Modular press tool for assembling and terminating electrical connectors

Abstract: A press tool (20) is provided for assembling an electrical connector assembly (44) which includes a modular rear housing component (46) and a mateable modular front housing component (48) defining a front-to-rear axis, and for terminating terminals in the connector assembly in response to mating of the housing components in the direction of the axis. The housing components are capable of being in different sizes and termination configurations. The press tool includes a base (22), and an anvil (26) projecting from the base for positioning a rear housing component of the electrical connector assembly. The anvil includes a comb member (37) having a plurality of slots (36) therethrough through which wires (50) projecting from the rear of the rear housing component extend. A ram (28) is movably mounted on the base (22) for movement toward and away from the anvil (26). The ram (28) is engageable with the front housing component (48) of the electrical connector assembly and may include interchangeable tooling (38a-38e) for accommodating modular front housing components of different sizes and termination configurations.

Description: This invention generally relates to the art of termination tools for electrical connectors and, particularly, to a press tool for assembling electrical connectors of different sizes and termination configurations. U.S. Patent No. 4,193,177 shows an apparatus for assembling an electrical connector housing and a conductor mounting comb in the shape of a press which utilizes various movable mechanisms to cut and position the wires prior to termination, and subsequently forces the wires in a direction perpendicular to the local wire axis. Obviously, the cable must be bared to free the wires or conductors which are to be arranged in the comb. A wire termination system which can be implemented more economically is shown in US-A 4,512,619 which discloses a collapsible insulation displacement terminal responsive to a force directed along the length of a wire received in the terminal. An electrical connector system which includes such self-terminating pin and socket terminals of US-A 4,512,619 is disclosed in US-A 4,955,816 and has forward mating ends and identical rear wire-receiving ends. The wire-receiving ends are mountable in a modular rear housing. The modular rear housing is mateable with either a front plug housing or a front receptacle housing. The terminals can be mass terminated by inserting a plurality of wires into the modular rear housing and by axially advancing the modular rear housing toward the front housing of the system. The housing components can readily be separated from one another for repair or replacement of terminals. Selected connectors can be lockingly mountable to panels and can be lockingly mateable with one another. However, multi-conductor electrical connectors have been provided in a wide variety of configurations for mass terminating a plurality of terminals to the conductors of a multi-conductor electrical cable. One of the problems in mass termination of these types of connectors is that a given connector of a particular construction can be used with a variety of different circuitry having a different array or configuration of terminals. Consequently, termination tools for assembling or terminating such connectors constantly have to be modified to accommodate the configuration of terminals. An object, therefore, of the invention is to provide a modular press tool for assembling and/or terminating an electrical connector assembly having varying circuit capabilities. This problem is solved by a press tool according to claim 1. For exemplary purposes, an electrical connector assembly is contemplated which, generally, includes a modular rear housing component and a mateable modular front housing component defining a front-to-rear axis, for terminating terminals in the connector assembly in response to mating of the housing components in the direction of that axis. The housing components are capable of different termination configurations. This invention contemplates a press tool which includes a base, with an anvil projecting from the base. The anvil positions the rear housing component of the electrical connector assembly and includes interchangeable tooling for accommodating modular rear housing components of different termination configurations. A ram is movably mounted on the base for engaging the front housing component of the electrical connector system. The ram may include interchangeable tooling for accommodating modular front housing components of different termination configurations. Means are provided for moving the ram and a positioned front housing component toward the anvil and a positioned rear housing component in the direction of the front-to-rear axis for mating the housing components and terminating the terminals. Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings. Brief Description of the Drawings The features of this invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with its objects and the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which: FIGURE 1 is a perspective view of a modular press tool incorporating the concepts of the invention and adapted for assembling and terminating a receptacle connector; FIGURE 2 is a perspective view of the press tool, adapted for assembling and terminating a plug connector; FIGURE 3 is a top plan view of the tool, adapted as in Figure 1, in a loading position; FIGURE 4 is a view similar to that of Figure 3, with the tool in a terminating position; FIGURE 5 is a top plan of the tool, adapted as in Figure 2, in a loading position; FIGURE 6 is a view similar to that of Figure 5, with the tool in a terminating position; FIGURE 7 is a vertical section taken generally along line 7-7 of Figure 1; FIGURE 8A is a vertical section taken generally along line 8A-8A of Figure 2; FIGURES 8B-8D are views similar to that of Figure 8A, but showing different modular press plates on the forward face of the ram; FIGURE 9 is a vertical section taken generally along line 9-9 of Figure 1; and FIGURES 9A-10B are views similar to that of Figure 9, but showing different interchangeable tooling on the anvil. Detailed Description of the Preferred Embodiment Referring to the drawings in greater detail, and first to Figures 1 and 2, a modular press tool, generally designated 20, is illustrated for assembling electrical connector assemblies which include modular components, as described hereinafter, and for terminating terminals in the connector assembly in response to mating of the components. More particularly, modular press tool 20 includes a base 22 projecting forwardly from a pneumatic piston and cylinder device 24. An anvil 26 projects upwardly from base 22 at the forward end thereof, the right-hand end as viewed in Figures 1 and 2. A ram 28 is slidably mounted on guide rods 30 which extend between anvil 26 and a front plate 32 of piston and cylinder device 24. A piston rod 34, of the pneumatic piston and cylinder device 24, extends through front plate 22 and is fixed to ram 28 for moving the ram in the direction of double-headed arrow "A". As seen in Figures 1 and 2, anvil 26 is provided with a plurality of slots 36 defined by ribs 37 (three are shown) and into which electrical wires can be located, as described in greater detail hereinafter. In comparing Figures 1 and 2, a modular press plate 38a (Fig. 1) or 38b (Fig. 2) is mounted to the front of ram 28 for engaging a front housing component of an electrical connector assembly. Again, as described in greater detail hereinafter, modular press plate 38a is configured for engaging a front housing component of a receptacle connector assembly, and press plate 38b (Fig. 2) is configured for engaging a front housing component of a plug connector assembly. As seen in both Figures 1 and 2, both press plates 38a and 38b have an array of contacts 40 which are coupled to test circuitry within a holder 42 mounted within ram 28. Conductors (not shown) are attached to such circuitry and extend out of ram 28 to complete the circuit with the free ends (not shown) of wires 50 (Fig. 3) to test the electrical continuity through the terminated contacts within an electrical connector assembly after termination. The embodiments shown in Figures 7-8D show a total of fifteen contacts 40 although it is understood that other configurations can be used provided there is no one contact for each terminal to be tested. Referring to Figures 3 and 4 in conjunction with Figure 1, an electrical connector assembly, generally designated 44, is illustrated as located between anvil 26 and press plate 38a of ram 28 prior to termination. The connector assembly shown is of the modular-type illustrated in U.S. Patent No. 4,955,816 described above. The connector assembly includes a rear housing component 46 and a front housing component 48. Terminals are mounted within rear housing component 46 for insulation-displacement termination with the conductors of electrical wires 50. Latch arms 52 project outwardly from front housing component 48 for latching engagement in latch devices 54 on rear housing component 46, in response to movement of the front housing component in the direction of arrow "B" (Fig. 3). Further details of connector assembly 44 can be derived from the aforesaid 4,955,816 patent. Front housing component 48 of electrical connector assembly 44 is a receptacle component having a generally planar front face 56 for engaging the flat face 58 of press plate 38a. When ram 28 is moved toward anvil 26 in the direction of arrow "B" (Fig. 3), flat face 58 of press plate 38a engages planar surface 56 of front receptacle housing component 48 and drives the front housing component into assembly with rear housing component 46 as seen in Figure 4. As can be seen in U.S. Patent No. 4,955,816, the terminals within rear housing component 46 are effectively terminated to the conductors of electrical wires 50 by an insulation displacement process in response to an actuating force directed along the axes of the wires. Therefore, as front housing component 48 is moved towards rear housing component 46, the insulation displacement terminals within rear housing component 46 are terminated to wires 50. Figures 5 and 6 are substantially identical to Figures 3 and 4, except that front housing component 48' of an electrical connector assembly 44' now comprises a plug connector component for assembly to modular rear