Cable terminating assembly with electrically insulating cutting blades

A cable terminating assembly for terminating a cable having a wire includes a wire manager having an end face facing in an insertion direction and a connector housing with a reception opening receiving at least a part of the wire manager. The end face holds the wire in a predetermined position along the insertion direction. The connector housing has a cutting blade formed by an electrically insulating material. The cutting blade cuts the wire upon insertion of the wire manager into the connector housing.

FIELD OF THE INVENTION

The present invention relates to a terminating assembly and, more particularly, to a cable terminating assembly with electrically insulating cutting blades.

BACKGROUND

Cable terminating assemblies for terminating a cable comprising at least one wire, in particular multiple twisted wire pairs, often require the at least one wire to be pushed into openings in one end of a connector housing until they contact a terminal of the connector. Excessive length of the at least one wire has to be sheared off and the remaining wire needs to be electrically insulated in order to securely terminate the cable and prevent any short circuit. There is a high demand for a miniaturization and reduction of costs of such a cable terminating assembly.

SUMMARY

A cable terminating assembly for terminating a cable having a wire includes a wire manager having an end face facing in an insertion direction and a connector housing with a reception opening receiving at least a part of the wire manager. The end face holds the wire in a predetermined position along the insertion direction. The connector housing has a cutting blade formed by an electrically insulating material. The cutting blade cuts the wire upon insertion of the wire manager into the connector housing.

DETAILED DESCRIPTION OF THE EMBODIMENT(S)

According to the following description of the various aspects and embodiments, elements shown in the drawings can be omitted if the technical effects of these elements are not needed for a particular application, and vice versa: i.e. elements that are not shown or described with reference to the figures but are described herein can be added if the technical effect of those particular elements is advantageous in a specific application. In the figures, the same reference numerals are used for elements which correspond to one another in terms of their function and/or structure.

FIG.1shows a schematic perspective view of a cable terminating assembly1according to the invention andFIG.2shows a profile view of the cable terminating assembly1. The cable terminating assembly1comprises a wire manager2with an end face4facing in an insertion direction I adapted to hold a wire6of a cable8in a predetermined position. The cable terminating assembly1further comprises a connector housing10with a reception opening12for receiving at least a part of the wire manager2along the insertion direction I.

In this exemplary embodiment, the cable8has four pairs of twisted wires6. The wires6have been untwisted inFIGS.1and2and the wire manager2holds each wire6in a predetermined position on the end face4.

The wires6protrude radially from the end face4, as shown inFIGS.1and2, and have to be cut to length when inserting the wire manager2into the connector housing10. For this, the connector housing10has cutting blades14arranged correspondingly to the predetermined positions of the wires6. The predetermined position in which the at least one wire6is held may be located opposite the at least one cutting blade14. During the insertion, the cutting blades14shear off the excessive length of the wires6.

The cutting blades14are formed by an electrically insulating material, such as an insulating resin material or a ceramic material, so that the wires6that have been cut to length by the cutting blades14of the connector housing10are further electrically insulated, rendering the need for a further insulation feature unnecessary. In an embodiment, the at least one cutting blade14may be formed by a nanometer fiber reinforced resin material and/or a glass fiber reinforced resin material.

FIG.2shows a profile view of the cable terminating assembly1from the perspective of the insertion direction I. The excesses of the length of the wires6is sheared off by an interaction between an outer edge16of the end face4and a cutting edge18of the cutting blades14that glide passed each other when inserting the wire manager2into the reception opening12of the connector housing10. Hence, the outer edge16and the cutting edge18form a shearing assembly19.

Both the connector housing10and the wire manager2comprise an annular shape in an embodiment, more specifically a polygonal shape in the form of a octagon20in the embodiment shown inFIGS.1and2. The profile perpendicular to the insertion direction I may comprise a polygonal shape. Each pair of twisted wires6is positioned on a side22of the octagon20arranged essentially perpendicular to the other sides22, so that the pairs of twisted wires6are positioned in a cross formation and distanced from one another, reducing the possibility of a wrongful positioning of the wires6. In other words, a pair of twisted wires6is arranged in every second side22of the octagon20, so that the adjacent pairs of twisted wires6along the circumference are essentially perpendicular to one another. Depending on the number of wires6in the cable8, any other polygonal form may be acceptable such as a hexagonal or dodecagonal form.

