only one-half as many rows of contacts 130 have to be positioned within the retainer or like components. Similarly, it will be appreciated by a person of skill in this art that the plating costs associated with plating contacts having this configuration is lowered as a result of more individual contacts being positioned on a single linear strip of contacts.

It will also be appreciated that the accuracy and reliability of the connector of this embodiment is improved over similar connectors of the prior art. In particular, the plurality of contacts are captured within a retainer and the retainer and a cover are configured to compress the high density cable so as to center cables within an opening that is defined by indentations on the retainer and cover. The compression occurs while the insulation displacement ends of the contacts are being urged into the opening defined by the indentations on the cover and the retainer. Hence, compressing the cover to the base with the retainer and the ribbon cable interposed therebetween simultaneously centers the conductors of the ribbon cable in the space while urging the blades of the contacts through the insulation to make electrical contact with selected conductors of the ribbon cable. Figures 10A-10D illustrate another embodiment of a connector 300 that is adapted to connect to a multi- conductor ribbon cable such as the multi-conductor ribbon cable 122 described above. In this embodiment, the connector 300 includes a base member 302 and a cover member 304. However, this embodiment of the connector 300 does not include a retainer such as the retainer 106 described above, rather, the base member 302 includes a plurality of indentations 306 formed on a first surface 312 of the base member 302 that are adapted to receive the individual conductors encapsulated by insulation of the multi-conductor ribbon cable. Similarly, the cover 304 also includes a plurality of indentation 310 formed on an inner surface 314 of the cover that are also adapted to receive the plurality of conductors encapsulated by insulation of the multi-ribbon cable. The first surface 312 of the base member 302 and the inner surface 314 collectively define a ribbon cable receiving area 309 that is adapted to receive the ribbon cable for electrical interconnection to the connector 300. More particularly, the indentations 306 and 310 extend across the full width of the base member 302 and cover member 304 and are positioned in parallel with each other over the entire length of the base member 302 and the cover member 304. Each indentation 306, 310 is adapted to engage with the outer surface of the insulation surrounding a single conductor of the multi-conductor ribbon cable and locate the insulation surrounded conductor within a space 311 defined by the indentations 306 and 310. This allows the insulation displacement ends of the contacts that are positioned within the base member 302 to make electrical contact with the insulated conductor in a manner that will be described in greater detail below.

As is also shown in Figure 10A, a plurality of openings 316 are formed in the first surface 312 of the base member 302 so that a single opening 316 is formed in each of the indentations 306. Similarly, there are matching openings 320 formed on the inner surface 314 of the cover member 304. As will be described in greater detail below, the openings 316 in the base member 302 are adapted to guide the contacts 322 into the space 311 defined by the indentations 306 and 310 so that the contacts can make electrical connection with the conductors of the multi-conductor ribbon cable positioned within the space 311. The openings 320 in the cover member 310 are adapted to receive the ends of the contacts 322 after they have made electrical connection with the conductors of the ribbon cable and the openings 320 secure the ends of the contacts 322 so that the ends of the contacts will not inadvertently touch adjacent contacts.

As is also shown in Figure 10A, the connector 300 also includes a locking mechanism, generally designated 324, that is adapted so that the cover member 304 can be secured to the base member 302 with the multi-conductor ribbon cable positioned within the cable receiving space 309. The locking mechanism 324 is adapted to secure the cover member

304 to the base member 306 to thereby retain the connector 300 in electrical connection with the ribbon cable. In this embodiment, the locking mechanism 324 is comprised of two male locking flanges 326a and 326b that are formed on the first and second ends 330a, 330b, respectively, on the base member 302. The locking flanges 326a, 326b are adapted to extend perpendicularly outward of the first surface 312 of the base member 302 in the manner shown in Figure 10A. Moreover, the outer ends 332a, 332b of the flanges 326a, 326b are tapered. The cover member 304 includes two mating connector members 334a, 334b that extend perpendicularly outward from the inner surface 314 of the cover member 304 and define a receptacle 336a, 336b that is adapted to receive the locking flanges 326a, 326b. The receptacles 336a,

336b are preferably configured so that when the cover member 304 is fully installed on the base member 302, the receptacles 336a, 336b engage with the flanges 326a, 326b so as to securely retain the cover 304 on the base member 302 in the manner shown in Figure 10B.

