Abstract:
A high-density connector establishes electrical connections between insulated wires and other wires. The connector has terminals made of electrically conductive materials, for a plurality of insulated wires and a corresponding connector cap which has a round shape. The connector also has a base on which the terminals and cap are positioned. Each insulated wire has an insulation jacket. The connector includes front facing holes through which the insulated wires can be inserted. The terminals of the connector include a plurality of keyholes, each keyhole having a tail and a round portion that serves as the clearance hole for an insulated wire as it passes therethrough along with its insulation jacket. As the connector cap is rotated, it pushes the insulated wire placed in the round portion of the keyhole into the tail of the keyhole, which cuts into and removes the insulation jacket of the wire, thereby effecting an electrical connection between the electrical conductors of the wire and the terminals of the connector. The keyholes are adapted with particular tail widths to accommodate insulated wires of various gauge sizes. The connector can also effect electrical connection for a plurality of insulated wire.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to connectors for making electrical connection between insulated wires and other wires. In particular, the present invention relates to connectors with front facing insertion holes which are adapted to perform electrical connections on multiple wires of different gauge sizes.  
         BACKGROUND OF THE INVENTION  
         [0002]    Connectors are available in the art for connecting insulated wires with other wires (insulated or uninsulated). A method of making electrical connections between insulated wires with others is to remove the insulation jacket, using pliers, with strippers or other tools, and expose the electrical conductors for direct electrical contact with another wire. Such a method is inefficient for making a large number of electrical connections because it is time-consuming and labor-intensive.  
           [0003]    Connectors have been developed in the art for making electrical connections without using tools. These connectors are designed with internal structures that have the ability to remove the insulation jacket of an insulated wire without utilizing tools such as pliers. One such connector is disclosed in U.S. Pat. No. 5,240,432, entitled “Insulation Displacement Connectors” and having the same inventorship as the present invention. An electrical connector is provided therein which has a terminal for an insulated wire. The insulated wire has an insulation jacket, where electrical conductors are disposed at least partly in such jacket. The electrical conductor has a portion that is connectable to a wire and a cap that is initially seatable in an up position on the insulation jacket. The electrical connector is designed to allow the insertion of the insulated wire into a space enclosed by the cap and the insulation jacket. The cap is adapted to be forcibly pushed down from the up position onto the insulation jacket so as to effect an electrical connection with the insulated wire in the space enclosed by the cap.  
           [0004]    A particular disadvantage of connectors in the art (such as the connector disclosed herein above) is that multiple wires cannot be simultaneously accommodated, since each wire needs to be inserted into a connector one-by-one. A further disadvantage is that multiple wires of different gauge sizes cannot be accommodated in the prior connector. A general need therefore exists in the art for a connector that can accommodate multiple wires in making electrical connections. Furthermore, a connector is needed to provide electrical connections for multiple wires of different gauge sizes.  
         SUMMARY OF THE INVENTION  
         [0005]    The present invention provides a high-density connector for making electrical connections between insulated wires and other wires. The connector according to the present invention has terminals, which are made of electro-conductive materials, for a plurality of insulated wires and a corresponding connector cap which has a round shape. The connector also has a base on which the terminals and cap are positioned. Each insulated wire has an insulation jacket. The connector includes front facing holes through which the insulated wires can be inserted. The terminals of the connector include a plurality of keyholes, each keyhole having a tail and a round portion that serves as the clearance hole for an insulated wire as it passes therethrough along with its insulation jacket. As the connector cap is rotated, it pushes an insulated wire placed in the round portion of a keyhole to the tail of the keyhole, which cuts into and removes the insulation jacket of the wire, thereby effecting an electrical connection between the electrical conductors of the wire and the terminals of the connector. The keyholes are adapted with particular tail widths to accommodate insulated wires of various gauge sizes. The connector of the present invention can also effect electrical connection for a plurality of insulated wires.  
