Electrical connector having an elongate rear slot communicating with conductor receiving channels via conductor receiving and holding notches

Techniques for terminating a plurality of free-ended insulated electrical conductors in respective insulation-piercing contacts carried in respective parallel channels of an electrical connector include supporting the connector on a base with the channels exposed to receive the respective conductors, and moving an insertion tool generally parallel to the connector to sequentially insert the conductors within the respective channels and insulation-piercing contacts. The connector may advantageously comprise a notched ridge, with each notch in communication with a respective channel for preparatory alignment before insertion. The entire terminating apparatus resembles a credit card impression mechanism with a wheeled carriage supported to traverse a base in opposite directions. In one embodiment, a wire cutter, supported by the carriage, advances in front of the insertion tool to cut the ends of the wires before insertion. In this embodiment, the insertion tool performs the insertion operation upon return of the carriage. In a second embodiment, the insertion tool includes the wire cutter and operates to cut the wires contemporaneously with insertion thereof. In another embodiment, a wire cutter is carried between a wire pulling and seating member and the insertion tool, whereby the individual wires are snugged in each channel, and then cut to a predetermined length before insertion. In each embodiment, the insertion tool resembles a gear having insertion members as gear teeth. In the first two mentioned embodiments, the gear is a cylindrical rotatable member, while in the third embodiment, a sector gear is pivotally mounted for rotation of less than a complete revolution.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to a method and apparatus for terminating insulated 
conductors in respective insulation-piercing contacts of an electrical 
connector, and electrical connector construction which advantageously 
facilitates conductor insertion. More specifically, the invention relates 
to techniques for sequentially inserting insulated conductors in 
respective insulation-piercing contacts of an electrical connector. 
2. Description of the Prior Art 
Termination of the free ends of a plurality of conductors in respective 
insulation-piercing contacts of an electrical connector is generally known 
in the art and ranges from machine insertion of a plurality of conductors 
simultaneously in respective insulation-piercing contacts to individual 
manual insertion of conductors. Each of these techniques has its 
advantages and disadvantages. For example, a machine may be utilized to 
advantage to quickly insert a large number of conductors. However, such 
machines are rather complex and expensive. On the other hand, manual 
insertion is relatively inexpensive in situations where a few conductors 
are to be terminated, yet becomes an extremely slow and expensive process 
when it is necessary to terminate a large number of conductors, 
particularly as a continuously repetitive operation. 
SUMMARY OF THE INVENTION 
It is therefore the primary object of the invention to provide a method and 
apparatus for terminating a plurality of electrical conductors in 
respective insulation-piercing contacts of an electrical connector by 
utilizing the advantages of both machine and hand insertion techniques, 
while at the same time overcoming the disadvantages normally attendant to 
machine and manual operations. 
Another object of the invention is to provide a new and improved manually 
operated conductor terminating machine. 
Another object of the invention is to provide an improved electrical 
connector construction which facilitates the positioning of conductors for 
machine insertion. 
Another object of the invention is to provide a new and improved manually 
operated conductor insertion machine which sequentially terminates a 
plurality of conductors in respective insulation-piercing contacts 
disposed in respective parallel aligned channels of an electrical 
connector. 
Still another object of the invention is to provide cutting apparatus 
operable to sequentially cut a plurality of conductors at a predetermined 
distance from respective insulation-piercing contacts. 
A manually operated conductor insertion machine comprises a base for 
supporting an electrical connector and a table whose individual conductors 
are to be terminated in the connector, and a wheeled carriage mounted on 
the base for movement therealong in opposite directions. The base and 
carriage are generally constructed along the lines of the well-known 
credit card impression machines, and it will be readily understood from 
the following description that such machines may be adapted to great 
advantage to practice the present invention. 
The carriage carries a rotatable member in the form of a gear whose teeth 
are a plurality of conductor insertion tools which sequentially press and 
force the conductors into the insulation-piercing contacts within 
respective channels of the connector as the carriage is moved along the 
base. 