As is also shown in Figure 10A, during assembly, the contacts 322 are initially positioned into the base member 302 via a second surface 342 of the base member 302. The second surface 342 of the base member 302 is positioned opposite the first surface 312 and, as will be discussed in greater detail below, the contacts 322 extend through the center of the base member 302 so that an end of the contacts 322 extends through the openings 316 into the individual conductor spaces 311 of the cable receiving area 309. As is also shown in Figure 10A, the contacts 322 are initially positioned on a carrier 344 during insertion into the second side 342 of the base member 302. Specifically, referring to Figure 10C, the contacts 322 are connected to the contact carrier 344 so as to extend out from the carrier 344 generally in a first direction. The contacts 322 are adapted to be positioned within openings 350 formed in the second side 342 of the base member 302. The openings 350 are further adapted to receive contacts from mating connectors, mating printed circuit boards and any other device that is to be connected to the multi-conductor ribbon cable via the connector 300. While the openings 350 in this embodiment are illustrated as a plurality of discrete openings 350 that are adapted to receive a plurality of contacts, it will be further appreciated that the openings 350 may comprise a single opening for a blade-type connection without departing from the spirit of the present invention.

As shown in Figure 10C, the plurality of contacts 322 are each inserted into the openings 350 in the second surface 342 of the base member 302 while still attached to the carrier 344. Hence, insertion of the plurality of contacts 322 into the openings 350 essentially loads the base member 302 with contacts 322 so that the contacts 322 can make electrical connection with conductors of a multi-conductor ribbon cable captured in the cable receiving area 309 in the manner that will be described in greater detail below.

As is further illustrated in Figure 10C, the locking flanges 326a, 326b each include a lip 352a, 352b and the receptacle member 344a, 344b also each include a catch member 356a, 356b that is positioned so as to respectively extend across the receptacles 336a, 336b. The catch members 356a, 356b can therefore engage with the lip 352a, 352b on the locking flange 332a, 332b so as to retain the cover member 304 in a locked configuration with respect to the base member 302.

As shown in Figure 10D, when the cover member 304 is mounted on the base member 302, the contacts 322 are preferably detached from the carriers 344 and are fully recessed within the openings 350. External pin contacts and the like can then make an electrical connection to the contacts 322 that are electrically connected, via the openings 316, to the conductors of the ribbon cable captured in the ribbon cable space 309 in the manner that will be described in greater detail below. It will, of course, be appreciated that the exact configuration of the openings 350 and the conductor spaces 311 defined by the indentations 306 and 310 on the base member 302 and the cover member 304, respectively, will vary depending upon the configuration of the external contacts and ribbon cable that are to be used in conjunction with the connector 300.

The contacts 322 will now be described in greater detail in reference to Figures 11A-11C and 12A-12D. Specifically, referring to Figures 11A-11C, the contacts 322 are initially formed connected to the carrier 344. In this embodiment, the contacts 322 and the carrier 344 can be formed using well-known stamping, molding or etching techniques and can be positioned on a spool 360 so that the plurality of contacts 322 can be unwound from the spool and a selected number of contacts 322 can be detached from the spool for insertion into the connector 300. As illustrated in

Figure 11 A, the contacts 322 are coupled to the carrier 344 at a first end 362 and a second end 364 comprises an insulation displacement end of the contact 322. The interconnection at the first end 362 of the contact 322 to the carrier 344 is made using a seamed, thin interface 366 that can be easily broken by bending the carrier 344 about the interface 366 with respect to the first end 362 of the contacts 322. Repeated bending of the carrier 344 about the interface 366 results in the carrier 344 detaching from the first end 362 of the contacts at the interface 366. The exact configuration of the contacts will now be described in greater detail in reference to Figures 12A-12D.

