# Patent

## Title
Junction box

## Abstract

A junction box for electrically connecting insulated conductors of a first cable to corresponding insulated conductors of a second cable, including a terminal housing; a plurality of electrically conductive contacts extending through the terminal housing, each contact of said contacts including first and second insulation displacement contacts (IDCs) opening into respective first and second sides of the terminal housing; and first and second lid members operatively coupled to the terminal housing so that relative movement between the terminal housing and the lid members urges insulated conductors interposed therebetween into corresponding IDCs for electric connection to the contacts, wherein said relative movement electrically connects the insulated conductors of the first cable on the first side of said sides of the terminal housing to corresponding insulated conductors of the second cable on the second side of said sides of the terminal housing via the IDCs of common contacts.

## Background
This application claims benefit of Serial No. 2009213018, filed 9 Sep. 2009 in Australia and which application is incorporated herein by reference. To the extent appropriate, a claim of priority is made to the above disclosed application.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a junction box, and to a method of electrically connecting insulated conductors of a first cable to corresponding insulated conductors of a second cable.
BACKGROUND OF THE INVENTION
Junction boxes are typically used to electrically connect the insulated conductors of a first cable to corresponding insulated conductors of a second cable. Junction boxes have previously used screw terminal connections to effect electric connections between corresponding pairs of insulated conductors. The following steps are typically performed in that regard:

    
    
        a. stripping the sheath off end sections of the cables to expose the insulated conductors;
        b. stripping the insulation off end sections of the insulated conductors to expose the copper conductors;
        c. twisting the pairs of conductors together;
        d. inserting the pairs of conductors into corresponding screw connectors; and
        e. tightening the screw connectors to secure the electric connections.
    
    


It may be generally inconvenient and/or labour intensive to connect insulated conductors to a junction box in the above described manner.
The above-described junction box is limited to effecting electric connections between insulated conductors of end sections of cables. It may be generally desirable to electrically connect the insulated conductors of an end section of a first cable to the insulated conductors of a mid section of a second cable. Further, it may be generally desirable to electrically connect the insulated conductors of a mid section of a first cable to the insulated conductors of a mid section of a second cable.
It is generally desirable to overcome or ameliorate one or more of the above mentioned difficulties, or at least provide a useful alternative.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, there is provided a junction box for electrically connecting insulated conductors of a first cable to corresponding insulated conductors of a second cable, including:

    
    
        (a) a terminal housing;
        (b) a plurality of electrically conductive contacts extending through the terminal housing, each contact of said contacts including first and second insulation displacement contacts (IDCs) opening into respective first and second sides of the terminal housing; and
        (c) first and second lid members operatively coupled to the terminal housing so that relative movement between the terminal housing and the lid members urges insulated conductors interposed therebetween into corresponding IDCs for electric connection to the contacts,
        
            wherein said relative movement electrically connects the insulated conductors of the first cable on the first side of said sides of the terminal housing to corresponding insulated conductors of the second cable on the second side of said sides of the terminal housing via the IDCs of common contacts.
        
        
    
    


Preferably, the lid members are operatively coupled to the terminal housing by hinges.
Preferably, the first and second lid members include a plurality of channels, for locating the insulated conductors for engagement with corresponding IDCs of said contacts.
Preferably, the channels are shaped to at least partially receive and seat therein an insulated conductor of a cable.
In accordance with another aspect of the invention, there is provided a method of electrically connecting insulated conductors of a first cable to corresponding insulated conductors of a second cable using a junction box, including the steps of:

    
    
        (a) interposing insulated conductors of the first cable between a first side of said sides of the terminal housing;
        (b) interposing insulated conductors of the second cable between a second side of said sides of the terminal housing; and
        (c) moving the lid members with respect to the terminal housing so as to urge insulated conductors interposed therebetween into corresponding IDCs for electric connection to the contacts.
    
    


In accordance with another aspect of the invention, there is provided a method of electrically connecting insulated conductors of a first cable to corresponding insulated conductors of a second cable using a junction box, including the steps of:

    
    
        (a) arranging insulated conductors of the first cable in channels of a first one of said lid members;
        (b) arranging insulated conductors of the second cable in channels of a second one of said lid members; and
        (c) moving the lid members with respect to the terminal housing so as to urge insulated conductors into corresponding IDCs for electric connection to the contacts.
    
    


Preferably, the insulated conductors of the first cable extend from an end section of the first cable into the channels of the first one of said lid members.
Preferably, the insulated conductors of the second cable extend from an end section of the second cable into the channels of the second one of said lid members.
Preferably, the insulated conductors of the first cable extend between lateral section sections of the first cable.
Preferably, the insulated conductors of the second cable extend between lateral section sections of the second cable.



BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention are hereafter described, by way of non-limiting example only, with reference to the accompanying drawing in which:
FIG. 1 is a front perspective view of a junction box;
FIG. 2 is a back view of the junction box shown in FIG. 1;
FIG. 3 is a front view of the junction box shown in FIG. 1;
FIG. 4 is a side view of the junction box shown in FIG. 1;
FIG. 5 is a front perspective view of a contact of the junction box shown in FIG. 1;
FIG. 6 is a top perspective view of the junction box shown in FIG. 1 arranged in another condition of use;
FIG. 7 is a front perspective view of the junction box shown in FIG. 6 arranged in another condition of use;
FIG. 8 is a front perspective view of the junction box shown in FIG. 7 arranged in another condition of use; and
FIG. 9 is an exploded view of the junction box shown in FIG. 8.



DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION
The junction box 10 shown in FIGS. 1 to 9 is used to electrically connect insulated conductors 12a, 12b, 12c of a first cable 12 to corresponding insulated conductors 14a, 14b, 14c of a second cable 14. The junction box 10 can be used to quickly and easily electrically connect:

    
    
        a. insulated conductors 12a, 12b, 12c of an end of one cable 12 to corresponding insulated conductors 14a, 14b, 14c of a lateral section of another cable 14, as shown in FIGS. 7 to 9; and
        b. insulated conductors of a lateral section of one cable with corresponding insulated conductors of a lateral section of another cable (not shown); and
        c. connect insulated conductors of an end of one cable to corresponding insulated conductors of an end of another cable (not shown).
    
    


The junction box 10 includes a terminal housing 16 and a plurality of electrically conductive contacts 18a, 18b, 18c extending through the terminal housing 16. As particularly shown in FIGS. 5 and 9, each one of the contacts including 18a, 18b, 18c includes first and second insulation displacement contacts (IDCs) 20a, 20b opening into respective first and second sides 22a 22b of the terminal housing 16. The junction box 10 also includes first and second lid members 24a, 24b operatively coupled to the housing so that relative movement between the terminal housing 16 and the lid members 24a, 24b urges insulated conductors 12a, 12b, 12c, 14a, 14b, 14c interposed therebetween into corresponding IDCs 20a, 20b for electric connection to the contacts 18a, 18b, 18c. The relative movement thereby electrically connects insulated conductors 12a, 12b, 12c of the first cable 12 on the first side 22a of the terminal housing 16 to corresponding insulated conductors 14a, 14b, 14c of the second cable 14 on the second side 22b of the terminal housing 16 via the IDCs 20a, 20b of common contacts 18a, 18b, 18c. 
A technician can use the junction box 10 to electrically connect insulated conductors 12a, 12b, 12c of the first cable 12 to corresponding insulated conductors 14a, 14b, 14c of a second cable 14 by performing the steps of:

    
    
        a. interposing insulated conductors 12a, 12b, 12c of the first cable 12 between the first side 22a of the terminal housing 16 and the first lid member 24a; 
        b. interposing insulated conductors 14a, 14b, 14c of the second cable 14 between the second side 22b of the terminal housing 16 and the second lid member 24b; and
        c. moving the lid members 24a, 24b with respect to the terminal housing 16 so as to urge insulated conductors 12a, 12b, 12c, 14a, 14b, 14c interposed therebetween into corresponding IDCs 20a, 20b for electric connection to the contacts 18a, 18b, 18c. 
    
    


