Abstract:
A method for manufacturing electrical receptacles using automated processes. A continuous strip of lead frames is fed into an apparatus which attaches and forms contact wires to each individual lead frame. Each lead frame is then affixed to a pre-formed terminal block. A forming process is performed on the lead frame and contact wires to create a base for the jack receptacle. A jack body is then placed over the contact wires, combining the contact wires into a final position to form the electrical receptacle.

Description:
FIELD OF THE INVENTION 
     The invention relates generally to a method for manufacturing electrical receptacles. More particularly, the invention relates to a method for manufacture of electrical receptacles for use in telecommunications. 
     BACKGROUND OF THE INVENTION 
     Telecommunication jacks are generally well known. By and large the telecommunication jacks of the past have been manufactured to standards required for analogue communications. This has allowed for communications paths which may withstand breaks in transmission of up to 100 milliseconds. However, since the world is changing from analogue to digital communications, a considerably higher quality jack is essential. In the digital world, a break in communications of 1 millisecond could produce an erroneous signal to, for example, a telephone switching system thereby producing undesired results. It is thus imperative to have a more reliable telecommunications connection. 
     The manufacture of telecommunication jacks, in the past, has also been labour intensive, and thus costly. The existing jacks have generally consisted of many parts and sub-assemblies requiring large amounts of manual labour. An automated method of manufacture, therefore, would be preferable to increase output and reduce costs. 
     Furthermore, the existing telecommunication jacks have been susceptible to corrosion by ingested contaminants from outside sources. The existing jacks have generally been manufactured with contact wires positioned at the bottom of a jack opening, with no protection to outside contaminants being provided. 
     The present invention is directed to providing solutions to the above-mentioned problems of existing telecommunication jacks. Firstly, the jack is designed such that it has a modular central core consisting of few parts, the jack assembly being performed by a continuous automated process. Secondly, the jack receptacle manufactured by the method of the present invention is designed to provide for the higher quality needs of digital communications. Finally, the jack receptacle thus manufactured has jack contact wires which are at the top of the jack opening, with the jack being enclosed by a plastic enclosure having a shutter to allow access to the jack opening; thus restricting the ingestion of contaminants. 
     SUMMARY OF THE INVENTION 
     The present invention is a method of automated manufacturing for electrical receptacles. The receptacles are manufactured in a continuous fashion from pre-formed lead frames which are interconnected by carrier strips. Each individual lead frame is fed into position where contact wires are crimped and welded to conductors of the lead frame. The individual lead frame is attached to the backside of a terminal block. A forming process is then performed in which the conductors of the lead frame are wrapped around the edges of the terminal block and fixed into place on the topside of the terminal block. The contact wires are also formed at this stage to create elastically deformable spring contacts. A retainer attached to the terminal block and used to hold the contact wires in an equidistantly spaced relationship is then separated from the terminal block. The contact wires are bent 90° at the terminal block such that the attached retainer forms a back panel for the receptacle. A receptacle body of an insulated material is then attached to the terminal block to form an electrical conductor receiving cavity. The conductors of the lead frame are then fixedly attached to the terminal block by screws to complete the assembly. A cover may then be added to the assembly to protect the internal contact wires if so desired. 
     Stated in other terms, the present invention is a method of automated manufacturing of an electrical receptacle, the method comprising the steps of: feeding a first lead frame into an assembly unit; forming first ends of a plurality of contact wires such that the contact wires will mate with first ends of conductors on the first lead frame; fastening the contact wires to the conductors; fixing the lead frame to a terminal block; forming second ends of the conductors such that they wrap around to a backside of the terminal block; securing the conductors on the backside of the terminal block; fixing the second ends of the contact wires to a retainer part on the terminal block; bending a first bend in second ends of the contact wires to form an acute angle; separating the retainer part of the terminal block from the terminal block; bending a second bend in second ends of the contact wires at a point intermediate the retainer and the terminal block such that the retainer is substantially perpendicular to the terminal block and is adjacent to the terminal block; attaching an insulated housing to the terminal block. 
