ELECTRICAL CONNECTOR ASSEMBLY

Abstract: Electrical connector assembly having a plurality of terminals (50) secured therein which cooperates with individual wires (4) to electrically terminate the wires (4) to the terminals (50). Connecting portions (54) and projections (53) of the terminals (50) are aligned in wire receiving cavities to ensure that the wires (4) are properly terminated to the connecting portions (54). The projections (53) cooperate with the wires (4) and the terminals (50) to prevent the terminals (50) from torsional forces during the termination process.

Description: ELECTRI CAL CONNECTOR ASSEMBLY The present invention relates to an electrical connector of the type having contacts that can penetrate the insulation of an electrical wire and , more particularly , to an electrical connector, the contacts of which are protected from torsionai forces that may occur when the contact penetrates the insulation . Electrical connectors of this type are well known and widely used for telephone cables. An electrical connector of this type has been already proposed by the present applicant in Japanese Unexamined Patent Publication No. 59-78481 . An example of the this electrical connector is shown in Figures 5 and 6. A plug 3 connected to a number of insulated wires 4 is inserted into a plug" receiving aperture 2 in a receptacle 1 , allowing plug contacts 6 of plug 3 to be connected with receptacle contacts 2a of receptacle 1 . Plug contacts 6 are press-fitted into plug 3 from a series of contact receiving slots 5a formed in the undersurface of a dielectric housing 5 of plug 3. An upper part of each plug contact 6 penetrates the insulation of each insulated electrical wire 4 inserted into bousing 5 , thus forming a connection with the conductor 4a of wire 4 as is shown in Figure 7. As can be seen in Figure 7, pressure exerted on each plug contact 6 causes upper portions 6a of plug contact 6 to pierce and penetrate the insulation of each wire 4, thus forming an electrical connection between conductor 4a and contact 6. A major problem with the above-described connector is present. An adequate force must be applied to plug contact 6 in order for portions 6a to pierce the insulation of wires 4, causing housing 5 to be bent upward by the force, as shown by the dotted line in Figure 8. This problem is magnified as the number of wires is increased. With an increased number of wires , the housing must have a larger width causing the housing to be more flexible which in turn causes a greater bend of the housing when the force is applied , resulting in an incomplete . electrical connection between wires 4 and plug contact 6. To avoid this problem , an upper wall 5a of housing 6 must be made thicker to increase the rigidity. This is not a desirable solution since it necessitates the production of a larger , more costly plug. In an effort to solve the above-mentioned problems , Japanese Unexamined Patent Publication No. 61-131379 has been proposed , as shown in Figures 9 and 10. A plurality of contacts 1 1 are equipped with connecting portions 11a abutting against electrical wires 4. The contacts are electrically connected with conductors 4a of wires 4 by pushing the ends of connecting portions 11a through the insulation of the wires. Each contact has projections 1 1b press-fitted into apertures 12a of cover 12 of housing 13 and retained on housing 13 by latching projections 11 b. This prevents warping of the upper wall of the housing , as shown in Figure 8. However, it is necessary to move the connecting portion 1 1a laterally relative to the projections 11 b of the contact 11 to avoid an abutment between the projections 11 b and the wire 4. Therefore, there is a possibility that the connecting portion 11a may be bent by the effect of a . torsionai moment as the connecting portion 11a penetrates the electrical wires 4. Moreover, when the connecting portion 11a is bent, a problem of incomplete connection between the conductor 4a and connecting portion 11a can occur. The electrical connector assembly of the present invention is comprised of a dielectric housing having a plurality of terminal receiving cavities with a like amount of terminals secured therein . A cover is provided which has a like plurality of slots which align with the terminal receiving cavities to form wire receiving cavities. Individual wires are positioned in the wire receiving cavities. Connecting portions and projections of the terminals extend into the wire receiving cavities and cooperate with the wires. The connecting portions are aligned with the centerline or longitudinal axis of the terminals while the projections are positioned to either side of the centerline such that the projections position a centerline of each wire in alignment with a centerline of each terminal . Consequently , as the wires are forced onto the connecting portions , which pierce the. insulation of the wires and thereby electrically connect the wires to the terminals , no torsionai force is created . The invention will be described by way of example by reference to the drawings in which: FIGURE 1 is an exploded perspective view of an electrical connector assembly of the present invention ; FIGURE 2A is a top plan view of a contact of the electrical connector assembly; FIGURE 2B is a side elevational view of the contact of the connector assembly; FIGURE 2C is a front end view of the contact of the connector assembly; FIGURE 3 is an exploded perspective view of one contact and a corresponding cover of the connector assembly; FIGURE 4 is a longitudinal cross-sectional view of an assembled