SOLDERLESS CONNECTING BLOCK

Abstract: A solderless connecting block has means for providing an electrical engagement between a contact wire (70, 72) and a terminal (74). The terminal (74) displaces the wires (70, 72), which are uninsulated in the contact zone, such that the terminal and wires are placed in electrical engagement. The cooperation of the wires (70, 72) with the terminal also provides the retention force required to maintain the terminal (74) in the connecting block. Consequently, no solder or mounting hardware is required to provide a positive and secure electrical connection between the wires and the terminal.

Description: SOLDERLESS CONNECTING BLOCK The invention is directed to a connecting block which insures that a positive electrical connection is effected between a contact post and conductive wires. In particular, the interconnection is effected without the. need of solder or the like. There are many instances in which a conductive wire must be electrically connected to a contact post of a connector. In order to insure that a positive electrical connection is provided, the wires are generally soldered to the post. However the use of solder to insure a positive electrical connection has several problems associated therewith. In order to perform the soldering operation, a soldering tool is required. Consequently, in field use, in order to perform repair and/or replacement of any defective parts, a tool must be carried by the operator. Also, the use of solder is time consuming to apply and relatively expensive to use. Another disadvantage of soldering is the space requirements associated therewith. In order to solder a wire to a post, enough space must be provided in order for the tool to be properly positioned. Consequently, in situations in which the posts are closely spaced, soldering is not always an effective option. It should also be noted that the use of solder prohibits the replacement of components. As an example, if a modular jack has posts which are soldered to wires, it is difficult to replace the modular jack without damaging the wires which are connected thereto. Consequently, the replacability of parts which are soldered are greatly inhibited. Other means, such as wire wrap, are available as an alternative to soldering. However, the alternatives suffer from many of the same problems inherent with soldering. Also many of the alternatives do not provide the electrical characteristics required to insure a positive electrical connection. It would therefore be beneficial to provide a means for electrically connecting the post to the wire, in which the electrical connection is effected without the need of solder or the like. This would be of great benefit in field use, and greatly enhance the replacability aspect of the connector. The present invention is directed to a connector housing which has a first major surface and a second major surface. Oppositely facing side surfaces extend from the first major surface to the second major surface, and oppositely facing end surfaces extend between the side surfaces. The connector housing has at least one terminal receiving opening which extends from the first major surface toward the second major surface. At least one wire receiving opening is provided in the connector housing. The wire receiving opening extends from a first side surface toward a second side surface, and intersects the terminal receiving opening, such that a portion of the wire receiving opening is provided in the terminal receiving opening. A cavity is provided adjacent the wire receiving opening, and proximate the terminal receiving opening, the cavity is dimensioned to receive a portion of a wire therein. Whereby, when a partially uninsulated wire is positioned in the wire receiving opening, and a terminal is inserted into the terminal receiving opening, the terminal will deform the wire into the cavity. As this occurs, the resilient nature of the wire maintains the wire in electrical engagement with the terminal. This invention is also directed to an electrical connector receptacle of the type comprising an insulating housing having a plug-receiving end and a rearward end. A first surface and an oppositely facing second surface extend from the plug-receiving end to the rearward end, the plug-receiving end having a plug-receiving opening extending therefrom. A plurality of spaced-apart side-by-side contacts are provided in the housing, each of the contacts has a contact spring portion, an intermediate portion, and a mounting portion. The mounting portions of the terminals extend through the second surface. The connector receptacle is characterized in that a connection block extends from the second surface of the housing in a direction away from the first surface. The connection block has a first major surface and a second major surface. A portion of the first major surface is provided in engagement with the second surface of the housing. Contact receiving openings are provided in the connection block, such that the mounting portions of the contacts are positioned in the contact receiving openings. Cavities extend from the contact receiving openings, the cavities being dimensioned to receive a portion of the contacts therein. Terminal receiving openings are provided in the connection block. The terminal receiving openings are positioned to intersect the contact receiving openings at a position proximate the cavities. An embodiment of the invention will now be described by way of example with reference to the accompanying drawings, in which: FIGURE 1 is an