JPH0477430B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a connector for terminating a plurality of insulated conductive wires, and particularly relates to a plug connector having a large number of interfitting members and a method for assembling the same. .

[Prior Art] Modular telephone connectors for packaging a large number of circuits with high density are known. Typically, a modular telephone plug includes an insulating housing having one or more wire receiving channels;
and a plurality of recessed electrical terminals movable within the housing to communicate with the wire receiving channel. An example of such a connector is disclosed in U.S. Pat. No. 3,761,869, in which a two-piece plug housing consisting of interfitting housing members has a mating surface forming a wire receiving channel. That is, each housing member is formed with wire receiving grooves for receiving half a side-by-side array of electrical cable conductors. One housing member has
A terminal receiving cavity is formed that extends into the wire receiving channel. The terminals received in these cavities are typically of die-cut and formed flat plate construction having an outer edge in slidable mating contact with the receptacle connector;
and an inner edge having an insulation-biting tip that is advanced toward a cable conductor received in the housing.

A strain relief is provided when the two housing members are crimped together, this strain relief being remote from the terminal. Automatic assembly speeds can be increased if wire handling is improved, particularly for wire sections in the immediate vicinity of the terminals. Four-conductor and six-conductor cables were developed for use in the telephone industry and are the largest in size. As digital technology becomes increasingly popular, input/output connector systems can take advantage of many of the benefits of modular plug features if they can be formed in compact packages with high packing density for significantly larger numbers of circuits. . In addition, if the housing shape can be simplified, it is economically attractive because it can reduce costs in the molding operation, improve control reliability, and reduce the reject rate of harnesses. becomes.

Another example of a modular telephone connector is disclosed in US Pat. No. 4,373,766, which provides some improvements in wire handling. In this configuration, the cable conductor is wrapped around the wire carrier, which is then inserted into the connector housing. Although this generally improves the automation of mass production, the handling of the wires at the termination points cannot be controlled and is done in a blind assembly process. Again, no strain relief is provided for the individual circuit conductors of the cable. Further, the terminal of this configuration is not a bite-type terminal as described above, but is a member formed of wire, which is easy to manufacture and has high reliability. Furthermore, there is a need for a simpler housing that will further reduce costs in the molding operation.

[Problems to be Solved by the Invention] Generally, in each of the above configurations and modular connectors, improvements in the harness assembly method are always being considered.

SUMMARY OF THE INVENTION It is, therefore, an object of the present invention to provide an improved harness assembly method for, for example, a high-density plug connector and a multi-circuit cable having flat-bladed insulation-piercing terminals.

Another object of the invention is to further improve the handling of the wire, in particular in simultaneous termination operations, for example for wire sections that are threaded by flat blade terminals.

Yet another object of the invention is to provide a smaller, higher density modular plug connector for multi-circuit cables.

These objects of the invention are achieved by the following configuration of a connector for terminating a plurality of insulated conductors. a housing having a forward mating end with an aperture, a rear cable receiving end with an aperture, and an internal passageway extending between the apertures; each terminal has a conductor engaging portion formed at a distal end portion facing the internal passageway and an internal mating contact portion formed at a rear end thereof, is movable between a first carrier-receiving position in which the conductor-engaging portion does not enter the internal passageway and a second terminal connection position in which the conductor-engaging portion enters the internal passageway; a conductor carrier received in the passageway, the conductor carrier having an external conductor-receiving surface that tapers toward the rear end adjacent the terminal and that receives the conductor and aligns it with the conductor-engaging surface of each terminal. the internal passage having a shape complementary to the conductor carrier and having a front opening larger than a rear opening so that the conductor carrier can hold the wire on its surface. This is achieved in a connector characterized in that the conductors are received in said internal passageway through a front opening of the housing after being received in said internal passageway, and that the conductors are connected to the terminals when the terminals are moved to their terminal connection position.

Furthermore, if the following features are added, the present invention can be better implemented. That is, the conductor carrier and the internal passageway are sized such that when the conductor carrier is inserted into the housing, the wire is pressed against the rear end of the housing by the conductor carrier to provide strain relief. It is desirable that

Further, the conductor carrier has a front end that is an opposite end to a rear end that is the end of the tapered external conductor receiving surface, and the front end has the plug connector that is fitted therein. Preferably, keying means are provided for providing a predetermined rotational alignment with the receptacle connector.