connector assembly; FIGURE 5 is a perspective exploded view of an electrical connector of the prior art; FIGURE 6 is a longitudinal cross-sectional view of the electrical connector of Figure 5; FIGURE 7 is a perspective part cross-sectional view of the plug connector of Figures 5 and 6; FIGURE 8 is a cross-sectional view of the plug connector taken along the line 8-8 in Figure 7; FIGURE 9 is an exploded perspective view of one contact and a corresponding cover of another electrical connector of the prior art; and FIGURE 10 is a longitudinal cross-sectional view of an assembled electrical connector of Figure 9. The electrical connector assembly of the present invention comprises a plurality of terminals 50 , a housing 20 , and a cover 30. Each terminal 50 , as best shown in Figures 2A, 2B and 2C , is stamped and formed from sheet metal having appropriate conductive and spring characteristics. A bifurcated female contact section 51 is provided at a front end of each terminal 50 for engagement with a corresponding male contact of another connector assembly. A middle section of terminal 50 has a projection 52 which is press-fitted into a contact receiving cavity 21 of housing 20. Interference-fit projections 53 are also provided on the middle section of terminal 50 proximate projection 52 opposite contact section 51 . Projections 53 extend in opposite directions laterally from the longitudinal axis of terminal 50 and have latching projections 53a on the ends thereof. Connecting portion 54 of each terminal 50 is disposed between projections 53 and includes spaced wire penetrating members that penetrate through the insulation of an electrical conductor 4 with is guided to connecting portion 54 between projections 53. As shown in Figure 2A, projections 53 are located to the front and rear of portion 54, as well as being symmetrically arranged to the right and left of portion 54. A wire retaining projection 55 is formed to the rear of projection 53. A projection 56 is also provided below projection 55 for engagement with an engaging slot 23a of housing 20 as shown in Figure 1 . Projection 56 limits vertical movement of a rear portion of contact 50 in housing 20. Housing 20 , made of insulating material , holds a plurality of contacts 50. A plurality of contact cavities 21 are provided in housing 20 to receive contact sections 51 of contacts 50. A like plurality of contact receiving slots 22 are provided in alignment with cavities 21 in housing 20 to receive the rear portion of contacts 50. Slots 22 are separated by walls 23 which have engaging slots 23a provided in a back end of each wall 23. A pair of mounting slots 24 and a pair of latching projections 25 are provided at both ends of housing 20 for engagement and retention of cover 30 (in the drawings, only a single end of housing 20 is shown due to the assembly being shown in cross section) . Housing 20 has a symmetrical top and bottom half such that contacts 50 can be linearly arranged in the bottom half as well as the top half. Consequently, a second cover 30 is required for the bottom half. Each cover 30 has a pair of opposing arms 31 , as shown in Figure 1 , one pair provided at each end of cover 30. Arms 31 have hooks 31a extending from an end thereof for engagement with respective projections 25 in slots 24. Wire receiving grooves 32 are arranged on cover 30 such that grooves 32 align with slots 22 of housing 20 so that wire 4 may be properly inserted into grooves 32 and slots 22. Grooves 32 are separated by partition walls 33 having apertures 34 extending therein. A rib 35 is provided at an end of wall 33 to grip an end of wire 4. To connect each wire 4 to the assembly , each contact 50 is fitted in housing 20 by inserting contact 50 into contact receiving cavity 21 from the rear. The rear portion of contact 50 is to be located in slot 22. At this stage, projection 52 is press-fitted into contact cavity 21 causing projection 56 to engage slot 23a . Contact 50 is now secured in housing 20. The ends of wires 4 are pressed into grooves 32 of cover housing 30 such that wires 4 are held in place by ribs 35. This configuration acts as a strain relief preventing axial tension on wire 4. Cover 30 is then press-fitted onto housing 20 causing hooks 31a of arms 31 to latchably engage projections 25 in slots 24. As shown in Figure 4 , projections 53a are then press-fitted into apertures 34 of cover 30. At the same time, portions 54 press wires 4 against an undersurface 32a of slots 32 and portions 54 penetrate the insulation of wires 4 causing conductors 4a of wires 4 to engage portions 54 creating electrical contact therebetween . As the above-mentioned termination occurs , contacts 50 remain free from torsionai force due to projections 53 being symmetrically arranged with respect to the centerl ine of contact 50 and portions 54 being in alignment with the centerline of contact 50. This configuration positions wires 4 directly above portions 54 thus eliminating unequal force being exerted from either side of the centerline. As termination occurs , forces exerted are symmetrical about the centerline axis of contacts 50 thereby eliminating the problem of contacts 50 making poor electrical contact with wires 4 due to torsionai forces being exerted on contacts 50. Also, as shown in Figure 4, when cover 30 is fitted to housing 20 to hold wires 4 therebetween , projections 55 also engage wires 4, the end part of projections 55 penetrating slightly into the insulation . Accordingly , this penetration prevents wires 4 from being pulled out by an external force, providing an axial strain relief.