exploded perspective view of a telephone receiver which has several connecting blocks of the present invention provided therein; FIGURE 2 is a perspective view of a respective connecting block, a portion of the connecting block has been removed in order to illustrate the interconnection between a wire and a pin; FIGURE 3 is a side view of a connecting block similar to that shown in Figure 2, with a portion thereof shown in cross-section to illustrate the electrical engagement of the pin with two different wires; and FIGURE 4 is a cross-sectional view of the connecting block shown in Figure 3, the wire being displaced due to the pin, such that the pin and the wire are placed in electrical engagement with each other. Figure 1 illustrates a typical environment in which a connection block of the present invention can be used. Telephone handset 4 has a microphone 6 and a listening device 8 provided therein. In order for the handset to operate, both the microphone and the listening device must be connected to modular jack 10. The modular jack is in turn connected to a telephone cord (not shown) . The interconnection between the telephone cord and the modular jack can be done in any number of well known ways. Modular jack 10 has a plug receiving end 12 and an opposed rearward end 14. First surface 16, second surface is, and side surfaces 20 are integral with, and extend between plug receiving end 12 and rearward end 14. A plug receiving opening 22 extends from plug receiving end 12 toward rearward end 14. Drawn wire contacts are provided proximate plug receiving opening 22. Mounting portions of the contacts extend from second surface- 18, in a direction away from first surface 16. Provided proximate second surface 18 of modular jacklO is a connection block 24. Connection block 24 has a first major surface 26 and a second major surface 28. End surfaces 30 and side surfaces . 32 are integral with, and extend between first major surface 26 and second major surface 28. As is shown in Figure 1, a portion of first major surface 26 of connection block 24 is provided adjacent second surface 18 of modular jack. This configuration insures that the mounting portions of the contacts will extend into the connection block. It should be noted that although connection block 24 is shown as a separate piece, it is conceivable that the connection block would be integrally molded to the modular jack. A second connection block 34 is provided in handset 4, at a position away from modular jack 10. Connection block 34 differs from connection block 24 in several aspects, however the manner in which the electrical connection is made is substantially the same. Therefore, for ease of explanation and understanding, the explanation of the operation of the connection block will be done with respect to the embodiments shown in Figures 2 through 4. As will be more fully explained, it is important to note that the manner in which the electrical connection is made is the same for connection blocks 24, 34, 50, and 80. The only significant difference is that connection block 34 has only one wire which is placed in electrical engagement with a respective pin terminal. As is shown in Figure 2, connection block 50 has an upper surface 52 and a lower surface 54. A first end surface 56, a second end surface 58, and side surfaces 60 extend between, and are integral with upper and lower surfaces 52, 54. A first wire receiving opening 62 extends from the first end surface to the second end surface. The axis of the first wire receiving opening is essentially parallel to the plane of the upper surface. A second wire receiving opening 64 is provided below first wire receiving opening 62 and is essentially parallel thereto. It should be noted that the openings 62, 64 can be in the form of a recess (as shown in Figures 1 and 3) . However, if a recess is provided, a securing means must be positioned in the recess in order to maintain the wire therein. An example of securing means would be embossments provided on the sidewalls of the recess. A cavity 66 is provided adjacent each opening 62, 64. As is shown in Figure 2, cavity extends from a respective opening 62, 64 toward a side surface 60. The length of the cavity will be varied according to the resilient characteristics desired, as will be more fully discussed. A terminal receiving opening 68 extends from upper surface 52 to lower surface 54. Terminal receiving opening 68 is positioned essentially perpendicular to openings 62, 64. It is important to note that opening 68 intersects openings 62, 64. However, the axis of opening 68 is offset from the axis of openings 62, 64. In operation wires 70, 72 are provided in respective openings 63, 64. A pin terminal 74 is then inserted into opening 68. As the terminal is inserted, the terminal will first engage wire 72, thereby causing wire 72 to be displaced into a respective cavity 66. The displacement of the wire is facilitated by the sloping surface provided at the end of the terminal. However, the resilient characteristics of the wire and the dimensioning of the cavity insure that the wire will resist this displacement. Consequently, the wire is maintained in electrical engagement with the terminal. As the wire is uninsulated, the terminal and wire are maintained in electrical engagement. The force which maintains the wire in cooperation with the terminal can be increased in several ways. First, the size of opening 64 can be controlled to provide frictional engagement between wire 72 and the sides of opening 64. This frictional engagement will prevent the