Preferably, the wire carrier has a conical shape and the key means is aligned with the axis of the conical wire carrier.

Preferably, the key means includes a protrusion extending from the larger front end of the cone, and the key means includes a recess extending inwardly from the larger end of the conductor carrier. It is desirable that

Furthermore, the objects of the invention described above are achieved by the following method of assembling a connector for terminating a plurality of insulated conductors. a housing having a forward mating end with an aperture, a rear cable receiving end with an aperture, and an internal passageway extending between the apertures; each terminal has a conductor engagement portion formed at a distal end portion facing the internal passageway and an internal mating contact portion formed at a rear end portion; , movable between a first carrier-receiving position in which the conductor-engaging portion does not enter the internal passageway and a second terminal connection position in which the conductor-engaging portion enters the internal passageway;
A conductor carrier is received in the passageway, the conductor carrier having an external conductor-receiving surface tapered toward a rearward end adjacent the terminal, and an external conductor-receiving surface for receiving the conductor and connecting it to the conductor-engaging portion of each terminal. means for aligning the internal passageway, the internal passageway having a complementary shape to the conductor carrier with the front opening being larger than the rear opening;
Insert the free end of the conductor cable through the receiving end of the housing so that the free end of the conductor extends out beyond the forward mating end of the housing opposite the cable receiving end, and engage the conductor with the exterior surface of the conductor carrier. together,
Terminate each wire by inserting the conductor carrier and conductor into the front mating end of the housing while maintaining engagement between the conductor carrier and the conductor, and moving the terminal toward the conductor carrier and into their termination position. This is accomplished in a method comprising the steps of:

[Embodiments] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

In the accompanying drawings, three embodiments are shown by way of example in order to explain the present invention, in which a cylindrical embodiment is shown in FIGS. 1 to 4, and a cylindrical embodiment is shown in FIGS. 5 to 8. A rectangular type is shown, and a hybrid type is shown in FIG.

1-4 of the accompanying drawings, a first embodiment of the connector of the present invention is indicated generally by the reference numeral 10. FIG. FIG. 1 shows a conductor carrier 12 of the present invention fitted with insulated circuit conductors 14 of a conventional multicircuit round cable 16. According to a preferred method of assembling connector 10, cable 16 and circuit conductors 14 are first inserted into a generally hollow cylindrical housing 30, and then the circuit conductors are inserted into the conductors, as shown in FIGS. 3a and 3b. It can be attached to the carrier 12.

FIG. 1 clearly shows the conductor carrier of the present invention in three dimensions. As shown in FIG. 1, the conductor carrier 12 is generally cylindrical;
It has a plurality of axially extending wire receiving grooves 18 in its outer surface 20. Conductor carrier 12
has a forward mating wall 22 from which an outwardly extending key member 24 projects along the axis of the conductor carrier 12. At the opposite end of the conductor carrier 12, the outer surface 20 is tapered away from the mating surface 22. Reference numeral 26 indicates a tapered portion of outer surface 20.

As shown in FIG. 1, cable 16 has an outer insulating sheath 28 that is removed to expose insulated circuit conductors 14. As shown in FIG.
The length of exposed conductor 14 extending between the tapered end of lead carrier 12 and the free end of sheath 28 is shown exaggerated for illustrative purposes. As will be appreciated by those skilled in the art, in practice the tapered end of the conductor carrier 12 will be brought very close to the free end of the sheath 28.

Referring to FIGS. 2 and 3, and referring first to FIG. 3a, the cable 16 is inserted into a generally hollow cylindrical housing 30. As shown in FIGS. As seen in Figure 3a, the housing 30 has an opening 34
It has a front mating end 32 with an opening 38 and a rear cable receiving end 36 with an opening 38. An internal passageway 40 extends between these openings 34 and 38. The free end of cable 16 is inserted into opening 38 and extended through passage 40 to a distance substantially beyond mating surface 32 to facilitate pressing conductor 14 onto conductor carrier 12 as shown in FIG. be made possible.