Specifically referring to Figure 12A, the insulation displacement end 364 of the contact 322 includes two blades 370a, 370b that define a space 372. The space 372 is adapted to receive a conductor of the multi-conductor ribbon cable so that the conductor makes electrical contact with the inner surfaces 382a, 382b of the blades 370a, 370b in the same manner as described in conjunction with the embodiment of contacts illustrated in Figures 6A-6C. The blades 370a, 370b preferably include points 374a, 374b that are adapted to pierce the insulation surrounding the conductor of the ribbon cable in the same manner as described above. The conductor receiving space 372 is wider at a position adjacent the points 374a, 374b but then narrows into a narrower section 380 that is preferably smaller in width than the width of the conductor to which the contact 322 is to be connected to ensure the outer surfaces of the conductor make contact with the inner surfaces 382a, 382b of the blades 370a, 370b. The space 372 is narrowed as a result of inward flange guiding surfaces 376a, 376b which are formed on the insulation displacement end 364 of the contact 322 adjacent the point 374a, 374b. The guiding surfaces 376a, 376b are adapted to guide the conductor embedded within the insulation material into the narrower section 380 of the space 372 so that the inner surfaces 382a, 382b of the blades 370a, 370b can make physical and electrical contact with the conductor.

The blades 370a, 370b also each preferably include an outer flanged surface 384 that extends outward from the point 374a, 374b that is adapted to urge a portion of the insulation surrounding the conductor away from the conductor. The conductor is then exposed to allow the conductor to be directed into the space 380 so that the inner walls 382a, 382b can physically contact the conductor. As is also illustrated in Figures 12A-12D, the insulation displacement end 364 of the contact 322 includes two indentations 390a, 390b that are formed in the blade members 370a, 370b. The indentations 390a, 390b are positioned in the blade members 370a, 370b at a location that is selected so that the indentations 390a, 390b lie within the plane defined by the conductors of the multi-conductor ribbon cable when the multi-conductor ribbon cable is positioned within the cable receiving space 309 of the connector 300. Hence, the indentations 390a, 390b are formed in the blades 370a, 370b at locations such that, when the contacts 322 are entirely positioned within the connector 300 in the manner shown in Figures 10B and 10D above, the indentations 390a, 390b are aligned with the cable receiving space 309 defined by the first surface 312 of the base member 302 and the inner surface 314 of the cover 304. The indentations 390 help to ensure that a greater distance and a greater quantity of insulation remains between the outer edge of the blade members 370a, 370b and adjacent conductors when the contacts 322 are connected to the conductors of the ribbon cable. Further, this configuration of contact also reduces the amount of cold flow of the insulation as will be explained in greater detail below.

As shown in Figures 12A and 12B, the contact 322 also includes a central section 394 which interconnects the insulation displacement end 364 and the first end 362 of the contact 322. At the interface between the central section 394 and the insulation displacement end 364 of the contact 322, a curved indentation 396 is formed on a first side of the central section 394. The curved indentation is adapted so that the central section 394 is bent slightly in the first direction so as to be biased towards the first direction. A contact face 400 is also formed on the first side of the central section 394 of the contact 322 so as to extend outward from the central section 394 of the contact 322 in the first direction. The contact face 400 is adapted to engage with an external pin connector of the device that is to be connected to the ribbon cable via the connector 300. As shown in Figures 13A and 13B, the contact face 400 is positioned adjacent the first end 362 of the contact

322 and the contact face 400 is positioned immediately adjacent the second side 342 of the base member 302 and adjacent one wall of the opening 350 when the contact 322 is mounted within the openings 350 and the base member

302. The central section 394 biases the contact 372 inward into the opening 350 so as to maintain good electrical connection between the external contact pin that is inserted into the openings 350 and the contact 322.

The contacts 322 can be formed in a variety of different manners and their exact dimensions vary depending upon configuration of the connector in which the contacts are to be positioned. It will be apparent from the following discussion that the contacts 322 can be used in conjunction with a connector having the configuration of the connector 300 or in conjunction with a connector similar to the connector 100 described above. Referring to Figures 13A and 13B, the positioning of the contacts 322 within the base member 302 and the insertion of the insulation displacement ends 364 of the contacts 322 into the multi-conductor ribbon cable will be described. Specifically, Figure 13A illustrates the position of the contacts 322 when the contacts 322 are initially positioned within the openings 350 on the second surface 342 of the base member 302 while still being connected to the carrier 344. As illustrated, the openings 350 extend fully through the base member 302 so as to communicate with the openings 316 that open into the indentations 306 formed on the first surface 312 of the base member 302. Initially, the contacts 322, while still connected to the carrier 344 are positioned so that the points 374a, 374b of the blades 370a, 370b are aligned with the apexes of the material forming the indentations 316 so that the insulation displacement ends 364 are recessed within the openings 316 in the manner shown in Figure 13A.