The lid members 24a, 24b are generally rectangular in shape and generally overlie respective first and second sides 22a, 22b of the terminal housing 16 when arranged in closed conditions of use. The lid members 24a, 24b thereby electrically isolate the contacts 18a, 18b, 18c when arranged in the closed condition of use.
As particularly shown in FIGS. 2 and 11, the lid members 24a, 24b are operatively connected to a common end 28 of the terminal housing 16 by hinges 26a, 26b. Each hinge 26a, 26b includes an axle 30 coupled to the common end 28 of the terminal housing 16 and a tongue member 32 coupled to the lid member 26a, 26b. The tongue member 32 includes a generally semicircular articular surface 34 which is shaped to slide around the axle 30 as the lid member 24a, 24b moves between open and closed conditions of use. The tongue member 32 also includes a flange member 36 which abuts the terminal housing 16 after a certain degree of rotation of the lid member 24a, 24b away from the terminal housing 16. The flange member 36 thereby limits the extent of rotation of the lid member 24a, 24b with respect to the terminal housing 16. In the example shown, the axle 30 includes a recess 38 which facilitates insertion of the tongue 32 during coupling of the lid member 24a, 24b to the terminal housing 16.
The junction box 10 includes fasteners 40 for securing the lid members 24a, 24b in the closed positions shown in FIGS. 1 to 4. The fasteners 40 preferably include corresponding male and female clips 42a, 42b which snap lock together when the lid members 24a, 24b are closed against respective sides 22a, 22b of the terminal housing 16. Alternatively, any suitable fastener 40 can be used to secure the lid members 24a, 24b in a closed condition of use. The lid members 24a, 24b preferably open and terminate independently with pliers. The lid members 24a, 24b includes recessed sections 43a, 43b shaped to engage distal ends of pliers.
As particularly shown in FIG. 4, outer peripheral surfaces of the lid members 24a, 24b are preferably tapered away from the hinges 26a, 26b so that the junction box 10 can more easily slide under wiring in a wiring installation, for example. The lid members 24a, 24b are preferably transparent so that the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c can be viewed through the lid members 24a, 24b when they are closed. It is thereby possible to view the connections to ensure that the insulated conductors are in correct positions.
As particularly shown in FIGS. 6, 7 and 9, the first and second lid members 24a, 24b include a plurality of channels 44a, 44b, 44c for locating the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c for engagement with corresponding IDCs 20a, 20b. The channels 44a, 44b, 44c are shaped to at least partially receive, and seat therein, lateral sections of respective ones of the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c of the cables 12, 14 in the manner shown in FIG. 7, for example. The channels 44a, 44b, 44c inhibit lateral movement of the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c. The channels 44a, 44b, 44c also include strain relief ribs 46 arranged to engage and inhibit movement of the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c when they are located in the channels 44a, 44b, 44c. 
As above-mentioned, the junction box 10 can be used to electrically connect insulated conductors 12a, 12b, 12c, 14a, 14b, 14c of cables in a number of different configurations. To facilitate this, the lid members 24a, 24b each include two openings 48a, 48b arranged at opposite ends of the channels 44a, 44b, 44c, the openings 48a, 48b being shaped to receive end sections 50 of the cables 12, 14. In the arrangement shown in FIG. 7, the opening 48a of first lid member 24a accommodates an end section 50 of the first cable 12 so that insulated conductors 12a, 12b, 12c extending from the end section 50 of the cable 12 feed into the channels 44a, 44b, 44c. Alternatively, the insulated conductors 12a, 12b, 12c of the cable 12 could be feed into the channels 44a, 44b, 44c from the opposite side via the opening 48b. The lid members 24a, 24b include termination holes 52a, 52b, 52c arranged at opposite ends of the channels 44a, 44b, 44c for receiving and electrically isolating terminal end sections of the insulated conductors 12a, 12b, 12c. Also as shown in FIG. 9, the cable 14 extends through both openings 48a, 48b of the lid member 24b. In this arrangement, the insulated conductors 14a, 14b, 14c are separated from a sheath of the cable 14 so that they can be arranged in respective channels 44a, 44b, 44c. The insulated conductors 12a, 12b, 12c of an end section 50 of the first cable 12 are thereby electrically connected to corresponding insulated conductors 14a, 14b, 14c of the a lateral section of the second cable 14.
Alternatively, the junction box 10 can be used to electrically connect insulated conductors 12a, 12b, 12c of a lateral section of the first cable 12 with corresponding insulated conductors 14a, 14b, 14c of a lateral section of the second cable 14; or to electrically connect insulated conductors 12a, 12b, 12c of an end section 50 of the first cable 12 with corresponding insulated conductors 14a, 14b, 14c of an end section of the second cable 14.
As particularly shown in FIG. 9, the contacts 18a, 18b, 18c are seated in contact mounts 54a, 54b, 54c that extend through terminal housing 16. The contacts 18a, 18b, 18c include anchors 56 arranged to frictionally engage the mounts 54a, 54b, 54c. The mounts 54a, 54b, 54c inhibit displacement of the bifurcated IDCs 20a, 20b during insertion of the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c. A good quality electric connection is thereby effected as the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c are urged into the IDCs 20a, 20b as the lid members 24a, 24b mover towards the closed condition of use. The IDCs 20a, 20b engage the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c at an angle of 45 degrees to a direction of extent DIC of the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c. That is, a side to side direction DSS of the IDCs 20a, 20b is substantially 45 degrees to the direction of extent DIC of the insulated 12a, 12b, 12c, 14a, 14b, 14c. 
The first and second sides 22a, 22b of the terminal housing 16 include a plurality of channels 58a, 58b, 58c shaped to receive the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c as they are forced into respective IDCs 20a, 20b. The extent to which the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c can be forced into the IDCs 20a, 20b is limited by these channels 58a, 58b, 58c. The channels 44a, 44b, 44c and the channels 58a, 58b, 58c engage lateral sections of the insulated conductors 12a, 12b, 12c, 14a, 14b, 14c and thereby inhibit their movement.
The junction box 10 includes mounting bosses 60a, 60b for securing the junction box to a structural support with a fastener such as a nail or a screw.
The first cable 12 and the second cable 14 are preferably power cables, each including three insulated conductors 12a, 12b, 12c, 14a, 14b, 14c. Alternatively, any suitable cable including insulated conductors could be used. The junction box 10 can be used to terminate 1 to 2.5 mm2 insulated conductors, for example. The junction box 10 can also preferably be used for other insulated conductor sizes, either smaller or larger. Mismatched wire sizes can be terminated.
The junction box 10 provides an insulated connection of the cables without the need for an additional plastic enclosure. The junction box 10 advantageously improves the speed of effecting electric connection of insulated conductors of cables. Individual insulated conductors are not required to be stripped before connection.
The overall size of the junction box 10 is preferably 73 mm long×49 mm wide×28 mm high.
While we have shown and described specific embodiments of the present invention, further modifications and improvements will occur to those skilled in the art. We desire it to be understood, therefore, that this invention is not limited to the particular forms shown and we intend in the appended claims to cover all modifications that do not depart from the spirit and scope of this invention.
Throughout this specification, unless the context requires otherwise, the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
LIST OF PARTS