In two of the embodiments of the invention specifically described herein, 
the gear is a circular gear mounted for rotation about a vertical axis as 
the carriage moves along the base. In one of these two embodiments, the 
gear performs the insertion function as the carriage moves in one 
direction, while in the other embodiment, insertion is performed as the 
carriage moves in the opposite direction. In the first of these 
embodiments, a cutter carried by the carriage moves ahead of the insertion 
gear, while in the other embodiment, the individual gear teeth include a 
cutting edge for cutting the conductors as they are being inserted. 
In a third embodiment of the invention disclosed herein, a sled-like member 
is advanced by the carriage to snug the conductors into the respective 
connector channels preparatory for insertion. The sled-like member carries 
a cutter for subsequently cutting the conductors to a desired length prior 
to insertion by a following insertion gear. The insertion gear in this 
embodiment is in the form of a pivotally mounted sector gear. 
An electrical connector is advantageously provided when at least one ridge 
along the rear end thereof with a plurality of notches which communicate 
with respective ones of the connector channels which have the 
insulation-piercing contacts mounted therein. The individual conductors 
may be easily positioned with the aid of these notches for subsequent 
insertion and trimming operations.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring to FIGS. 1 and 2, a conductor terminating machine is generally 
referenced 10 and illustrated as comprising a base 12, and a carriage 14 
rollingly supported by the base 12. 
At one end, the base 12 is provided with a spacing and fastening structure 
16 for securing a pair of coplanar spaced plates, or spaced legs of the 
same plate, 18 and 20 in a vertically-spaced relationship with respect to 
a similar plate structure (only one being shown) in the form of the plate 
32 to form a longitudinal channel 34 on each side of the base 12. Inasmuch 
as each of the embodiments of the apparatus of the invention are 
symmetrical, therefore the same on each side of the apparatus, only one 
side will be discussed in detail herein. 
The spaced plates 18 and 20 define a channel 22 for receiving an electrical 
connector 24. The electrical connector 24 is provided with a groove 26 on 
each side thereof which receives a cutting bar 28 which is fixed to the 
base 12. Upon insertion into the slot 22, the electrical connector is 
moved against a lock stop 30 and is locked into position. Another stop may 
be affixed to the base 12 at the other end of the connector 24, if 
necessary. 
The carriage 14 comprises a pair of downwardly extending side plates 40 and 
42 which carry a plurality of rollers 36 within the channel 34. The 
rollers 36 are suitably journalled to the side plates at 38. 
The carriage 14 also comprises a handle 44 secured between the side plates 
40 and 42 for moving the carriage back and forth along the base and 
carrying the cutting and insertion mechanisms. A pair of forwardly and 
downwardly extending arms 46 and 48 rotatably carry a shaft 50 and a pair 
of cutting wheels 52 and 54 therebetween. Each cutting wheel includes a 
grooved surface 56 for receiving the individual conductors therein and a 
flange 58 having a cutting edge 60 which cooperates with a cutting edge 62 
of the cutting bar 28 to cut the individual conductors at a predetermined 
distance from their respective insulation-piercing contacts, as the 
carriage is advanced to the left in FIG. 1. 
The carriage 14 also rotatably supports a cylindrical gear 64 having a 
plurality of teeth 66 which may advantageously be in the form of the 
insertion blade illustrated in FIG. 9. 
The gear 64 is rotatably mounted at 68 and adapted for movement toward and 
away from the connector by a mechanism illustrated at 70. This mechanism 
may take the form of an angularly disposed slot or a lever and stop 
arrangement wherein the gear 64 does not function to insert the conductors 
in their respective channels on movement of the carriage toward the left, 
but is moved toward the connector for the insertion operation as the 
carriage is moved in the opposite direction. This feature permits an 
operator to clear wire trimmings out of the way before insertion, if 
necessary. 
The connector 24 is provided with a longitudinally extending slot 72 which 
receives all of the conductors therein for guided direction into 
individual contact containing channels 74 by communication through 
respective notches 75 between the longitudinal groove 72 and the 
individual channels 74. This feature aids in guiding and aligning the 
conductors 76 for proper cutting and insertion, and may also be 
advantageously utilized with the other embodiments of the invention. 