           [0006]    The present invention is advantageous because it can effect electrical connections for multiple insulated wires. A further advantage is that the connector of the present invention can accommodate a plurality of insulated wires of various gauge sizes. Another advantage is that the connector of the present invention, by virtue of its “L” shape tails, allows multiple wire wrap connections to its base. Yet another advantage of the present invention is that the round design of the connector and the cap minimizes the materials needed for, and cost of, fabrication.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    Other features and advantages of the present invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings, in which like reference designations represent like features throughout the enumerated Figures. The drawings referred to herein will be understood as not being drawn to scale, except if specifically noted, the emphasis instead being placed upon illustrating the principles according to the present invention. In the accompanying drawings:  
         [0008]    [0008]FIG. 1 is an exploded perspective view of an exemplary embodiment of a connector according to the present invention;  
         [0009]    [0009]FIG. 2 is another exploded perspective view of the connector according to the present invention;  
         [0010]    [0010]FIG. 3 is a perspective diagram of the connector according to the present invention when the cap, twin terminals and the base thereof are pushed together to form a single mechanical unit;  
         [0011]    [0011]FIG. 4 is a diagram of another perspective view of the cap of the connector according to the present invention;  
         [0012]    [0012]FIG. 5 is a diagram of another perspective view of one of the twin terminals of the connector according to the present invention;  
         [0013]    [0013]FIG. 6 is a diagram of a perspective view of the cap and the twin terminals of the connector according to the present invention when they are in the fastened position;  
         [0014]    [0014]FIG. 7 is a diagram of a plan view of the cap and the twin terminals of the connector according to the present invention when they are in the fastened position;  
         [0015]    [0015]FIG. 8 is a diagram of yet another plan view of the cap and the twin terminals of the connector according to the present invention when they are in the fastened position;  
         [0016]    [0016]FIGS. 9A, 9B, and  9 C are diagrams of cross-sectional views of the connector and its components according to the present invention; and  
         [0017]    [0017]FIG. 10 is a diagram illustrating a cross-sectional view of the connector of the present invention in a wire wrap connection.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0018]    [0018]FIG. 1 is a diagram illustrating the components of a connector according to the present invention. Referring to FIG. 1, the connector includes a cap  1 , twin terminals  2 , and a base  3 . The twin terminals  2  are made of electrically conductive materials, e.g., metals. Cap  1  and base  3  are made of non-electrically-conductive materials, e.g., plastics. Cap  1 , which has a round shape, can be rotated and is adapted to receive twin terminals  2  and to allow insulated wires to pass through cap holes  12  and the round portions of keyholes  20  located on the twin terminals  2 .  
         [0019]    Cap  1 , twin terminals  2 , and base  3  can be pushed together to collapse into a single mechanical unit. When Cap  1  is pushed down against base  3 , a downwardly extending circular portion  10 ′ to cap notch  10 , Cap  1  is securely received in base notch  30  (which also has a round shape), with twin terminals  2  disposed therebetween. Cap  1  can be securely fastened to base  3  by pushing cap hooks  14  through base grooves  34  so as to hook onto the bottom of base  3 . Twin terminals  2  are secured onto base  3  by pushing L-shaped tails  22  through terminal slits  32  in the base  3  and hooking onto the bottom of base  3 .  
         [0020]    [0020]FIG. 2 is a diagram showing another angular view of the connector according to the present invention. Cap  1 , twin terminals  2 , base  3  and their respective components are similarly shown in FIG. 2.  
         [0021]    [0021]FIG. 3 is a diagram illustrating the bottom of the connector of the present invention when cap  1 , twin terminals  2  and base  3  are pushed together into a single mechanical unit. Referring to FIG. 3, cap  1  has been pushed together with base  3 , with twin terminals  2  disposed therebetween. However, twin terminals  2  are not seen in this perspective view, except for L-shaped tails  22  thereof. Base  1  is securely fastened onto base  3  by pushing cap hooks  14  through base grooves  34 . This is facilitated by the compressible shape of the cap hook protrusion  16  at the ends of the hooks  16 , which allow them to compress when they pull through grooves  34  and then extend to hook onto the bottom of base  3  to provide a retaining force for the cap  1  on the base  3 . Similarly, L-shaped tails  22  and L-shaped tail protrusions  24  (FIG. 9B) are proportioned so that they can pass through terminal slits  32  and the tail protrusions  24  can hook onto the bottom of base  3 . However, in this preferred embodiment since the base  3  is made of plastics, the slits  32  can expand to accommodate the tail protrusions  24  as they pull through. (FIG. 9C).  