housing component 46. It can be seen that the plug connector component includes a plurality of silos 60 defining terminal receiving bore-like cavities. The silos are spaced apart defining slots 62 therebetween. Referring to Figure 2 in conjunction with Figures 5 and 6, press plate 38b on ram 28 has a plurality of ribs 64 which project into slots 62 between silos 60 for engaging a flat surface 66 at the base of the silos. Otherwise, like numerals have been applied in Figures 5 and 6 to identify like components described in relation to Figures 3 and 4. Therefore, just as with the above description of the operation of the press tool in relation to Figures 3 and 4, when ram 28 is moved in the direction of arrow "C" (Fig. 5), the distal ends of ribs 64 engage surface 66 on plug connector component 48 and move the connector component into an assembled condition relative to modular rear housing component 46 and, at the same time, terminate the terminals within the rear housing component to the conductors of wires 50. From the foregoing, it can be seen that modular press tool 20 can assemble and terminate either a receptacle connector assembly 44 (Figs. 3 and 4) or a plug connector assembly 44' (Figs. 5 and 6) simply by changing the configuration of press plates 38a and 38b on the front of ram 28. The invention also contemplates providing means on modular press tool 20 for laterally supporting the outside walls of modular rear housing component 46 during an assembly and termination operation. More particularly, with the insulation displacement terminals and electrical connector assemblies shown in the aforementioned U.S. Patent Nos. 4,515,619 and 4,955,816, the terminals are terminated to the electrical wires by an actuating force directed along the axes of the terminals. This may result in outward forces on the walls of modular rear housing component 46 in the direction of double-headed arrows "D" (Figs. 4 and 6). In order to laterally support modular rear housing component 46, and referring again to Figures 3-6, a fixed nesting plate 68 is mounted to anvil 26, and a movable clamping member 70 is slidably mounted to the anvil. A cam member 72 is slidably mounted on one of the guide rods 30 and is biased in the direction of arrow "B" (Fig. 3) by means of a spring 74 surrounding the guide rod and sandwiched between cam member 72 and press plate 38a (or 38b in Fig. 5). Complementary interengaging wedge surfaces 76 and 78 are provided on movable clamping member 70 and cam member 72, respectively, for engagement when ram 28 is moved toward anvil 26. When so moved, surfaces 76 and 78 engage and move the movable clamping member 70 in the direction of arrows "E" (Figs. 4 and 6) to position the movable clamping member into engagement with the side of modular rear housing component 46 opposite fixed nesting plate 68. Therefore, during the assembly and termination operation, nesting plate 68 and clamping member 70 support the outside walls of modular rear housing component 46 against the termination forces directed outwardly in the direction of double-headed arrow "D" (Figs. 4 and 6). Figures 3-6 also show a retaining member 79 having a projecting flange 79a overlying a corner of rear housing component 46. The retaining member helps to retain the rear housing component against anvil 26. Figures 7 and 8A-8D illustrate various configurations of modular press plates for mounting on the forward face of ram 28 and for engaging different front housing components of electrical connectors of different configurations. These press plates all are interchangeable to enable use of modular press tool 20 with a variety of connector assemblies. More particularly, Figure 7 shows the configuration of press plate 38a already described in relation to Figures 1, 3 and 4. In the illustrated embodiment of the invention, the press tool and its modularized components are shown capable of assembling connector assemblies having a maximum of fifteen terminals arranged in three rows of five terminals, as can be seen in Figure 7. However, it should be understood that the invention can be incorporated in press tools for assembling and terminating other numbers of terminals in connector assemblies of different configurations. With the array of terminals illustrated, press plate 38a shown in Figure 7 would be used on the press tool to assemble and terminate receptacle connector assemblies having a front receptacle housing component 48 (Figs. 3 and 4) regardless of the number of terminals and the corresponding lateral configuration of the connector assembly. This is because, as seen in Figures 3 and 4, all of the front receptacle housing components will have a planar face 56 (Figs. 3 and 4) for engagement by the flat face 58 of press plate 38. However, when assembling and terminating plug connector assemblies, such as plug connector assembly 44' including front plug housing component 48' described in relation to Figures 5 and 6, different configurations of press plates would be used. For instance, Figure 8A shows press plate 38b (Figs. 2, 5 and 6) having four ribs 64 extending the full length of the three rows of five terminals. This press plate would be used with a connector assembly which has a full compliment of fifteen terminals. Comparing Figures 