In operation, the connector 24 is slid into the slot 22 to lock stop 30 and 
the table of 78 of pressed into a cavity 82 of a holder 80 through a 
narrower passage formed between a pair of projections 84 and 86. The 
conductors are then dressed into the comb slots or notches 75 in 
accordance with a desired contact termination schedule. The carriage 14 is 
then moved toward the left to push down and snug the wires within the 
notches 75 and to cut the individual conductors to predetermined lengths. 
During this movement, the gear 64 is laterally displaced away from the 
connector. Finally, the carriage 14 is returned in the opposite direction, 
during which time the gear 64 is moved toward the connectors so that the 
insertion teeth 66 promptly insert the conductors 76 into the respective 
insulation-piercing contacts mounted within the channels 74. The 
terminated cable and connector is then removed from the fixture. 
Referring now to FIGS. 3 and 4, it is readily apparent that the base 12 and 
the carriage 14 are basically the same as illustrated in FIGS. 1 and 2, 
and a detailed description of that apparatus will not be given here. In 
FIG. 3, however, a manually operated terminating machine is generally 
indicated at 88 as comprising, on each side of the machine, a comb 90 
having a portion 92 with an elongate adjustment aperture 94 therein which 
receives a screw 96 for permitting movement of the comb 90 toward and away 
from the connector 24. The comb 90 includes another portion 98 which 
extends into the groove 26 in a manner similar to the cutting member 28 of 
FIGS. 1 and 2. The portion 98 includes a plurality of notches 100 between 
the fingers 102 of the comb, and a back edge 104 of each notch which forms 
a cutting edge for the respective conductor 76. 
In this embodiment of the invention, the cutting and insertion operations 
are performed in a sequential, staggered sequence during a single traverse 
of the carriage 14 along the connector. More specifically, the carriage 14 
carries a cylindrical gear 106 having gear teeth 108 with a sharp lower 
edge (edge 182 in FIG. 9) which cooperates with the edge 104 within each 
notch 100 to cut the conductor immediately prior to insertion into the 
respective channel. As the gear 106 traverses the connector 24, each 
conductor is first cut and then inserted before the next conductor is cut 
and inserted. 
In operation, the connector 24 is slid into the slot 22 in much the same 
manner as in FIG. 1 to rest against a lock stop (not shown). The comb 90 
may be moved laterally to permit ease of entry of the connector 24, or to 
permit different widths of connectors to be terminated on the same 
machine. The cable 78 is pressed into the holder 80 and the individual 
conductors are pressed into the notches 75 and the notches 100. The 
carriage 14 is then moved to carry the gear 106 along the connector 24 to 
sequentially cut and insert the conductors into the slots 74. The carriage 
14 is then returned to the left and the terminated cable and conductor are 
removed from the fixture. 
Referring now to FIGS. 5-8, a third embodiment of the invention, the most 
preferred embodiment, is illustrated as comprising a pair of cooperable 
sections 112 by which the base may be shaped, or which may be carried on 
the base of the previously described apparatus. The cooperable members 111 
and 113 of the apparatus 112 define a slot 122 for receiving the connector 
24 as previously described. 
The member 113 (and likewise the member 111) comprises a horizontal surface 
114 and an intregal cutting bar portion 116 having a cutting edge 118 
disposed parallel to the connector 24 and partially received within the 
groove 26 thereof. 
The member 113 (and the member 111) includes a downwardly and outwardly 
sloping surface 120 for draping of the conductors 76. 
Inasmuch as the apparatus 112 may replace or be mounted upon the upper 
surface 18 of the base 12 illustrated in FIGS. 1 and 3, a channel for 
receiving the rollers of the carriage is diagrammatically illustrated at 
reference 34 as in the previous figures. 
In this particular embodiment, the carriage 130 is also provided with a 
plurality of rollers or wheels 36 journalled at 38 to a pair of downwardly 
and forwardly extending side walls 132 and 134. 