         [0022]    Base grooves  34  serve as the angular rotational stop for cap hooks  14  so that cap  1  can be rotated by twisting an upwardly extending portion  10 ″ of cap notch  10  to an “aligned” position, i.e., a point where cap hooks  14 , along with cap hook protrusions  16 , are stopped by base grooves  34 . The purpose for this is described below.  
         [0023]    [0023]FIG. 4 is a diagram of another angular perspective view of cap  1  of the connector according to the present invention. In FIG. 4, the downward extension of cap notch  10  is seen, along with cap holes  12 , cap hooks  14  with cap hook protrusions  16 , and cap fins  18  with cap fin ends  15 . The cap outside surface defines the cap holes  12 . Further, FIG. 4 illustrates the location of cap inside holes  13  defined by cap fins  18 , cap inside wall  19  and cap inside surface  17 . Viewing the bottom of cap  1 , cap fins  18  receive twin terminals  2 . Cap holes  12  and cap inside holes  13 , both of similar size, allow passage of insulated wires from the top of cap  1  through cap fins  18 . Cap fins  18  are permanently affixed to cap inside wall  19 . Spacing A between the cap inside upper surface  17  and the cap fins  18  (FIG. 9A) is formed such that the cap can be fastened with twin terminals  2  by fitting the top of twin terminals  2  into the spacing (FIG. 9C).  
         [0024]    [0024]FIG. 5 is a diagram of another angular perspective view of one of the two twin terminals  2  of the connector according to the present invention. Both terminals of twin terminals  2  are substantially identical. In FIG. 5, it is shown that one of the twin terminal  2  includes three keyholes  20 , each with keyhole tails  29  and keyhole round portions  27  and formed in terminal top surface  26 . A terminal side surface  28  extends perpendicular to top surface  26 . The two terminals also include L-shaped tails  22  with L-shaped tail protrusions  24 .  
         [0025]    Keyhole round portions  27  are approximately the same size as cap holes  12  and cap inside holes  13  of cap  1 . Each of the keyhole tails  29  are dimensioned such that they are only large enough to permit the electrical conductors of an insulated wire (not shown) to pass through. Each of keyhole tails  29  is not large enough to permit passage of the insulated wire with its insulation jacket. The upper rectangular portions of twin terminals  2  are dimensioned such that they can be fastened with cap  1  by sliding terminal top surface  26  into the space between cap fins  18  and cap inside surface  17 . (FIG. 9C). Terminal side surface  28 , which is concave-shaped, is disposed between cap fin ends  15  of cap fins  18  and the downwardly extending cap notch  10 ′ (FIG. 4) when the twin terminals  2  are fastened with cap  1 .  
         [0026]    [0026]FIG. 6 is a diagram of cap  1  and twin terminals  2  of the connector according to the present invention, when they are fastened together. Referring to the figure, twin terminals  2  are fastened with cap  1  by positioning terminal top surface  26  into the space between cap fins  18  and cap inside surface  17  of cap  1 . Terminal side surface  28  is disposed between lower cap notch  10 ′ and cap fin ends  15  of cap fins  18 . Cap  1  and twin terminals  2 , as shown in FIG. 6, are in the so-called “aligned” position. Cap  1  and twin terminals  2 , in the aligned position, have cap holes  12 , keyhole round portions  27  of keyholes  20 , and cap inside holes  13  aligned such that insulated wires (not shown) can pass through them. Each of the round openings created by cap holes  12 , keyhole round portions  27 , and cap inside holes  13  allows an insulated wire, along with its insulation jacket, to pass therethrough.  