Referring again to FIG. 3a, the housing 30
has a large diameter forward cylindrical section 42, a rearward tapered transition section 44, and a small diameter rearward cylindrical section 46. aisle 40
is defined by radial directions 42', 44' and 46' of wall portions 42-46. Conductor carrier 12
has complementary shaped outer surfaces 20, 26 which, when the subassembly of FIG. 44' and a tight fit. When pulled rearwardly through the housing 30, the tapered surface 26 of the conductor carrier forces the conductor 14 against the tapered inner surface 44' of the housing, providing improved strain relief for the insulated conductor. If the conductor 14 is of very small size or delicate, the depth of the wire-receiving groove 18 formed in the conductor carrier 12 may be carefully controlled so that the wire receiving groove 18 lies between the surfaces 26, 44'. The conducting wire 14 can be appropriately compressed. Or again,
The wire carrier 12 can also be sized and shaped to simultaneously engage the wire carrier's outer surface 20 and inner surface 42'.

Referring to FIGS. 2 and 3a, a plurality of generally planar plate-shaped terminals 50 are mounted in passageways 56 of housing 30, and these terminals have external mating contact portions 52 and internal mating contact portions 52. It has a conductive wire engaging portion 54 extending in the direction. Conductor engagement part 5
Preferably, 4 comprises an insulating coating piercing tip as shown. However, other known termination connections may be used in the connector configurations described herein. For example, one variation may include opposing edge members of the insulation piercing type that straddle the conductive portion when cutting into the insulation insulation from the outside thereof.

As can be seen by comparing FIG. 3a with FIG.
In this termination position, the conductor-engaging portion 54 extends into the passageway 40 and into the wire-receiving groove 18, where it can be inserted into the conductor received therein. . In the embodiment shown, all terminals 50 are simultaneously terminated to their respective conductors 14 in one simultaneous termination operation. However, these terminals can be terminated sequentially to the individual conductors one at a time or in diametrically oriented pairs, or they can be terminated in other ways.

The configurations of Figures 3a and 3b are nearly ideal. The difference is that FIG. 3a shows a shielded cable and FIG. 3b shows an unshielded cable. The connector of FIG. 3a includes a metallic shield member 60 overlying the outer surface of the housing 30 and extending from the rear end 3.
6 and extends forward into passageway 40 overlying surfaces 46' and 44'. The cable shield 62 is folded back over the outside of the cable sheath so that it contacts the tapered free end 64 of the connector shield 60 when the cable and conductor carrier are placed within the housing 30. The cable shield 60 is
It can have finger-like protrusions extending towards or near the terminal receiving cavity 56 of the housing 30. This finger-like projection is formed on the contact surface 5 of the terminal 50.
2, and can be fitted into a receptacle terminal of a similar form.

In the embodiment shown in FIG.
extends on the front circular portion 42 of the housing;
It is bent onto the front end wall 32 between the terminals 50 . A bent portion 60' formed near end wall 32 and extending over portion 42 serves as an additional plug contact in conjunction with the function of mating with receptacle terminal 84 of receptacle connector 66. Although not shown, a terminal 50 is provided at the front of the shield 60.
The slot is cut to avoid electrical contact with the mating surface 52 of the connector.

The right-hand portion of Figure 3a shows a mating receptacle connector of cylindrical shape, which
Central cylindrical plug-receiving socket-shaped recess 70
an insulating housing 68 extending from the mating surface 72 . Recess 70 is defined by a circular inner wall 74 having a plurality of inwardly extending protrusions 76 aligned at an angle with the terminal location of plug 30 . A plurality of wire molded receptacle terminals 78 are arranged around the circular wall 74 . These terminals 78 are connected to the recess 7
0 and a second mating end 80 for connecting to an external circuit (not shown) such as a printed circuit board.
It has a tail portion 82. Also disposed around circular wall 74 are one or more ground contacts 84 that mate with the ground contacts disposed between terminals 50 . An example of a ground terminal mating with terminal 84 is shown in FIG.
0 to the mating end of the connector 10.