Subsequently, multi-conductor ribbon cable 404 is positioned adjacent the first surface 312 of the base member 302 and the cover member 304 is attached to the base member 302 using the locking mechanism 324. The ribbon cable

404 is then captured in the cable receiving space 309 defined by the inner surface 314 of the cover member 304 and the first surface 312 of the base member 302. As discussed above, the ribbon cable 404 is comprised of a plurality of conductors 412 each surrounded by insulation 410. The insulation 410 is generally a plastic material and the insulation 410 surrounding each conductor is connected to the insulation 410 surrounding the adjacent conductor 412. The indentations 306 and 310 are formed so as to define a space 311 that is slightly smaller than the outer diameter of the insulation 410 surrounding each of the conductors 412. Hence, the inner walls of the indentations 306, 310 engage with the insulation 410 so that the insulation 410 is compressed when the cover 304 is attached to the base member 302 such that the insulation surrounded conductors 412 are located in a desired orientation in the spaces 311 with respect to the openings 316 in the base member 302 that contain the contacts 322. In this embodiment, the conductors 412 are substantially centered in the conductor space 311. There is some flexibility in the insulation connecting adjacent conductors to allow for the lateral movement of the conductors 412 needed to substantially center each of the conductors 412 of the ribbon cable 404 in the spaces 311.

Subsequently, the contacts 322 are urged so that the insulation displacement ends 364 of the contacts 322 pierce the insulation 410 surrounding the conductors 412. The contacts 322 guide the embedded conductors 412 into the narrow section 380 of the insulation displacement end 364 of the contact 322 so that the inner walls 382a, 382b of the blades 370a, 370b make physical contact with the conductor 412 in the manner shown in Figure 13B. In this embodiment, the contacts 322 are urged into the base member 302 so that the contacts 322 make electrical connection to the conductors 412 by the assembler urging the carrier 344 towards the second surface 342 of the base member 302. The openings 350, in this embodiment, include a guide section 420 located immediately adjacent the first surface

312 of the base member 302. The guide section 420 is preferably only slightly larger than the width of the widest section of the insulation displacement end 364 of the contacts 322. The guide section 420 reduces the likelihood that the blades 370a, 370b of the insulation displacement end 364 will be bent towards an adjacent conductor 412 during the insulation displacement process. Specifically, since the blade members 370a, 370b are substantially confined within the guide section 420 during the insertion process, the likelihood that the blades 370a, 370b will bend away from conductor 412 positioned within the space 311 is reduced as the moment arm of the blades 370a, 370b is limited by the proximity of the guide section 420 to the conductors 412. In one respect, the narrow guide section 420 serves as a retainer so as to retain the blades 370a, 370b of the insulation displacement end 364 of each of the contacts 322 in the desired relationship with the corresponding conductor 412 captured in the space 311 during the insertion process. Further, as is also shown in Figure 13B, the indentations 390a, 390b are sized and positioned on the blade members 370a, 370b, respectively, so that the indentations 390a, 390b are interposed along a line between adjacent conductors 412 of the ribbon cable 404 once the contacts 322 are connected to their respective conductor 412. Consequently, the contacts 322 are configured so that when the contacts 322 are positioned in the cable receiving area 309 the indentations 390a, 390b increase the distance between the contacts 322 and the adjacent conductors 412. This increase in distance results in better isolation between the outer edges of the contacts 322 and the adjacent conductors

412 in the cable receiving area 309. As illustrated in Figure 13B, the base member 302 separate adjacent contacts 322 from each other. Moreover, the openings 320 in the cover member 304 also receiving the points 374a, 374b of the blades 370 after the connection to the conductors 412 have been made so as to further isolate the insulation displacement ends 364 of the adjacent contacts 322. It is only in the cable receiving area 309 that contacts 322 are positioned adjacent other contacts 322 or conductors 412. However, the indentation 390a, 390b improve the isolation between the contacts

322 and the adjacent conductors 412 in this embodiment by increasing the distance between the outer edges of the contacts 322 and the adjacent conductors 412.