     Stated in yet other terms, the present invention is an electrical receptacle, the receptacle comprising: a plurality of conductors insulated one from another; a plurality of contact wires insulated one from another and connected to first ends of the plurality of conductors in a one to one relationship; a terminal block to which the conductors are attached; second ends of the plurality of conductors wrapped around to a backside of the terminal block and secured to the backside of the terminal block; a retainer substantially perpendicular to the terminal block and adjacent to the terminal block; the plurality of contact wires formed to mate with a plurality of channels on the retainer, and folded over the retainer to thereby form a plurality of equidistantly spaced elastically deformable electrical contact wires for electrical connection to a mating connector; an insulated housing attached to the terminal block, the insulated housing having a plug receiving cavity, opposing parallel side walls, and a back plate opposite and parallel to the plug receiving end; the plug receiving cavity containing the plurality of equidistantly spaced elastically deformable electrical contact wires. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be further understood from the following description with reference to the accompanying drawings, in which: 
     FIG. 1 is a bottom plan view of a terminal block; 
     FIG. 2 is a top plan view of a lead frame strip; 
     FIG. 3 is a top plan view of an individual four conductor lead frame; 
     FIG. 4 is a top plan view of an individual six conductor lead frame; 
     FIG. 5 is a top plan view of a crimp form; 
     FIG. 6 is a side elevational view of a crimp form after it has been formed; 
     FIG. 7 is a cross-sectional view of the crimp form of FIG. 6 taken along the section lines 7--7; 
     FIG. 8 is a cross-sectional view of a thread form; 
     FIG. 9 is a bottom plan view of a terminal block; 
     FIG. 10 is a top plan view of the terminal block of FIG. 8; 
     FIG. 11 is a cross-sectional view of the terminal block of FIG. 9 taken along section lines 11--11; 
     FIG. 12 is a cross-sectional view of the terminal block of FIG. 9 taken along section lines 12--12; 
     FIGS. 13a-13g are perspective views indicating the steps of manufacture of a jack receptacle; 
     FIGS. 14-16 and 18-21 are detailed bottom plan views of the steps of manufacture of a jack receptacle; 
     FIG. 17 is a bottom plan view of a terminal block after the final forming step; 
     FIG. 22 is a cross-sectional view of the jack receptacle after a final forming step; 
     FIG. 23 is a top plan view of a jack body; 
     FIG. 24 is a cross-sectional view of the jack body of FIG. 23 taken through the section lines 24--24; 
     FIG. 25 is a bottom plan view of the jack body of FIG. 23; 
     FIG. 26 is a cross-sectional view of the jack body of FIG. 23 taken through the section lines 26--26; 
     FIG. 27 is a cross-sectional view of the jack receptacle in its final form; and 
     FIG. 28 is an exploded view of the jack receptacle. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 is a bottom view of an assembly of lead frame 110, contact wires 300, and terminal block 200 which together form part of jack receptacle 1000 of the present invention. The method of manufacture of jack receptacle 1000 is described in the following discussion. 
     FIG. 2 is a top plan view of a portion of lead frame strip 100 having lead frames 110, 120, and 130. Lead frame strip 100 is initially created by stamping a single strip of metal to form a plurality of lead frames, as well as carrier strips 20 and 30. Carrier strips 20 and 30, having positioning holes 22, are used to facilitate automated feeding of the lead frames into an assembly unit. Each lead frame 110, 120, and 130 is temporarily attached to carrier strips 20 and 30 by links 24. The lead frames are used to make electrical contact between a jack receptacle and external wiring (for example, the wiring from a telephone company). 
     FIG. 3, incorporating similar reference numbers as FIG. 2, shows a top plan view of an individual lead frame 140 attached to carrier strips 20 and 30. Lead frame 140 comprises four conductors 40a, 40b, 40c, and 40d. Each conductor 40 has within it an oblong clearance hole 12 and a thread hole 14 for accepting a screw after formation of lead frame 140. Clearance hole 12 is made oblong to account for variations in positioning caused by a step of the forming process. Adjacent clearance hole 12 are barbs 16 which are provided to aid in temporarily fixing conductor 40 to a terminal block. Thread form 15, surrounding thread hole 14, is provided to interact with a screw and a terminal block to thereby increase the amount of torque that may be applied to the screw. A relieve hole 18 is provided to facilitate bending of conductor 40 in a step of the forming process. Heat stake post hole 19 is provided to accept a heat stake post on a terminal block which is used to fasten lead frame 140 to the terminal block. Central to lead frame 140 each conductor 40 terminates in a crimp form 11 which is used to interconnect conductor 40 with a contact wire. Each crimp form 11 is temporarily attached to an adjacent crimp form 11 by a detachable link 26. 