Claims: [received by the International Bureau on 09 February 1987 (09.02.87) original claims 1 and 5 amended ;other claims unchanged (3 pages)] 1 . An electrical connector assembly comprising : a dielectric housing means (20) having a plurality of terminal receiving cavities (21 , 22) ; a like plurality of terminals (50) positioned in the terminal receiving cavities (21 , 22) and secured therein by first securing means (52) ; dielectric cover means (30) having a like plurality of slots (32) , such that when the cover means (30) is brought into engagement with the housing means (20) , the slots (32) of the cover means (30) align with the cavities (22) of the housing means (20) to form wire receiving cavities for receiving respective insulated wires (4) ; second securing means (24, 25 , 31 , 31a) provided on the housing means (20) and the cover means (30) which cooperate to secure the cover means (30) to the housing means (20) ; connecting portions (54) of the terminals (50) extend into the wire receiving cavities such that as the cover means (30) is placed over the housing means (20) with the wires (4) in the corresponding slots , the wire (4) engages the connecting portion (54) , allowing the connecting portion (54) to pierce the insulation of the wire, placing a conductor (4a) of the wire (4) in electrical contact with the terminal (50) , the connector being characterized in that: front and back projections (53) are positioned on the terminal on either side of the connecting portion (54) , the projections (53) extending to opposite sides of the centerline of the terminal (50) such that as the cover means (30) is placed over the housing means (20) , the wire (4) is guided directly onto the connecting portion (54) in such a manner so as not to create torsionai force; the connecting portions (54) of the terminals (50) extend into the wire receiving cavities such that the wire (4) remains essentially stationary as connecting portions ( 54) pierce wires (4) , eliminating the harmful stresses which result when wires (4) are displaced as piercing occurs; and a latching portion ( 53a) positioned on ends of the front and back projections (53) such that as the cover means (30) is brought into contact with the housing means (20) , the latching portion (53a) engages the cover means (30) , latchably securing the cover means (30) to the terminals (50) , thereby maintaining constant pressure on the wires (4) , ensuring a positive electrical connection between the wires ( 4) and the terminals (50) . 2. An electrical connector assembly as recited in claim 1 , characterized in that the second securing means is provided with arms (31 ) having hooks (31a ) on the cover means (30) which cooperate with latching projections (25) on the housing means (20) to secure the cover means (30) to the housing means (20) . 3. An electrical connector assembly as recited in claim 1 , characterized in that an electrical wire retaining projection (55) is formed on the terminal ( 50) to the rear of the back projection ( 53 ) . 4. An electrical connector assembly as recited in claim 3 , characterized in that a tab (56 ) is provided on the terminal ( 50) below the wire retaining projection ( 55) for engagement with an engaging slot ( 22) of the terminal receiving cavity of the housing (20) , the tab ( 56) and the slot (22) cooperating to limit the vertical movement of a rear portion of the terminal in the housing means (20) . 5. An electrical connector assembly comprising dielectric housing means (20) having a plurality of terminal receiving cavities ( 21 , 22) , a l ike plurality of terminals (50) positioned in the terminal receiving cavities ( 21 , 22) , the terminals ( 50) provided with first securing means (52) to secure the terminals (50) in the terminal receiving cavities ( 21 ) , cover means ( 30) having a like plurality of slots (32) , the cover means (30) having latch means (31 , 31 a) to latch the cover means (30) to the housing means (20) , the slots (32) and the terminal receiving cavities (21 ) aligned to form wire receiving cavities , connecting portions (54) of the terminals (50) extending into the wire receiving slots , the electrical connector assembly being characterized in that: front and back projections (53) are positioned on each terminal (50) and extend into the corresponding wire receiving cavity , the projections ( 53 ) are positioned on either side of the connection portion ( 54) and extend to opposite sides of a centerline of the terminal ( 50) , the projections (53) having second securing members (53a) which secure the terminals ( 50) to the cover means (30) , whereby , individual insulated wires (4) are inserted into corresponding slots (32) of the cover means (30 ) , the cover means ( 30) is then brought into contact with the housing means (20) and the terminals (50) , such that the wires (4) are placed into the wire receiving cavities , allowing the projections ( 53) to guide the wires (4) onto the connecting portions (54) of the terminals ( 50) ensuring that a centerline of each wire (4) is positioned over the centerline of the corresponding terminal (50) , so that no torsionai force is created , enabling the connecting portion ( 54) to easily and reliably pierce the insulation of the wire (4) without creating harmful stresses on the wire , placing the wire (4) in electrical connection with the terminals (50) . 6. An electrical connector assembly as recited in claim 5 , characterized in that the latch means is provided with arms ( 31 ) having hooks (31a) on the cover means (30) which cooperate with latching projections ( 25) on the housing means (20) to secure the cover means (30 ) to the housing means ( 20) . 7. An electrical connector assembly as recited in claim 5 , characterized in that an electrical wire retaining projection (55) is formed on the terminal (50) to the rear of the back projection ( 53) on the opposite side from the connecting portion (54) .

Inventors: FUJIURA YOSHITSUGU, NISHIMURA RYOJI, FUJIURA, YOSHITSUGU, NISHIMURA, RYOJI
Applicants: AMP INC, AMP INCORPORATED
Application year: 1986
Main classification: H01R4
IPC codes: H01R4