    Junction box
    12 Cable
    12a, 12b, 12c Insulated conductor
    14 Cable
    14a, 14b, 14c Insulated conductor
    16 Terminal housing
    18a, 18b, 18c Contact
    20a, 20b Insulation displacement contact
    22a, 22b Side of terminal housing
    24a, 24b Lid member
    26a, 26b Hinge
    28 Common end of terminal housing
    30 Axle
    32 Tongue
    34 Articular surface of tongue
    36 Flange member
    38 Recess
    40 Fastener
    42a, 42b Male and female clips parts
    43a, 43b Recessed section
    44a, 44b, 44c Channel
    46 Strain relief rib
    48a, 48b Opening
    50 Ens section of cable
    52a, 52b, 52c Termination holes
    54a, 54b, 54c Contact mounts
    56 Anchor
    58 Channel
    60a, 60b Boss

## Claims

1. A junction box for electrically connecting insulated conductors of a first cable to corresponding insulated conductors of a second cable, comprising:
(a) a terminal housing;
(b) a plurality of electrically conductive contacts extending through the terminal housing, each contact of said contacts including first and second insulation displacement contacts (IDCs) opening into respective first and second sides of the terminal housing; and
(c) first and second lid members operatively coupled to the terminal housing so that relative movement between the terminal housing and the lid members urges insulated conductors interposed therebetween into corresponding IDCs for electric connection to the contacts,
wherein said relative movement electrically connects the insulated conductors of the first cable on the first side of said sides of the terminal housing to corresponding insulated conductors of the second cable on the second side of said sides of the terminal housing via the IDCs of common contacts;
wherein the first and second lid members include a plurality of channels for locating the insulated conductors for engagement with corresponding IDCs of said contacts;
wherein the first and second lid members each include an opening adjacent an end of the channels, the opening being shaped to receive an end section of a cable; and
wherein the first and second lid members include termination holes arranged at another end of the channels for receiving and electrically isolating terminal end sections of the insulated conductors.

2. The junction box claimed in claim 1, wherein the first and second lid members are operatively coupled to the terminal housing by hinges.

3. The junction box claimed in claim 1, wherein each of the channels is shaped to at least partially receive and seat therein an insulated conductor of a cable.

4. The junction box claimed in claim 1, wherein the channels inhibit lateral movement of the insulated conductors.

5. The junction box claimed in claim 1, including strain relief ribs arranged to engage and inhibit movement of the insulated conductors.

6. The junction box claimed in claim 1, wherein the opening of each one of said lid members accommodates an end section of a cable so that insulated conductors extend from the end section of the cable into the channels.

7. The junction box claimed in claim 1, wherein the first and second lid members each include a pair of openings adjacent opposite ends of the channels, shaped to receive respective end sections of a cable extending therethrough.

8. The junction box claimed in claim 7, wherein each pair of openings is positioned so that the insulated conductors extend between the end sections of the cable via the channels.

9. The junction box claimed in claim 1, wherein the IDCs engage the insulated conductors at an angle of 45 degrees to a direction of extent of the insulated conductors.

10. The junction box claimed in claim 1, including mounting bosses for securing the junction box to a structural support with a fastener.

11. The junction box claimed in claim 10, wherein the fastener is a nail or a screw.

12. The junction box claimed in claim 1, wherein the first and second lid members are substantially transparent so that the insulated conductors can be viewed therethrough.

13. The junction box claimed in claim 1, including fasteners for securing the first and second lid members in a closed condition of use over respective sides of the terminal housing.

14. The junction box claimed in claim 13, wherein the fasteners are clips.

15. The junction box claimed in claim 1, wherein an outer peripheral side of each one of said first and second lid members is tapered.

16. The junction box claimed in claim 1, wherein the first cable and the second cable are power cables, each including three insulated conductors.