Disposed along the axis of the cylindrical recess 70 is a recess 88 that is complementary shaped to receive the key member 24 of the plug connector. As shown in the end view of FIG. 2, the conductor carrier 12 and housing inner surface 42' are provided with complementary projections/protrusions for coupling that angularly secure the individual conductors 14 with their corresponding terminals 50. It has a depression. Keying means 24, 88 between the plug and receptacle connectors may rotationally align them and orient the conductive members of the connector assembly.

The end view of FIG. 2 also includes a resilient locking arm 92 integrally molded with the plug housing 30. Arm 92 interlocks into cooperating recesses (not shown) formed near the mating surface of receptacle housing 68 and circular walls 72,74.

In the embodiment shown, the shield of the plug connector extends over the forward circular portion 42 of the housing and, as shown in the end view of FIG.
It is bent toward the front end wall 32 between the ends. This bent portion 60' formed near end wall 32 and extending over portion 42 serves as an additional plug contact in conjunction with the function of mating with receptacle terminal 84 of receptacle connector 66.
Although not shown in the accompanying drawings, a slot is provided in the forward portion of the shield 60 to avoid electrical contact with the mating surface 52 of the terminal 50.

5-8, another embodiment of the invention is shown having a generally rectangular or flat shape. This alternative embodiment receptacle connector is indicated generally by the reference numeral 110 and includes a rectangular conductor carrier 112 to which a plurality of insulated circuit conductors 114 of a conventional flat cable 116 are attached. As will be apparent from the following description, wire carrier 112 is very similar to the generally cylindrical wire carrier 12 described above.
The main difference is that the conductor carrier 112 in this alternative embodiment is shaped to mate with a rectangular socket in a receptacle connector, and the flat cable 11
6 can be easily terminated.

Therefore, the conductor carrier 112 is connected to the mating surface 122.
A first rectangular or box-shaped front portion 120 having a diameter. A key projection 124 extends outwardly from the mating surface 122 and is configured to mate with a mating receptacle connector. In addition, the conductor carrier 112 includes a rearwardly tapered surface 126 that connects the conductors 114 of the cable 116 and the forward portion 12 of the conductor carrier.
forming a transition between 0 and 0. A plurality of axially extending slots or grooves 118 are formed in the outer surfaces 120, 126 of the carrier portion for receiving individual insulated conductors 114. As shown in FIG. 5, channels 118 can be disposed on the sides, top, and bottom of the conductor carrier 112. Alternatively, these side, top and bottom sides of the conductor carrier can be provided with coupling depressions or projections.

As shown in FIGS. 7 and 8, the cable 11
6 is inserted into a generally hollow housing 130 having a generally rectangular cross-sectional shape. Housing 130 has a forward mating end 132 with an opening 134 and a rear cable receiving end 136 with an opening 138. An internal passageway 140 extends between these openings 134 and 138. The free end of cable 116 is connected to passage 14
0 into the opening 138 and the mating surface 132
conductor 1 on conductor carrier 112 as shown in FIGS. 5 and 7.
14 can be easily positioned.

The housing 130 has a large front portion 142
and a rear tapered transition portion 144, and can optionally include a rectangular portion 146 of reduced size compared to portion 142 described above. Passageway 140 is defined by the inner surfaces of sections 142 and 144. These inner surfaces have a complementary shape to and can engage the surfaces 120, 126 of the conductor carrier 112. When pulled rearwardly through the housing 130, the surface 126 of the conductor carrier forces the conductor 114 against the inner surface of the housing portion 144, creating improved strain relief for the insulated conductor.

a plurality of generally flat plate-shaped terminals 150;
is mounted within a passageway 156 of housing 130 and has an external mating contact portion 152 and an inwardly extending lead engagement portion 154. The conductor engaging portion 154 preferably comprises an insulation piercing tip as shown. However,
As described above with reference to FIGS. 1 to 4,
Other common termination connections for terminal 150 may also be provided.