movement of the wire and insure that the wire will be maintained in engagement with the terminal. A second means of increasing the retention force, is to shorten the length of the cavity. The shorter the length of the cavity, the more force required to displace the wire, as the walls of the openings prevent the displacement of the wire. A third means to increase the retention force is to provide a tab terminal rather than a pin terminal. The increased width of the tab terminal will cause the wire to be displaced a greater amount, thereby increasing the forces associated therewith. Consequently, the wire is retained in engagement with the terminal. It should be noted that the force provided between the wires and the terminal not only provides the electrical engagement required, but also provides the mechanical means to retain the terminal in the opening. The continued insertion of terminal 74 causes terminal 74 to engage wire 70. The cooperation of terminal 74 with wire 70 is identical to that described in relation to wire 72. Therefore, the identical explanation will not be repeated. With terminal 74 fully inserted into block 50, terminal 74 is maintained in the block without the need of mounting hardware or solder. This is an extremely advantageous result. As no special tools or hardware is required, the cost of the block is reduced. Also, as the retention of the terminals in the block is provided by the cooperation of the wires with the terminal as explained, the terminal can be easily removed and replaced. In other words, the entire block does not have to be replaced if a part is damaged. As an example, referring back to Figure 1, if the microphone or listening device is defective, it is merely unplugged and a new unit plugged in. This greatly facilitates field repairs. Connection block 80, shown in Figures 3 and 4 operates in the same manner as above. However, as is shown, it is possible to have two or more terminal receiving openings provided in any given connection block. It should also be noted that the connection block is not limited to use where only one or two wires are to be electrically connected to the terminal. It is possible for three or more wires to be connected to a respective terminal. Changes in construction will occur to those skilled in the art and various apparently different modifications and embodiments may be made without departing from the scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only. It is therefore intended that the foregoing description be regarded as illustrative rather than limiting.

Claims: CLAIMS : 1. A connector housing (24,34,50,80) having a first major surface (26,52) and a second major surface (28,54), oppositely facing side surfaces (32,56,58) extend from the first major surface (26,52) to the second major surface (28,54), oppositely facing end surfaces (30,60) extend ' between the side surfaces (32,56,58), at least one terminal receiving opening (68) which extends from the first major surface (52) toward the second major surface (54) ,the connector housing characterized in that: at least one wire receiving opening (62,64), the wire receiving opening (62,64) extends from a first side surface (56) toward a second side surface (58) , the wire receiving opening (62,64) intersects the terminal receiving opening (68) , such that a portion of the wire receiving opening is provided in the terminal receiving opening; a cavity (66) is provided adjacent the wire receiving opening (62,64), and proximate the terminal receiving opening (68) , the cavity (66) being dimensioned to receive a portion of a wire (70,72) therein; whereby, when a partially uninsulated wire (70,72) is positioned in the wire receiving opening (62,64), and a terminal (74) is inserted into the terminal receiving opening (68) , the terminal (74) will deform the wire (70,72) into the cavity (66), the resilient nature of the wire (70,72) maintaining the wire (70) in electrical engagement with the terminal (74) . 2. A connector housing (24,34,50,80) as recited in claim 1 further characterized in that two wire receiving openings (62,64) are provided, each opening having a longitudinal axis which extends in a plane which is essentially parallel to the plane of the first major surface (52) . 3. A connector housing (50) as recited in claim 1 further characterized in that the cavity (66) extends from proximate the first side surface (56) to proximate the second side surface (58) , the length of the cavity (66) being dimensioned to provide the resilient characteristics required for a given wire (70,72). 4. A connector housing (80) as recited in claim 1 further characterized in that the cavity (66) extends from the first major surface (52) toward the second major surface (54) . 5. A connector housing (80) as recited in claim 4 further characterized in that securing means are provided in the cavity (66), to maintain the wire (70,72) in the cavity (66) . 6. A connector housing (24) as recited in claim 1 further characterized in that the connector housing (24) is integrally attached to a modular jack (10) , the modular jack (10) having wire contacts which are provided in respective wire receiving openings, such that the wire contacts will be provided in electrical engagement with a terminal inserted into the terminal receiving opening (22).

Inventors: BRUMMANS WILHELMUS JOHANNES, STERKEN CORNELUS ADRIANUS HENR, BRUMMANS, WILHELMUS, JOHANNES, STERKEN, CORNELUS, ADRIANUS, HENRICUS, MARIA
Applicants: AMP INC, AMP INCORPORATED
Application year: 1989
Main classification: H01R13
IPC codes: H01R13, H04M1