Moreover, when the insulation displacement ends 364 of the contacts 322 enter the insulation 410 surrounding each of the conductors 412, a portion of the insulation 410 is urged away from the space 372 of the contacts 322 by the outward flanging surfaces 384a and 384b of the blades 370a and 370b. Some or all of this portion of the insulation 414 is urged into the indentation 390a, 390b when the contacts 322 are fully inserted into the ribbon cable 404. Hence, not only do the indentations 380a, 380b increase the distance between the contacts 322 and the adjacent conductors 412, the indentations 390a, 390b are preferably filled with insulation material 410 which further enhances the isolation between the contacts and the adjacent conductors. Moreover, the Applicant has observed that because the indentations 390a, 390b allow the insulation 412 to relax into indentations 390a, 390b following the insertion of the insulation displacement end 364 of the contacts 322 into the cable 411, the conductors 412 are more likely to remain substantially aligned in a common plane after the connection of the connector 300 to the multi-conductor ribbon cable 404. In this embodiment, the common plane is the plane of the cable receiving area 309. The substantial alignment of the conductors 412 in the plane defined by the cable receiving area

309 results in less stress being applied to the insulation 410 which reduces the amount of cold flow of the insulation 410 in the regions of multi-conductor ribbon cable adjacent the outer edge of the contact 322. The likelihood that the insulation separating the contacts 322 from the adjacent conductors cold flowing as a result of the stress resulting from the conductors being displaced is therefore reduced. Consequently, adjacent conductors are more likely to remain isolated from the contacts when the contacts are inserted into the multi-conductor ribbon cable.

From the foregoing, it will be appreciated that the connector 300 discloses an embodiment of a connector that does not require the use of a retainer member and further allows the contacts to be gang loaded into the outer surface of the base member 302. A region of the base member 302 adjacent the first surface 312 of the base member 302 is sized to laterally confine the blades 370a, 370b so that the blades are correctly positioned to be inserted into the conductor as described above, it will be appreciated that this configuration of connector can be used with a variety of different configurations of contacts including the contacts described in reference to Figures 6A-6C above.

Moreover, from the foregoing discussion, it will also be apparent that the embodiment of the connector 300 also describes a contact that is adapted to improve isolation between the outer edges of the contact and adjacent conductors. It will further be appreciated that the exact configuration of the contact will vary depending upon the application and that the indentations described in reference to the contacts 322 can also be formed in other configurations of contacts, such as the contacts discussed above in relation to Figures 6A-6C, without departing from the spirit of the present invention.

Although this embodiment of the present invention has shown, described and pointed out the fundamental novel features of the invention as applied to these embodiments, it will be understood that various omissions, substitutions, and changes in the form of the detail of the device illustrated may be made by those skilled in the art without departing from the spirit of the present invention. Consequently, the scope of the invention should not be limited to the foregoing description but should be defined by the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A connector for a multi-conductor ribbon cable that has a plurality of conductors, the connector comprising: a plurality of contacts that have a first end configured to be electrically connected to conductors within the ribbon cable and a second end that provides a contact point for external contacts to make connection with the plurality of conductors in the ribbon cable via the plurality of contacts; a base member having a first surface and a second surface and a plurality of openings extending therethrough, wherein the first surface includes a plurality of indentations and the plurality of openings are positioned within the base member so that each indentation has an opening communicating with the indentation and wherein the openings are adapted to receive the plurality of contacts so that the first end of each of the contacts can extend into a respective indentation via an opening; and a cover member having a first surface that is adapted to be secured to the base member, wherein the first surface of the cover member and the first surface of the base member respectively define a cable receiving area that is configured so that, when the ribbon cable is positioned between the cover member and the base member, the individual conductors of the ribbon cable are urged into a desired location with respect to the openings in the base member so that the first ends of the plurality of contacts can be inserted into the ribbon cable so as to make electrical connection with the conductors located therein.

2. The connector of Claim 1, wherein the first surface of the cover member includes a plurality of indentations corresponding to the plurality of indentations on the first surface of the base member and wherein the plurality of indentations on the first surface of the base member and the first surface on the cover member are adapted to engage with the insulation surrounding the conductors so as to precisely locate the conductors within the space defined by corresponding indentations on the base and cover members with respect to the opening in the base member.