     FIG. 4 shows a top plan view of an individual lead frame 110. Lead frame 110 is similar to lead frame 140 of FIG. 3 except that lead frame 110 has six conductors (40a, 40b, 40c, 40d, 40e, 40f) as opposed to four. It can be realized that a lead frame can have any number of conductors incorporated in the design. 
     FIG. 5 shows a top plan view of a crimp form 11 attached to a conductor 40a at one end. Affixed to the opposite end of crimp form 11 is a detachable link 26. Crimp form 11 is shaped such that a contact wire placed longitudinally central to crimp form 11 will be fastened by angular formations 13 when angular formations 13 are formed around the contact wire. FIGS. 6 and 7 illustrate the shape of crimp form 11 after an initial forming step. After a final forming step, crimp form 11 essentially takes on a cylindrical shape as viewed in cross-section. 
     FIG. 8 illustrates features of thread form 15. Thread form 15 comprises a spiral dome which acts as a tension device on a screw inserted into thread form 15. A screw inserted through a terminal block (to be described) will contact thread form 15. As the screw is screwed into thread form 15, the screw head will eventually contact the terminal block. At this point thread form 15 interacts with the screw and the terminal block to provide a resistance sufficient to allow the screw to be torqued down to the terminal block to a force of 8 inch pounds minimum. 
     FIG. 9 is a plan view of backside 280 of dielectric terminal block 200 showing contact forms 210 (a-h). Each contact form 210 is constructed to accept a conductor 40 from lead frame 110. Within each contact form 210 is a ridge 201 having a terminal hole 202 therein for accepting a screw. Ridge 201 interacts with thread form 15 of a conductor 40 to provide the screw resistance described above. Channels 214, on terminal block 200, are provided to accept contact wires (not shown in this Figure). FIG. 9 also illustrates how retainer 208, having channels 204 formed thereon (also provided to accept contact wires), is temporarily held in position by links 212. Post holes 203 are provided to accept posts of a jack body (to be described later). Also illustrated are heat stake posts 209 which are provided to interact with heat stake post holes 19 on lead frame 110 to fasten conductors 40 to terminal block 200. 
     FIG. 10 is a top plan view of the topside 290 of terminal block 200. Each terminal hole 202 resides in a channel 205 which is separated from other channels 205 by an insulated ridge 206. Channels 205 are provided to accept the ends of conductors 40 after they have been formed around terminal block 200 (to be described later). Channels 205 cooperate with barbs 16 on conductors 40 to aid in temporarily fixing conductors 40 in-place until conductors 40 are fastened to terminal block 200 by screws. 
     FIG. 11 illustrates terminal block 200 in cross-section through channels 205 and terminal holes 202. FIG. 11 further illustrates features of terminal block 200 as described above. 
     FIG. 12 is illustrative of the form of retainer 208 as seen in cross-section. 
     FIGS. 13a to 13g are provided as an overview of the steps of manufacture of the jack receptacle of the present invention. FIGS. 13a to 13g are illustrative of the manufacture of a six conductor jack receptacle. It can be realized that the process is the same for jack receptacles of other than six conductors. A detailed description of the steps of manufacture will follow the discussion of FIGS. 13a to 13g. 
     FIG. 13a shows lead frame 110 in position with contact wires 300 ready for assembly. 
     FIG. 13b illustrates terminal block 200 in position, ready to accept lead frame 110. 
     FIG. 13c shows the resulting product after contact wires 300 have been crimped to lead frame 110 and placed on the backside 280 of terminal block 200 (i.e. the items of FIGS. 13a and 13b have been mated to result in the item depicted in FIG. 13c). A forming process then takes place in which conductors 40 and contact wires 300 are bent (in direction A) perpendicular to the plane of backside 280 resulting in the formation illustrated in FIG. 13d. 
     A further forming process, indicated in FIG. 13e, is then executed in which conductors 40 are bent (in directions C and D as appropriate) such that they contact terminal block topside 290. Contact wires 300 are also bent (in direction B) at this stage to form an angle to the plane of terminal block topside 290. 
     Retainer 208 is detached from terminal block 200 by cutting links 212. Contact wires 300 are bent intermediate retainer 208 and terminal block 200 such that retainer 208 is perpendicular to terminal block topside 290 and forms a back panel. The result is indicated in FIG. 13f. 
     Finally, in FIG. 13g, an insulated receptacle body 500 is attached to terminal block 200 by posts 510 being inserted in post holes 203. Conductors 40 are secured in place by terminal screws 400. 