         [0027]    [0027]FIG. 7 shows another view of cap  1  and twin terminals  2  in the aligned position. In this view, it can be seen that terminal side wall  28  and L-shaped tails  22  of twin terminals  2  hug cap fins  18  of cap  1 , with terminal side wall  28  disposed between cap notch  10 ′ and cap fin ends  15 . The terminal top surface  26  is larger than cap fins  18  such that keyhole tails  29  can be aligned with cap holes  12  and cap inside holes  13 .  
         [0028]    Cap  1  and twin terminals  2  can switch from the aligned position to the nonaligned position by rotating cap  1 . A user of the connector according to the present invention can rotate cap  1  by twisting cap notch portion  10 ″. As cap  1  is rotated, it pushes the insulated wires placed in keyhole round portions  27 , which are aligned with cap holes  12  and cap inside holes  13  in the aligned position, to keyhole tails  29 , which are aligned with cap holes  12  and cap inside holes  13  in the non-aligned position. During the transition from the aligned position to the non-aligned position, keyhole tails  29  cut into and remove the insulation jacket from the insulated wires. As the insulation jacket of the insulated wires is removed, the electrical conductors of the insulated wires are exposed. Since twin terminals  2  are made of electrically conductive materials, an electrical connection is effected between the conductors of the insulated wires and the twin terminals  2 .  
         [0029]    Keyhole tails  29  can be adapted with particular widths to accommodate insulated wires of various gauge sizes. Since there are multiple cap holes  12  for receiving multiple insulated wires, the connector according to the present invention can advantageously effect an electrical connection for a plurality of insulated wires simultaneously, merely by twisting cap  1 . Furthermore, L-shaped tails  22  of twin terminals  2  permit multiple wire wrap connections so that additional connections to a circuit can be easily made.  
         [0030]    [0030]FIG. 8 is a diagram of another perspective view of the connector according to the present invention in the non-aligned position. Referring to the figure, cap  1  is rotated to the non-aligned position such that keyhole tails  29  of twin terminals  2  are aligned with cap holes  12  and cap inside holes  13 . In the aligned position, the insulated wires (not shown) pass through cap holes  12 , keyhole round portions  27 , and cap inside holes  13 . During the transition from the aligned position to the non-aligned position, the insulation jacket of the insulated wires is removed and an electrical connection is effected between the electrical conductors of the insulated wires and twin terminals  2  by way of the metal keyholes  29 .  
         [0031]    [0031]FIGS. 9A, 9B, and  9 C are diagrams of cross-sectional views of the connector and its components according to the present invention. In particular, FIG. 9A illustrates the cross-sectional perspective of cap  1  of the connector according to the present invention. FIG. 9B illustrates the cross-sectional perspective of cap  1  and twin terminals  2  when they are fastened together. FIG. 9C illustrates the cross-sectional perspective of the connector when cap  1 , twin terminals  2 , and base  3  are pushed together to form a single mechanical unit.  
         [0032]    Referring to FIG. 9A, cap  1  is dimensioned such that the space A between cap inside surface  17  and cap fins  18  will accommodate terminal top surface  26 . By fitting terminal top  26  into that space A, twin terminals  2  are fastened with cap  1 . Cap inside holes  13  on cap fins  18  are constructed to be aligned with cap holes  12 . Cap  1  can be rotated by twisting cap notch  10 ″.  
         [0033]    In the present embodiment, cap notch  10  is a hexagonal socket head comprising a hexagonal head bolt  50  surrounded by the thin wall of notch portion  10 ″. A user of the connector of the present invention can rotate cap  1  using a {fraction (7/16)}-inch, type  216  socket wrench, which is commercially available from Lucent Technologies, the assignee of the present invention. Cap notch  10  can alternatively include a screwdriver slit (single or cross, e.g. slit B of FIG. 9C), so that cap  1  can be rotated using a screwdriver. In addition, cap notch  10  can be a knob, a wing nut, a notch with a handle, or any device that a user can use to rotate cap  1 .  