3. The connector of Claim 2, wherein the indentations on the base member and the cover member precisely locate the conductors so that the conductors are centered with respect to the openings of the base member that communicate with the indentations in the first surface of the base member.

4. The connector of Claim 1, wherein the plurality of contacts are adapted to be positioned into the plurality of openings of the base member from the second surface of the base member.

5. The connector of Claim 1, wherein the cable receiving area is substantially planar and the indentations are formed in the base member and the cover member so as to positioned in parallel with each other extend across the length of the planar cable receiving area.

6. The connector of Claim 5, wherein each of the plurality of contacts have at least one indentation formed in an outer surface of the contact at a location that is selected so that the at least one indentation is positioned within the cable receiving area when the plurality of contacts are inserted into the ribbon cable so as to be electrically connected to the conductors of the ribbon cable.

7. The connector of Claim 6, wherein the at least one indentation increases the distance between the outer surface of the contact and the adjacent conductor so that the contact is better isolated from the adjacent conductor.

8. The connector of Claim 7, wherein first ends of the plurality of contacts are insulation displacement ends adapted to displace insulation surrounding the conductors of the ribbon cable so as to make electrical contact with conductors embedded within the insulation.

9. The connector of Claim 8, wherein the insulation displacement ends of the contacts includes two blades defining a space therebetween and wherein the indentations on the base member and the cover member are adapted to engage with the insulation surrounding the conductors when the cover member is attached to the base member so as to position the conductors embedded within the insulation in a position within the cable receiving area such that the two blades of the insulation displacement ends of the contacts are positioned on either side of the conductor so that the inner walls of the blades can make electrical connection to the conductors.

10. The connector of Claim 9, wherein the at least one indentation is comprised of two indentations that are formed on the outer surfaces of the blades.

11. The connector of Claim 10, wherein the insulation displacement end is adapted so that a portion of the insulation displaced during insertion of the contact into the ribbon cable is positioned in the indentation when the contact is fully inserted into the ribbon cable.

12. The connector of Claim 11, wherein the indentations result in the conductors of the ribbon cable remaining in substantially the same plane after connection by the plurality of contacts so as to reduce the amount of cold flow of the insulation positioned between adjacent contacts after insertion.

13. A connector for a multi-conductor ribbon cable that has a plurality of conductors surrounded by insulation, the connector comprising: a plurality of contacts that have an insulation displacement end adapted to be inserted into the insulation surrounding the conductors of the ribbon cable so as to electrically connect to the conductors of the ribbon cable and wherein the plurality of contacts also have a second end that provides a contact point for external connection with the plurality of conductors int he ribbon cable via the plurality of contacts; a base member having a first surface and a second surface and a plurality of openings which provide access from the first surface to the second surface, wherein the first surface includes a plurality of indentations and the plurality of openings are positioned within the base member so that each indentation has an opening communicating with the indentation and wherein the openings are adapted to receive the plurality of contacts so that the insulation displacement end of each of the contacts can extend into a respective indentation via an opening and wherein each of the plurality of openings include a guide section formed in the base member adjacent the first surface which is adapted to guide the insulation displacement ends into the ribbon cable and retain the insulation displacement ends in the indentation during insertion into the ribbon cable; and a cover member having a first surface, the cover member being adapted to be secured to the base member wherein the first surface of the cover member and the first surface of the base member respectively define a cable receiving area that is configured so that, when the ribbon cable is positioned in the cable receiving area, the first surface of the cover member and the indentations of the base member engage with the insulation surrounding the conductors of the ribbon cable so as to locate the conductors of the ribbon cable in a desired location with respect to the openings in the base member so that the insulation displacement ends of the plurality of contacts can be inserted into the ribbon cable so as to make electrical connection with the conductors located therein.

14. The connector of Claim 13, wherein the first surface of the cover member includes a plurality of indentations corresponding to the plurality of indentations on the first surface of the base member and wherein the plurality of indentations on the first surface of the base member and the first surface on the cover member are adapted to engage with the insulation surrounding the conductors so as to precisely locate the conductors within the space defined by corresponding indentations on the base and cover members with respect to the opening in the base member.

15. The connector of Claim 14, wherein the indentations on the base member and the cover member precisely locate the conductors so that the conductors are centered with respect to the openings of the base member that communicate with the indentations in the first surface of the base member.