The side walls 132 and 134 are spaced apart and interconnected by a member 
136 which carries a handle 138 connected between a pair of spaced 
extending arms 140 and 142. 
The member 136 includes a forwardly facing surface 144 which carries a pair 
of sled-like members or boots 146 and 148, each of which includes a 
forwardly and upwardly extending rounded edged surface 150 and a cutting 
blade 152 mounted within a recess 166. 
Each boot 146, 148 includes a downwardly projecting wedgelike portion 154 
for moving the trimmed conductors outwardly of the connector 24 after the 
same have been cut from the ends of the conductors 76. 
Each boot 146, 148 is designed to move along the cutting edge 118 to snug 
the conductors into their respective notches (75 in FIGS. 1 and 3) in such 
a manner that the cutting blade 152 cooperates with the cutting edge 118 
to cut the conductors. The trimmed ends of the conductors 76 are ploughed 
outwardly by the wedge-like portions 154 to displace the same in a 
noninterfering relationship with the subsequently received conductor end 
insertion apparatus. 
In this embodiment, a sector gear 156 is pivotally mounted to the member 
136 for rotation about an axis, here the pin 158. The sector gear includes 
a plurality of teeth 160, constructed as illustrated in FIG. 9, for 
inserting the trimmed conductors 76 into the respective channels and 
insulation-piercing contacts of the connector 24. 
As the carriage 130 is moved to the left in FIG. 5, the individual 
conductors are sequentially snugged, then cut, and then inserted by the 
teeth 160 of the sector gear 156. In order to initiate the insertion 
operation, the sector gear 156 is provided with a hook or other means 162 
for engaging a pin 164, or the like, to initiate pivotal action about the 
pin 158. 
Referring to FIGS. 6-8, one of the boots 146 is illustrated, particularly 
from an inside view thereof, wherein a cutting blade 152 is secured within 
a recess 166 by a screw 164. The cutting blade 152 includes a sharpened 
cutting edge 162 which is disposed at an angle to create a cutting depth 
below horizontal, that is, below the cutting edge 118 of, for example, 
0.30-0.40 inches. This dimension is illustrated by the arrows referenced 
186. The angle of attack of the rounded edge surface 150 has been found to 
be 15.degree., the plough 30.degree., in a particular application, with 
the rounded edge being at 1/8 inch radius. The particular blade angle 
found advantageous in cooperation with the other angular structure was 
8.degree., with respect to horizontal. 
As can be seen from FIG. 6, and particularly from FIG. 7, a waste conductor 
plough 154 is provided to extend downwardly from an angle to urge the 
trimmed conductors out of the way of the advancing sector gear 156. 
It will be noted from the drawings that the surface 168 is adapted to slide 
over the conductors and snug the same as they are advanced between the 
surface 150 and the cutting bar 116, severing of the conductors occurring 
after snugging of the same. 
Referring to FIG. 9, an elevational view of an insertion tool 170 is 
illustrated as comprising a conductor engaging and pressing edge 172 
having a pair of spaced projections 174, 176 spaced to span a set of 
insulation-piercing contacts and insure bottoming of the conductor within 
the contacts. The insertion blade 170 may also include a narrow edge 178 
formed by milling one or more faces of the blade, as indicated at 180, to 
press the conductor into a strain release mechanism formed at the 
outermost ends of the connector, in the area of the notched ridge having 
the notches 75 therein, or simply to insure pressing of the conductor 
within the channels and notches 74 and 75. Although this particular 
insertion tool blade construction is illustrated herein, any other 
suitable tool structure may be employed for the gear teeth of the gears 
64, 106, and 156 of FIGS. 1, 3, and 5. 
Although I have described my invention by reference to specific 
illustrative embodiments thereof, these illustrations have been provided 
as non-limiting examples of the invention, and many changes and 
modifications of the invention may become apparent to those skilled in the 
art without departing from the spirit and scope of the invention. I 
therefore intend to include within the patent warranted hereon all such 
changes and modifications as may reasonably and properly be included 
within the scope of my contribution to the art.