         [0034]    [0034]FIG. 9B illustrates cap  1  and twin terminals  2  when they are fastened together. Referring to the figure, twin terminals  2  are fastened with cap  1  by fitting terminal top  26  into the space A between cap inside surface  17  and cap fins  18 , with the terminal side wall  28  being disposed between cap notch portion  10 ′ and cap fins  15 . Cap fins  18  extend under terminal top surface  26  such that the cap inside holes  13  (which are aligned with cap holes  12 ) are aligned with keyhole round portions  27  in the aligned position (as shown in FIG. 7) or with the keyhole tails  29  in the non-aligned position (as shown in FIG. 8).  
         [0035]    [0035]FIG. 9C illustrates the connector according to the present invention when cap  1 , twin terminals  2  and base  3  are pushed together to form a single mechanical unit. Referring to the figure, cap  1  is fastened with base  3  by inserting cap hooks  14  into base grooves  34 . Cap hooks  14  are retained by hooking cap hook protrusions  16  onto base bottom  36  of base  3  as noted above. Twin terminals  2  are fastened with base  3  by inserting L-shaped tails  22  into terminal slits  32 . Twin terminals  2  are retained by hooking L-shaped tail protrusions  24  onto base bottom  36  as noted above. L-shaped tails  22  extend downward from terminal slits  32 . Terminal top surface  26  and terminal side wall  28  of twin terminals  2  are disposed within cap  1  and base  3 . In particular, terminal top surface  26  is disposed between cap fins  18  and cap inside surface  17 . Base notch  30  is disposed between the lower portion  10 ′ of cap notch  10 , and terminal side wall  28 , with terminal side wall  28  being disposed between base notch  30  and cap fin ends  15 .  
         [0036]    Base grooves  34  serve as the angular rotational stop for cap hooks  14 . Thus, cap  1  can be rotated by twisting cap notch  10  to the aligned position, i.e., a point where cap hooks  14 , along with cap hook protrusions  16 , are stopped by base grooves  34 . As cap  1  is rotated, the insulated wires placed in keyhole round portions  27  are engaged by keyhole tails  29  which cut into and remove the insulation jacket of the insulated wires (not shown), thereby effecting an electrical connection between the electrical conductors of the insulated wires and twin terminals  2  of the connector. Keyhole tails  29  of twin terminals  2  are adapted with particular widths to accommodate insulated wires of various gauges.  
         [0037]    [0037]FIG. 10 is a diagram illustrating the connector according to the present invention in use for wire wrap connections with wire wraps  40 . The wire wraps  40  are connected with the connector of the present invention by wrapping around twin terminals  2 . Wire wraps  40  can be located around twin terminals  2  in a fast and convenient manner using wire wrap tools which are commercially available.  
         [0038]    Once the unit is assembled, insulated wires may be placed into cap holes  12  on the top of the cap. They will extend through these holes and into cap inside holes  13  and terminal keyhole round portions  27 , all of which are in the aligned position. As cap  1  is rotated by twisting cap notch  10  into the non-aligned position, the insulated wires placed in keyhole round portions  27  are engaged by keyhole tails  29  which cut into and remove the insulation jacket of the insulated wires (not shown) and the electrical conductors disposed therein are exposed. As a result, the electrical conductors make contact with twin terminals  2 , which are made of conductive materials. Electrical connections are effected between the twin terminals  2  and wire wraps  40 , either before or after the insulated wires are connected to the twin terminals by rotation of the cap  1 .  
         [0039]    Twin terminals  2  can electrically connect six insulated wires at (terminal top surface  26 ) and wire wrap two wires at L-shaped tails  22 . Thus, the connector according to the present invention can advantageously effect an electrical connection for a plurality of insulated wires simultaneously to a single wire. However, the ratio of terminals to access holes for insulated wires can be much greater or less. Another advantage of the present invention is that the round design of cap  1  and the connector minimizes the materials needed for, and cost of, fabrication.  
         [0040]    While the present invention has been particularly shown and described with reference to the preferred embodiments thereof, the embodiments are not intended to be exhaustive or to limit the present invention to the precise forms disclosed herein. It will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the present invention. Similarly, any process steps described may be interchangeable with other steps in order to achieve the same result. It is intended that the scope of the present invention is defined by the following claims and their equivalents.