16. The connector of Claim 15, wherein the indentations on the first surface of the base member and the indentations on the first surface of the cover member are positioned in parallel with each other along the entire length of the cable receiving area and wherein the indentations on the first surface of the base member and the first surface of the cover member are formed to a substantially uniform depth across the entire width of the cable receiving area so that the entire inner surface of the indentations can engage with the insulation of the ribbon cable so as to precisely locate the conductors with respect to the openings in the base member.

17. The connector of Claim 1, wherein the plurality of contacts are adapted to be positioned into the plurality of openings in the base member from the second surface of the base member.

18. The connector of Claim 17, wherein the plurality of contacts are initially formed so as to be connected to a carrier so that the plurality of contacts can be simultaneously into the plurality of openings in the base member and wherein the carrier is adapted so that exertion of force on the carrier towards the second surface of the base member when the ribbon cable is captured in the ribbon cable receiving area results in the insulation displacement ends of the plurality of contacts being inserted into the ribbon cable so as to make electrical connection with the conductors of the ribbon cable.

19. The connector of Claim 18, wherein the carrier is connected to each of the plurality of contacts adjacent the second end of the contacts and wherein the carrier is adapted to be detached from the plurality of contacts as a result of bending the carrier with respect to the second end of the plurality of contacts.

20. The connector of Claim 1, wherein each of the plurality of contacts have at least one indentation formed in an outer surface of the contact at a location that is selected so that the at least one indentation is positioned within the cable receiving area when the plurality of contacts are inserted into the ribbon cable so that the at least one indentation increases the distance between the outer surface of the insulation displacement end of the contact and the adjacent conductor of the ribbon cable.

21. The connector of Claim 20, wherein the insulation displacement ends of the contacts includes two blades defining a space therebetween and wherein the indentations on the base member and the cover member are adapted to engage with the insulation surrounding the conductors when the cover member is attached to the base member so as to position the conductors embedded within the insulation in a position within the cable receiving area such that the two blades of the insulation displacement ends of the contacts are positioned on either side of the conductor so that the inner walls of the blades can make electrical connection to the conductors.

22. The connector of Claim 21, wherein the at least one indentation is comprised of two indentations that are formed on the outer surfaces of the blades.

23. The connector of Claim 20, wherein the insulation displacement end is adapted so that a portion of the insulation displaced during insertion of the contact into the ribbon cable is positioned in the indentation when the contact is fully inserted into the ribbon cable.

24. The connector of Claim 23, wherein the indentations result in the conductors of the ribbon cable remaining in substantially the same plane after connection by the plurality of contacts so as to reduce the amount of cold flow of the insulation positioned between adjacent contacts after insertion.

25. A connector for a multi-conductor ribbon cable that has a plurality of conductors, the connector comprising: a plurality of contacts that have a first end configured to be electrically connected to conductors within the ribbon cable and a second end that provides a contact point for connection with the plurality of conductors in the ribbon cable via the plurality of contacts, wherein each of the plurality of contacts has at least one indentation formed in an outer lateral surface of the contact; a base member having a first surface and a second surface and a plurality of openings extending therethrough, wherein the plurality of openings are adapted to receive the plurality of contacts so that the first end of the contact extends out of the first surface when the plurality of contacts are positioned within the base member; and a cover member adapted to be secured to the base member, wherein the cover member has a first surface and defines a cable receiving area when secured to the base member with the ribbon cable positioned adjacent the first surface of the cover member and wherein the plurality of contacts positioned in the openings in the base member can be inserted into ribbon cable so as to make an electrical connection with the conductors of the ribbon cable positioned in the cable receiving area and wherein the at least one indentation formed in the outer lateral surface of each of the contacts is adapted to be positioned in the cable receiving area when the contacts are electrically connected to the conductors of the ribbon cable so that the at least one indentation in the contact is interposed between the outer surface of the contact and the conductor of the ribbon cable positioned adjacent the contact.

26. The connector of Claim 25, wherein the first ends of the plurality of contacts are insulation displacement ends adapted to displace insulation surrounding the conductors of the ribbon cable so as to make electrical contact with conductors embedded within the insulation.

27. The connector of Claim 26, wherein the insulation displacement ends of the contacts includes two blades defining a space therebetween that is adapted to receive the conductor embedded within the insulation so as to make electrical connection with the inner walls of the blades.