In addition to the facilitated correct positioning of the wires, the annular shape, in particular the octagonal shape20of the connector housing10may increase the tension equalization capabilities of the connector housing10. Due to the annular and/or polygonal shape, an even force flow is acquired, during the insertion of the wire manager2into the reception opening12. The annular shape and/or polygonal shape may prevent and/or minimize a deflection of the cutting blades14during the insertion of the wire manager2into the reception opening12.

The wire manager2is explained in more detail with reference toFIG.3andFIG.4, which show a perspective view of the wire manager2according to the invention. InFIG.4, the wire manager2is shown holding multiple wires6of a cable8.

The wire manager2, as shown inFIG.4, has a longitudinal body24extending essentially parallel to the insertion direction I from the end face4to a front face. A cable tunnel26for inserting the cable8with the at least one wire6extends from the end face4to the front face in the form of a through hole28. The cable8can be inserted into the cable tunnel26, whereby an insulation of the cable8is removed prior to inserting the cable8. The cable8may comprise multiple different wires6, in an embodiment pairs of twisted wires6. Free ends30of the wires6protrude from the cable tunnel26at the end face4and are bent essentially perpendicularly, so that the free ends30of the wires6extend essentially parallel to the end face4of the wire manager2. The excessive length of the wires6extends beyond the outer circumference of the end face4and needs to be sheared off, during insertion of the wire manager2into the connector housing10.

Essentially U-shaped wire holders32, shown inFIGS.3and4, are provided on the end face4of the wire manager2for holding the wires6in the predetermined position. For each wire6, a corresponding wire holder32is provided. Two wire holders32are arranged adjacent to one another on a side22along the circumference of the polygonal shape, in this exemplary embodiment the octagon20. Four pairs of wire holders32are arranged in a rectangular arrangement, i.e. every second side22of the octagon is provided with a pair of wire holders32. Therefore, a pair of wires can be positioned on one side22of the octagon20, whereby each wire6of the pair is held by a different wire holder32.

The wire holders32, as shown inFIGS.3and4, have a slot34in which the wires6may be seated. For further increasing the holding force with which the wires6are held in the predetermined position, the wire holders32may feature retention blades36. The retention blades36are adapted to at least partially cut into an insulation of the wires6to further secure the fastening of the wires6to the wire manager2. The retention blades36are, in an embodiment, arranged on each side of the slot34. Hence, the wire holders32may be formed similarly to an insulation displacement contact. As the retention blades36are not intended for forming an electrical connection, the retention blades36do not necessarily need to cut through the insulation of the wires6so that they contact the conductive cores of the wires6. Quite to the contrary, an electrical connection between the retention blades36and the wires6is not desired. Therefore, an insulating material such as a glass fiber reinforced resin material in an embodiment forms the retention blades36and/or the retention blades36only partially cut into the insulation of the wires6.

The wire holders32comprise two U-shaped seats33, which are radially distanced from one another, so that a gap35is formed between the two seats33, as shown inFIG.3. The gap35may be adapted to receive a contact terminal arranged in the connector housing10to electrically contact the wires6. The contact terminal may, for example, be formed as an insulation displacement contact with conductive blades that cut through the insulation of the wires6and electrically contact the conductive core. The two U-shaped seats33may function as a bearing creating a back-pressure for the at least one wire8balancing an insertion force, when the at least one wire6is pushed against the contact terminal.

As shown inFIGS.3and4, a separation column37extending in the insertion direction I beyond the wire holders32may separate the adjacent wire holders32arranged on the same side22. The separation column37has a tapered tip39and may be used for the separation of twisted wires. This provides a better and faster handling, as normally one needs to untwist the wire pairs completely. With the separation column37, it is possible to splice the pair by putting the wires6over the separation column37after only half a turn.

Coding features38, such as a color scheme and/or symbols, may be provided in order to determine the position in which the different wires have to be held. The coding features38may be provided on each side22of the octagon20which comprise wire holders32, as shown inFIGS.3and4. The coding features38may ensure a correct positioning of the different wires6and may further serve to fool proof the cable terminating assembly1.