8A-8D, examples of different configurations of the press plates on ram 28 are illustrated to exemplify the interchangeable tooling on the ram for accommodating modular front plug housing components of different termination configurations. More particularly, as stated, Figure 8A shows press plate 38b as illustrated in Figure 2 wherein ribs 64 extend the entire height of the press plate. Turning to Figure 8B, it can be seen that a press plate 38c is provided wherein ribs 64c do not extend the entire width of the press plate. This press plate is designed to terminate electrical connector assemblies which have either four or twelve contacts. Figure 8C shows a press plate 38d having still shorter ribs 64d centered in the middle of the press plate. This press plate is designed to accommodate front plug housing components having either three or nine contacts. Figure 8D shows still another press plate 38e having still shorter ribs 64e, and this press plate is provided for accommodating front plug housing components having either two or six contacts. In all of the configurations of ribs 64-64e, generally the peripheral bounds of the ribs are the same as the outside bounds or sizes of the front plug housing components which are being assembled. In all of the instances of the different press plates 38a-38e shown in Figures 7 and 8A-8D, the press plates are mounted to ram 28 by means of bolts 80 whereby the press plates are readily interchangeably mountable to the forward face of the ram. In order to interchange the press plates, and referring back to Figures 1 and 2, a pair of bolts 82 are threaded into one edge of base 22 and a second pair of bolts 84 are threaded into the distal ends of guide rods 30 to hold anvil 26 securely in position. These bolts simply are removed, the anvil is temporarily removed and the press plates can be interchanged. Bolts 80 are removed to free the press plate from ram 28 and then the press plate is simply slid over guide rods 30 and removed. A different press plate is slid onto the guide rods and the press mechanism is reassembled. Figures 9-10B illustrate examples of different interchangeable tooling mountable on anvil 26 for accommodating modular rear housing components of different termination configurations and/or sizes. More particularly, Figure 9 shows nesting plate 68 for receiving a rear housing component which contains fifteen contacts for assembly to a front plug housing component which is engaged by press plate 38b described in relation to Figures 2 and 8A. Nesting plate 68 has a side wall 88 and a bottom wall 90 defining two sides of a recess for receiving the rear housing component. Clamping member 70 has a forward face 92 defining a side of the recess opposite wall 88 of nesting plate 68. Cam member 72 is shown in phantom. As stated above, cam member 72 moves clamping member 70 in the direction of arrow "C" to engage the rear housing component in response to movement of ram 28. Consequently, side wall 88 of nesting plate 68 forms an abutment wall against which the rear housing component abuts when clamping member 70 is moved to engage the rear housing component. It can be seen that clamping member 70 is reciprocally movable within slot 94 in nesting plate 68. Retaining member 79 also is shown (see Figures 3-6) for holding the rear housing component against the anvil, i.e., against ribs 37. Nesting plate 68 is removably secured to anvil 28 by a bolt 96, and retaining member 79 is secured to nesting plate 68 by a bolt 98. Figure 9A shows a nesting plate 68a having a side wall 88a and a bottom wall 90a which define a smaller recess for receiving rear housing components which mount either six, nine or twelve contacts. Otherwise, the remaining components of the tooling are the same as shown and described in relation to Figure 9. For instance, side wall 88a defines an abutment wall opposite face 92 of clamping member 70 which is moved in the direction of arrow "C" by cam member 72. Retaining member 79 is held in the same position as described in relation to Figure 9 by means of bolt 98. Figure 9B shows the interchangeable tooling configured to accommodate a modular rear housing component which mounts either two, three or four contacts. With this tooling, nesting plate means are configured to define still a further, smaller recess by means of a bottom wall 90b and a side abutment wall 88b of a nesting filler plate 68b inside nesting plate 68a. The filler plate is appropriately secured against abutment wall 88a of nesting plate 68a, as by bolts. Clamping member 70 again is mounted as described in relation to Figures 9 and 9A, with face 92 opposite abutment wall 88b of nesting plate 68b. However, retaining member 79 has been moved inwardly toward the smaller recess and is mounted to nesting filler plate 68b by a bolt 98b. Whereas Figures 9-9B show examples of interchangeable tooling for nesting modular rear housing components on anvil 26 which are assembled to front plug housing components as described in relation to Figures 2, 5 and 6, Figures 10-10B illustrate interchangeable tooling for modular rear housing components which are assembled to front receptacle housing components such as described in relation to Figures 1, 3 and 4. More particularly, in comparing Figures 