     The process will now be described in more detail, with reference to FIGS. 14 to 21. Each step of the process is performed on one jack receptacle assembly at a time. 
     To start the process lead frame strip 100 is fed into a machine (not shown) by carrier strips 20 and 30 and guide holes 22. Carrier strip 30 is removed by cutting links 24 from conductors 40. Crimps 11 are separated by removing links 26. The result is shown in FIG. 14. 
     Contact wires 300 are then added and formed, two at a time, such that ends of contact wires 300 have a 90°  bend, thereby allowing their placement over forms 11 while maintaining a spatial relationship between each individual contact wire 300. Contact wires 300 are held in place by crimping crimps 11 around contact wires 300, as shown in FIG. 15. 
     Contact wires 300 are further held in place by their ends being resistance welded to conductors 40 at points W, as indicated in FIG. 16. (In a preferred embodiment, the pull strength of the weld is a minimum of 6 pounds.) The welding process further provides better electrical contact between contact wires 300 and conductors 40. 
     Lead frame 110 and contact wires 300 are then placed on terminal block 200 (which is fed into the assembly unit as an individual item) such that conductors 40 align with contact forms 210 and heat stake post holes 19 fit over heat stake posts 209, as shown in FIG. 18. Lead frame 110 is heat staked to terminal block 200 at points S (heat stake posts 209) to hold the assembly together. Contact wires 300, which now lie in channels 204 and 214 (not shown in FIG. 18), are fixed in position by heat staking channels 204 and 214. 
     FIG. 17 provides a clearer representation of the jack receptacle at this stage of the process. FIG. 17 is a bottom view of the assembly of lead frame 110, contact wires 300, and terminal block backside 280. FIG. 17 is illustrative of the one to one relationship of each conductor 40 with contact form 210. FIG. 17 is further illustrative of the positioning of contact wires 300 in channels 204 and 214. 
     Links 24 are clipped from between lead frame sections 110 and 120, as shown in FIG. 19. Terminals 40 are then bent down towards topside 290 of terminal block 200 such that they are perpendicular to topside 290 and then bent again such that they are parallel to topside 290 and wrap around terminal block 200 (FIG. 20). 
     Lead frame 110 is then cut from carrier strip 20 by removing links 24. Contact wires 300 are bent approximately 90° to the plane of terminal block topside 290. Contact wires 300 are then further bent such that they form an angle with the plane of terminal block topside 290. Retainer 208 is cut from terminal block 200 by removing links 212. Contact wires 300 are bent 90° intermediate retainer 208 and terminal block 200 such that retainer 208 is placed perpendicular to the plane of terminal block topside 290. The resultant form of contact wires 300 is illustrated in FIG. 22. Self tapping terminal screws 400 are then inserted into clearance holes 12, through terminal holes 202, and finally through thread holes 14, interacting with thread forms 15 to secure conductors 40 and allow for interconnection of the jack receptacle to wires from the telephone company. 
     FIGS. 23-26 illustrate the features of insulated receptacle body 500. Body 500 comprises a dielectric housing having a plug receiving end 560, rearward end 570, and having a plug receiving cavity 530 which extends from plug receiving end 560 to rearward end 570. Plug receiving cavity 530 comprises lower and upper internal sidewalls 532, 534, and internal end walls 536. Plug receiving cavity 530 is contoured to receive a mating plug, which may have a latch which interacts with the contour of plug receiving cavity 530 to maintain a positive engagement of the mating plug with jack receptacle 1000. Within plug receiving cavity 530 is comb 520. The purpose of comb 520 is to maintain a spatial relationship between contact wires 300 as well as to maintain a maximum angle of contact wires 300 with respect to terminal block topside 290. 
     FIG. 27 is illustrative of the assembled jack receptacle as seen in cross-section. In this Figure can be seen the relationships between terminal block 200, insulated receptacle body 500 and contact wires 300. 
     FIG. 28 further illustrates the components of jack receptacle 1000 and how jack receptacle 1000 can be fitted into a suitable baseplate 700. 
     In a preferred jack receptacle: the contact wires are C654 wire; the lead frame is made of 260 brass, 1/2 hard, 0.41 millimeters thick; and the terminal block and jack body are made of flame retardant plastic. 
     Numerous other modifications, variations, and adaptations may be made to the particular embodiment of the invention described above without departing from the scope of the claims.