On two opposing sides22of the octagon20, which are not provided with wire holders32, a guiding slot40may be formed. The guiding slot40may extend along the insertion direction I and may be open at the end face4for receiving a complementary formed guiding feature41, e.g. a guiding post42(seeFIGS.1and5). Hence, the rotational position in which the wire manager2may be inserted into the reception opening12is predetermined and it may be ensured that the wires6are terminated in the correct position. In an embodiment, for further stabilization, at least two guiding features41and corresponding slots40may be provided, which are arranged on opposing sides of the polygonal shape20.

The wire manager2may be formed as a monolithic part44in an embodiment, e.g. as a molded, in particular injection molded piece. In an embodiment, a nanometer and/or glass fiber reinforced material with a high elastic modulus of about 16000 forms the monolithic part44.

In the following, the connector housing10according to an exemplary embodiment is described in detail with reference toFIG.5.FIG.5shows a perspective view of an inventive connector housing10. The connector housing10has an annular shaped, and in an embodiment an octagonal shaped sleeve50surrounding the reception opening12for at least partially receiving the wire manager2in the insertion direction I.

In the reception opening12, contact terminals for electrically contacting the wires6may be provided. The contact terminals may be formed as insulation displacement contacts and be arranged opposite to the gaps35on the end face4of the wire manager2. The reception opening12may be formed complementary to the end face4of the wire manager2, so that the end face4of the wire manager2may be fittingly inserted into the reception opening12.

As shown inFIG.5, the cutting blades14are formed on a front face52of the sleeve50opposite the predetermined position of the wires6in the insertion direction I. In an embodiment, the number and arrangement of the cutting blades14corresponds to the number and arrangement of the wire holders32. Each wire holder32may be arranged opposite to a cutting blade14, so that there exists a corresponding cutting blade14to each wire holder32. The at least one wire holder32may be radially offset from the at least one cutting blade14, preventing any damage to the wire holder32and/or cutting blade14during insertion.

Guiding posts42extend essentially parallel to and against the insertion direction I from the front face52correspondingly to the guiding slots40of the wire manager2, as shown inFIG.5. Therefore, the rotational position of the connector housing10and the wire manager2relative to one another may be determined. The wire manager2may be inserted in two different rotational positions, wherein in one position the wire manager2is turned 180 degree relative to the other position.

A pair of cutting blades14is arranged adjacent on the same side22of the octagon20, as shown inFIGS.5and6. The at least two cutting blades14may be arranged adjacent to one another along the circumference of the connector housing10. In order to reduce the cutting force peak, a first cutting blade54of the pair is arranged in a first plane56essentially perpendicular to the insertion direction I and a second cutting blade58of the pair is arranged in a second plane60distanced from the first plane56in the insertion direction I. The first and second cutting blades54,58may be arranged adjoining to one another along the circumference of the sleeve50. Consequently, during the insertion of the wire manager2, a timely offset is provided for shearing the adjacent wires6. Hence, the insertion force peak may be reduced.

As shown inFIGS.5and6, the connector housing10may be formed as a monolithic component62with the cutting blades14. The connector housing10, in particular the cutting blades14may be formed of a glass fiber reinforced resin material with a high elastic modulus of about 16000. A high elastic modulus may prevent a deformation of the cutting blades14and therefore increase the wear resistance and number of possible mating cycles. The annular-shaped form may further increase the wear resistance, since the annular shape promotes the tension equalization and further prevents a deflection of the cutting blades14.

As can be seen inFIG.1, the connector housing10may at least partially be encased in a second outer housing64, e.g. a die cast part, for further stabilizing the connector housing10.

FIG.6displays a schematic cut view of an inventive cable terminating assembly1. The cutting blade14has a cutting edge18formed on the front face52of the sleeve50facing the end face4of the wire manager2. The cutting edge18glides past the outer edge16of the end face4. The interaction between the cutting edge18and the outer edge16leads to the shearing of the excessive part of the wire6.

In order to further increase the wear resistance of the cable terminating assembly1, in particular of the connector housing10, the cutting edge18may comprise a bevel angle66shown inFIG.6of about 90°. A bevel angle66of about 90° further prevents a deflection of the at least one cutting blade14during shearing off the at least one wire6, increasing the number of mating cycles of the cable termination assembly1.

By having the cutting blades14formed of an electrically insulating material, the cutting blades both cut the wires6to length and electrically insulate the wires6. In this exemplary embodiment, only two parts, the wire manager2and the connector housing10are necessary to cut eight wires6. The cable terminating assembly1provides a compact and cost effective design.