Comparing FIG. 7 and FIG. 8, the terminal 150 is
The conductor carrier 112 is movable between a first conductor carrier receiving position and a second termination position in which the conductor engaging portion 154 extends toward the passageway 140 and the conductor carrier 112 is movable between a first conductor carrier receiving position and a second termination position. Enter channel 118. In the embodiment shown, all terminals 150 are simultaneously terminated to their respective conductors 114 in a single simultaneous termination operation. However, other termination operations are also possible. Although not specifically shown, the connector configuration of FIGS. 5-8 can readily accommodate an external metal shield substantially similar in form and function to that of FIG. 3a described above. This shield is connected to terminal 150
The conductor extends between carrier portions 120,126. The forward portion of the cable shield adjacent the mating surface 122 of the conductor carrier 112 can serve as a terminal mating member that is easily terminated into a receptacle connector.

In FIG. 9, yet another embodiment of a conductor carrier is indicated generally by the reference numeral 212. This conductor carrier 212 is similar in function and shape to the conductor carriers 12 and 112 described above. The main difference is that the conductor carrier 212 has a rectangular front surface 220 as shown in FIGS. 5-8 and a cylindrical or conical rear surface 227 as shown in FIGS. 1-4. It is something that we have. Between these surfaces 220 and 227 is a transition surface 226.
is provided and a continuous wire receiving recess or channel 218 extends along surfaces 220, 226 and 227.

The conductor carrier 212 has a front mating surface 222 from which a projection 224 extends.

Although not shown, it is understood that the housing that receives the conductor carrier 212 has a complementary shaped internal channel that receives the conductor and the conductor carrier. Therefore, strain relief for the individual conductors 14 of the round cable 16 is provided on surfaces 226 and/or 220 as well as on surfaces 2.
27 can be provided. Therefore, the transition surface 22
6 is comprised of upper and lower surfaces that are generally parallel to each other and converge in a direction away from the mating surface 222.
If this converging configuration is provided for the intermediate surface 226, a wedge-shaped strain relief can be obtained in the central part of the conductor carrier 212. Similarly, rear surface 227 may be cylindrical or conical, and if conical to provide strain relief, its taper extends away from mating surface 222 .

The terminal connection to the conductor carried by member 212 is
This can be done in the same way as above. That is,
A terminal inserted into the insulation sheath can be applied to a portion of the conductor 14 that is present in a channel section formed in the front part 220 of the conductor carrier. As described above with respect to the first embodiment of FIGS. 1-4 and the second embodiment of FIGS. Can be configured.

In each of the embodiments described with reference to the accompanying drawings,
It will be apparent that a two-piece plug connector has been provided which can be easily adapted to automatically terminate at the same time. In each example,
The terminals are preloaded into the connector housing so that they are precisely aligned with the internal passageways of the housing. The conductor carrier, which receives the conductors of a given cable, is coupled in precise alignment with the terminals carried by the housing for easy and simple assembly. Insertion of the conductor carrier into the housing automatically provides strain relief for the individual circuit conductors and simultaneously prepares the connector assembly for termination operations.

[Effects] As is clear from the above description, the present invention provides a configuration of a high-density plug connector having a flat-blade insulation-coated piercing type terminal and an improved harness assembly method for a multi-circuit cable. improved wire handling, especially in simultaneous termination operations, e.g. for wire sections inserted by flat blade terminals, and also provides compact, high-density modular plug connectors for multi-circuit cables. offered.

[Brief explanation of the drawing]

The accompanying drawings illustrate embodiments of the invention, and FIG. 1 is a perspective view showing a cylindrical conductor carrier of the invention installed in preparation for terminating round cable conductors into a cylindrical mating housing; , FIG. 2 is an end view of the insert of FIG. 1 when fully inserted into the cylindrical, generally hollow plug housing, and FIG. 3a is an end view of the harness assembly of FIG. 3b is an exploded cross-sectional view illustrating an assembly technique prior to termination; FIG. 3b is an unshielded version of the structure of FIG. 3a; FIG.
FIG. 5 is a perspective view of the rectangular conductor carrier of the present invention with the circuit conductors of a multi-conductor flat cable installed; FIG. 6 is an end view showing the assembled harness using the insert of FIG. 5, just before termination, and FIG. 7 is an exploded view of the connector of FIGS. 5 and 6. 8 is a partial sectional view of the fully assembled and terminated connector of FIGS. 5-7, and FIG. 9 is a perspective view of yet another conductor carrier of the present invention. It is. 10...Connector, 12...Conductor carrier, 1
4...Circuit conductor, 16...Round cable, 18...
... wire receiving groove, 22 ... front mating wall,
24... Key member, 26... Tapered portion, 28... Insulating sheath, 30... Hollow cylindrical housing, 32... Front mating end, 34, 38
...Opening, 36...Rear cable receiving end, 40
... Internal passage, 42 ... Front cylindrical portion, 44
...rear tapered transition section, 46...
Rear cylindrical portion, 42', 44', 46'...inner surface, 50...plate-shaped terminal, 52...external fitting contact portion, 54...conductor engagement portion, 56...passage, 60... ...metallic shield member, 66... receptacle connector, 84... receptacle terminal.