10, 10A and 10B with Figures 9, 9A and 9B, respectively, it can be seen that respectively identical nesting plates 68, 68a and 68b are utilized. However, it can be seen that the location of retaining member 79 has been moved to a position at the bottom of the nesting plates versus the sides of the nesting plates as illustrated in Figures 9-9B. Moving the location of the retaining member is necessary because of differences in the outside configurations of the receptacle housing components versus the plug housing components. Otherwise, the nesting plates still perform the function of providing a recess of a particular size for receiving a particular modular connector component and provide an abutment opposing the forces of clamping member 70. It should be understood from the foregoing description that the interchangeable tooling on ram 28 as described in relation to Figures 7-8B and the interchangeable tooling on anvil 26 as described in relation to Figures 9-10B, are examples of interchangeable tooling which might be used in assembling and terminating electrical connector assemblies as disclosed in U.S. Patent Nos. 4,512,619 and 4,955,816 which have been incorporated herein by reference. However, the invention contemplates a modular press tool for assembling other electrical connector assemblies wherein relatively movable tool components, such as ram 28 and anvil 26, can be provided with a wide variety of interchangeable tooling to thereby provide a modular press tool for assembling and terminating modular connector assemblies.

Claims: A press tool (20) for assembling electrical connector assemblies (44) which include: a first housing component (46), a second housing component (48), said first and second housing components (46, 48) being matable along a mating axis each housing component including a plurality of hollows each of which define a hollow axis which extend parallel to said mating axis, said hollows accomodating terminals which are adapted to terminate a plurality of wires (50) when said housing components (46, 48) are mated together; said press tool (20) comprising: a base (22); an anvil (26) secured to and projecting from said base (22) for positioning said first housing component (46) of the electrical connector assembly (44) prior to termination of said terminals, said anvil (26) including interchangeable tooling and comb means (37) having a plurality of slots (36) through which wires (50) projecting from the rear of the first housing component (46) extend, interchangeable tooling being adapted to accommodate first housing components (46) of differenz termination configurations, said comb means (38) being positioned so that each said hollow axis extends through an associated one of said slots (36); a ram (28) including interchangeable tooling for accommodating second housing components (48) of different termination configuration and being movably mounted on said base (22) for reciprocal movement along said mating axis to engage the second housing component (48) and mate the first and second housing components (46, 48) thereby terminating each terminal to an individual wire (50); and moving means (24) for moving said ram (28) a predetermined distance along said mating axis. The press tool of claim 1, including abutment means (88) mounted on the anvil (26) for engaging one side of a respective first housing component (46) and clamp means (70) for engaging an opposite side of the first housing component (46) to support opposite sides of the first housing component transversely of said mating axis. The press tool of claim 1 or 2 wherein said interchangeable tooling on the ram (28) includes a plurality of press plates (38a-38e) of different configurations mountable on the front face of the ram (28). The press tool of claim 3 wherein said press plates (38a-38e) are provided with different configurations of parallel ribs (64, 64c, 64d, 64e) for engaging plug connector components having different configurations of terminal receiving silos (60) arranged in rows, the ribs being adapted to project between the rows. The press tool of any of claim 1 to 4 wherein said interchangeable tooling on the anvil include a plurality of nesting plates (68, 68a, 68b) interchangeably mountable on the anvil (26) and having recess means (88, 90, 92) of different configurations for nesting the rear housing components (46) of different termination configurations. The press tool of claim 5 wherein said recess means (88, 90, 92) of each of said nesting plates (68, 68a, 68b) includes an abutment wall (88) for engaging one side of the respective first housing component (46) and clamp means (70) for engaging an opposite side of the first housing component (46) transversely of said axes. The press tool of claim 6, including means (94) movable mounting said clamp means (70) in the path of movement of said ram (28), and including means (72, 74) operatively associated with the ram (28) for moving the clamp means (70) into engagement with said opposite side of the first housing component (46) in response to movement of the ram (28) toward the anvil (26).

Inventors: ANDERSON DANIEL J, ANDERSON, DANIEL J.
Applicants: MOLEX INC, MOLEX INCORPORATED
Application year: 1992
Main classification: H01R43
IPC codes: B23P19, H01R43