28. The connector of Claim 27, wherein the at least one indentation is comprised of two indentations that are formed on the outer surfaces of the blades.

29. The connector of Claim 28, wherein the insulation displacement end is adapted so that a portion of the insulation displaced during insertion of the contact into the ribbon cable is positioned in the indentation when the contact is fully inserted into the ribbon cable.

30. The connector of Claim 29, wherein the indentations result in the conductors of the ribbon cable remaining in substantially the same plane after connection by the plurality of contacts so as to reduce the amount of cold flow of the insulation positioned between adjacent contacts after insertion.

31. The connector of Claim 25, wherein the base member includes a plurality of indentations formed on the first surface and the plurality of openings are positioned within the base member so that each indentation has an opening communicating with the indentation and wherein the openings are adapted to receive the plurality of contact so that the first end of each of the contacts can extend into a respective indentation via an opening and wherein the indentations are adapted to engage with the insulation surrounding the conductors of the ribbon cable so as to urge the conductors into a selected location with respect to the openings in the base member when the cover member is secured to the base member.

32. The connector of Claim 25, wherein the first surface of the cover member includes a plurality of indentations corresponding to the plurality of indentations on the first surface of the base member and wherein the plurality of indentations on the first surface of the base member and the first surface on the cover member are adapted to engage with the insulation surrounding the conductors so as to precisely locate the conductors within the space defined by corresponding indentations on the base and cover members with respect to the opening in the base member.

33. The connector of Claim 32, wherein the indentations on the base member and the cover member precisely locate the conductors so that the conductors are centered with respect to the openings of the base member that communicate with the indentations in the first surface of the base member.

34. A method of mounting a connector to a ribbon cable comprising: positioning the ribbon cable in a cable receiving area defined by a first surface of a base member and a first surface of a cover member wherein the positioning step results in the base member engaging with the insulation surrounding each of the conductors so that the conductors are located in a desired orientation with respect to a plurality of openings formed in the first surface of the base member; securing the cover member to the base member; positioning a plurality of contacts into the plurality of openings formed in the base member; inserting a first end of the plurality of contacts into the ribbon cable so that the first end of the plurality of contacts make an electrical connection to the conductors located in the desired location with respect to the openings in the base member; and making an electrical connection to a second end of the contacts when the contacts are electrically connected to the conductors of the ribbon cable so as to be electrically connected to the conductors of the ribbon cable via the plurality of contacts.

35. The method of Claim 34, wherein the act of positioning the ribbon cable in the cable receiving area comprises positioning the ribbon cable between a first surface of the base member having a plurality of indentations and a first surface of the cover member having a plurality of indentations wherein the indentations engage with the insulation surrounding the plurality of conductors so as to position the conductors in the desired location with respect to the openings in the base member.

36. The method of Claim 34, wherein the act of positioning the plurality of contacts into the plurality of openings in the base member comprises positioning the plurality of contacts, while the contacts are coupled to a carrier, into the openings in the second side of the base member.

37. The method of Claim 36, wherein the act of inserting the first end of the plurality of contacts into the ribbon cable comprises depressing the carrier so that the first end of the plurality of contacts are simultaneously inserted into the ribbon cable.

38. The method of Claim 37, further comprising detaching the carrier following insertion of the first ends of the contacts into the ribbon cable.

39. The method of Claim 34, wherein the act of inserting the first end of the plurality of contacts into the ribbon cable comprises inserting a plurality of contacts into the ribbon cable so that at least one indentation formed in an outer surface of each of the plurality of contacts is interposed between an outer edge of each of the contacts and adjacent conductor of the ribbon cable.

40. The method of Claim 39, wherein the act of inserting the first end of the plurality of contacts into the ribbon cable comprises inserting an insulation displacement end having two blades into the ribbon cable so that the conductor is positioned between the two blades and also so that an indentation formed on the outer surface of both of the blades is interposed between the outer surface of the contact and the adjacent conductor in the cable receiving area.

41. The method of Claim 39, wherein the act of inserting the first end of the plurality of contacts into the conductors comprises inserting the first end into the ribbon cable so that a portion of the insulation surrounding the conductor is displaced and is positioned within the at least one indentation.