Claims (1)

[Scope of Claims] 1. A connector for terminating a plurality of insulated conductive wires, comprising a front mating end provided with an opening, a rear cable receiving end provided with an opening, and a connector extending between these openings. a housing having an internal passageway, and a plurality of terminals mounted around the housing, each terminal having a conductor engaging portion formed at a distal end portion facing the internal passageway and a conductor engagement portion formed at a rearward end portion; and an internal mating contact portion,
The terminal is movable between a first carrier-receiving position in which the conductor-engaging portion does not enter the internal passageway and a second terminal connection position in which the conductor-engaging portion enters the internal passageway; , a conductor carrier received in the passageway, the conductor carrier having an external conductor receiving surface tapering toward a rear end adjacent the terminal and a conductor engaging surface for receiving the conductor and connecting the conductor to the conductor engaging surface of each terminal. and means for aligning the
The internal passageway has a complementary shape to the conductor carrier, with the front opening being larger than the rear opening, so that the conductor carrier can
A connector characterized in that the wires are received in said internal passageway through the front opening of the housing after receiving the wires on its face, and that the conductors are connected to the terminals when the terminals are moved to their said terminal connection position. 2. The conductor carrier and the internal passageway are sized such that the wire is pressed against the rear end of the housing by the conductor carrier to provide strain relief when the conductor carrier is inserted into the housing. A connector according to claim 1. 3 The conductor carrier has a front end that is the opposite end to the rear end that is the end of the tapered external conductor receiving surface, and the front end has the plug connector that fits therein. 2. A connector as claimed in claim 1, wherein keying means are provided for imparting a predetermined rotational alignment with the receptacle connector. 4. The connector according to claim 1, wherein the conductor carrier has a conical shape. 5. A connector according to claim 3, wherein said key means is aligned with the axis of said conical conductor carrier. 6. The connector of claim 5, wherein said key means comprises a protrusion extending from the larger front end of said cone. 7. A connector according to claim 5, wherein said key means comprises a recess extending inwardly from the large end of said conductor carrier. 8. A method of assembling a connector for terminating multiple insulated conductors, which connector:
a housing having a forward mating end with an aperture, a rear cable receiving end with an aperture and an internal passageway extending between the apertures; and a plurality of terminals mounted around the housing. each terminal has a conductor engagement portion formed at a distal end portion facing the internal passageway, and an internal mating contact portion formed at a rear end portion; The conductor-engaging portion is movable between a first carrier-receiving position in which the conductor-engaging portion does not enter the internal passageway and a second terminal connection position in which the conductor-engaging portion enters the internal passageway; a lead carrier receiving a lead carrier having an external lead receiving surface tapered toward a rearward end adjacent the terminal and means for receiving the lead and aligning it with a lead engagement surface of each terminal; and the internal passageway has a shape complementary to the conductor carrier and has a front opening larger than a rear opening, and wherein the free end of the conductor cable is inserted through the cable receiving end of the housing. the conductor so that the free end of the conductor extends outwardly beyond the forward mating end of the housing opposite the cable-receiving end, and engages the conductor with the exterior surface of the conductor carrier and engages the conductor with the conductor carrier. inserting the conductor carrier and the conductor into the forward mating end of the housing while maintaining the conductor carrier and moving the terminal toward the conductor carrier and into their terminating position to terminate each wire. A method for terminating multiple insulated conductors, characterized by: