MODULAR TERMINAL BLOCK ASSEMBLY

Abstract: The invention is a modular terminal block assembly (20). The modular terminal block assembly (20) includes a base module (28) in which communications company lines (54) may be dressed and retained during the dressing operations. A connector module (26) is provided for attachment over the base module (28) and to engage distribution lines (52) retained in the base module (28) with insulation displacement connectors (IDC) (110) which are retained in the connector module (26). A protection module (30) is provided for engagement with an opposite side of the base module (28) so that protection can be provided on the lines without interfering with the connection termination of customer service line on the connector module (26). The modular terminal block assembly (20) provides structures which allow the assembled modular terminal block to be retained on a standard U-shaped mounting frame (24) or for attachement to a rod frame system (22).

Description: MODULAR TERMINAL BLOCK ASSEMBLY Background The present invention relates to a communication connector terminal block assembly system and more particularly to modular terminal block assemblies for termination of distribution lines and interconnection with service lines. A variety of communication line connector terminal block assemblies are available to terminate and interconnect communication company distribution lines with customer service lines. While some of these terminal blocks provide adequate termination and interconnection, all ofthe terminal blocks encounter some form of problem which degrade the efficiency, integrity or other characteristics ofthe system. For example, there are two primary equipment mounting systems which are widely used throughout the world. Many systems employ a U-shaped frame for mounting multiple terminal blocks. The U-shaped frame with the multiple terminal blocks attached thereto can then be attached to a cabinet or large multi-unit frame. Additionally, some available terminal blocks do not provide line isolation for two- way testing. When there is a line failure, it is important to be able to isolate the customer service line from the distribution line to permit tracing ofthe line problem. Because prior art terminal blocks do not provide line isolation, it is very difficult to trace and identify line fault problems. As such, it would be highly desirable to provide line isolation and testing capabilities in a terminal block assembly system. Most terminal blocks do not provide the ability to selectively attach half-tap assemblies. While some terminal blocks may provide half-tap assemblies, the block must be specifically ordered with this feature. Such a specialized terminal block increases inefficiencies associated with the system and therefore is undesirable. It would be desirable to provide a terminal block assembly system in which half-tap assemblies may be selectively added as needed for specific lines. corrosion on the conductive components and degrade the operation ofthe assembly. As such, even in intemal uses, it may be desirable to provide environmental protection ofthe terminal blocks. Other terminal blocks are designed for extemal use. The extemal terminal block, however, are typically designed as a separate assembly from the intemal terminal blocks. It would be desirable to provide a single terminal block assembly system which can be used internally or externally in order to exploit efficiencies which would be inherent in such a universal design. For example, cost efficiencies may be exploited since one type of terminal block assembly system is produced for intemal and extemal uses. There are skill efficiencies which result from the tradesperson having to be familiar with only one type of structure. The skill efficiencies translate into installation reliability since fewer installation errors will be encountered. Further, replacement parts and expansion requirements can be more quickly accommodated since inventories of only one type of terminal block assembly system need to be maintained. Still a further problem encountered by prior art terminal blocks is that they do not provide constant line protection. Some prior art terminal blocks provide line protection but the line protection devices are attached to the customer service connection portion of the terminal block. This is a problem because the protection must be removed in order to access the customer service line. When the protection device is removed, the personnel working on the system and the equipment connected to the system are not protected. It is important to provide constant line protection for both personnel and equipment. Briefly, and in accordance with the foregoing, the present invention envisions a modular terminal block assembly. The modular terminal block assembly includes a base module in which communications company lines may be dressed and retained during the dressing operation. A connector module is provided for attachment over the base module and to engage the distribution lines retained in the base module with insulation displacement connectors (IDC) which are retained in the connector module. A protection module is provided for engagement with an opposite side ofthe base module so that protection can be provided on the lines without interfering with the connection termination of customer service line on the connector module. The modular terminal block assembly provides stmctures which allow the assembled modular terminal block to be retained on a standard U-shaped mounting frame or for attachment to a rod frame system. The protection module maintains protection on the lines while the terminal block assembly is in contact with the U-shaped frame and rod frame system. A half-tap assembly may be attached to the modular terminal block, independent ofthe service line assembly for the addition of a line to the terminal block. An environmental protectant is retained in the modular terminal block to protect the conductive connections retained therein from detrimental environmental effects. Objects and Summary A general object ofthe claimed invention is to provide a modular terminal block assembly which includes several modules for the termination of distribution lines and service lines. Another object satisfied by the claimed invention is to provide a modular terminal block assembly which can be used in an intemal or extemal environment such that in the extemal environment, the assembly can provide environmental protection. Still another object satisfied by the claimed invention is to provide a modular terminal block assembly to which a protection module may be attached and which protection module provides constant line protection. Yet a further object satisfied by the claimed invention is to provide a modular terminal block assembly to which a half-tap assembly may be added. Still a further object satisfied by the claimed invention is to provide a modular terminal block assembly which provides line isolation and test port capabilities associated with each side ofthe interconnected line when the line connectors are isolated. FIG. 5 is a perspective view ofthe bottom portion ofthe connector module showing a distribution line cutoff stmcture and frame mounting stmctures as well as wire engaging stmctures; FIG. 6 is a perspective view ofthe top portion ofthe connector module showing an actuator positioned in a connection cavity and a half-tap assembly attached to a half- tap area ofthe connector module; FIG. 7 is a partial fragmentary, top plan view of a portion ofthe connector module; FIG. 8 is a partial fragmentary, cross-sectional, side elevational view taken along line 8-8 in FIG. 7 showing the connector module attached to a base module and a protection module attached to the base module to show the cross-sectional stmcture thereof; FIG. 9 is a partial fragmentary, cross-sectional, side-elevational view taken along line 9-9 in FIG. 7; FIG. 10 is a partial fragmentary, cross-sectional, side elevational view taken longitudinally through a portion ofthe modular terminal block assembly as shown in FIG. 7-7; FIG. 11 is a partial fragmentary, cross-sectional, side elevational view taken along line 10-10 in FIG. 7; Brief Description ofthe Drawings The organization and manner ofthe stmcture and function ofthe invention, together with further objects and advantages thereof, may be understood by reference to the following description taken in connection with the accompanying drawings, wherein like reference numerals identify like elements, and in which: FIG. 1 is a perspective view of a modular terminal block assembly ofthe present invention attached to a rod mounting frame, showing customer service lines and telephone company distribution lines attached to the modular assembly; FIG. 2 is a perspective view ofthe modular terminal block assembly ofthe present invention as shown in FIG. 1 and in which the modular assembly is attached to a U-shaped frame member for mounting to a rack assembly; FIG. 3 is an exploded, perspective view ofthe modular terminal block assembly showing a connector module exploded from the first side of a base module and a protection module exploded from a second side ofthe base module with connectors and components detached from these modules; FIG. 4 is an enlarged, partial fragmentary, perspective view of a portion ofthe base module showing telephone company distribution lines positioned in receiving channels for engagement with connectors upon attachment ofthe connector module to the first side ofthe base module; FIG. 17 is a partial fragmentary, cross-sectional, side elevational view taken along line 17-17 as shown in FIG. 16 showing the connection ofthe protection module to the ground bar and the gripper portions ofthe tip clip and ring clip attached to the protection module housing. 10 FIG. 12 is an enlarged, exploded, perspective view of a half-tap assembly such as those shown in the preceding figures attached to the half-tap area ofthe connector module; FIG. 13 is a partial fragmentary, cross-sectional, side elevational view of a half- tap assembly taken along line 13-13 in FIG. 7, and in which the actuator is in the raised positioned and showing retaining protmsions ofthe half-tap housing engaging a detent recess in the actuator; FIG. 14 is an enlarged, partial fragmentary, perspective view ofthe upper portion ofthe protection module as shown in FIG. 3 and in which ring clips and tip clips are retained in the module; FIG. 15 is an enlarged, partial fragmentary, perspective view of a bottom portion ofthe protection module housing showing the frame cavity, rod mounting stmcture and protection module compartments in the underside ofthe housing in which the protection modules have been removed; FIG. 16 is an enlarged, partial fragmentary, perspective view ofthe underside of the protection module housing similar to that as shown in FIG. 15 and in which a ground bar has been installed in a central channel, ring and tip clips have been installed with gripper portions extending into the protection module compartments, and a protection module installed in the protection module compartment; and apertures 38 formed through each ofthe modules 26, 28, 30 at opposed ends ofthe modules. Additionally, with regard to the U-shaped frame 24, the assembly may be used with or without the protection module 30. If the assembly is used without the protection module 30 (see the lower portion of FIG. 2) mounting flanges 40 ofthe U-shaped frame 24 are inserted through the frame mounting apertures 38 with a biased locking finger 42 engaging an opening 44 in the flange 40. When the module 20 is attached to the U- shaped frame 24 with the protector module 30 in place, the flange 40 is inserted into the frame mounting apertures 38. A biased portion 46 of a grounding bar stmcture 48 retained in the protection module 30 is biased into conductive contact against an inside surface 50 ofthe U-shaped frame 24. As shown in the illustrations, distribution lines 52 are retained between the connector module 26 and the base module 28 and service lines 54 are connected to a service connection assembly 56 on the connector module 26. A second set of service lines 58 may also be attached to a half-tap assembly 60 on the connector module 26. Although the lines 52, 54, 58 are shown in partial perspective view, these lines 52, 54, 58 may be groomed or retained in grooming rings 62 on either side ofthe connector module 26. The lines 52, 54, 58 may also be groomed rearwardly behind the module 20 in accordance with standard line dressing practices. Having now briefly reviewed the overall stmcture and function ofthe present invention 20, we now turn to the illustrations in order to more specifically describe the stmctures and functions ofthe components ofthe invention. More particularly, with reference to FIGS. 3-5, the base module 28 is more fully described. As shown in FIG. 3, the first side 32 ofthe base module 28 includes a plurality of wire dressing stmctures 64. These wire dressing stmctures 64 are arranged to be associated and paired with a 12 Description While the present invention may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, an embodiment 5 with the understanding that the present description is to be considered an exemplification ofthe principles ofthe invention and is not intended to limit the invention to that as illustrated and described herein. With reference to FIGS. 1, 2, and 3, a modular terminal block assembly 20 is 10 shown mounted to a rod frame stmcture 22 (see FIG. 1) and to a U-shaped frame 24 (see FIG. 2). With further reference to FIG. 3, the terminal block assembly 20 has been exploded to show the various modules and components associated with each module. More particularly, with reference to FIG. 3, there is shown a connector module 26 having a connector module housing 27, a base module 28 having a base module housing 15 29, and a protection module 30 having a protection module housing 31. The base module 28 has a first side 32 and a second side 34. The connector module 26 attaches to the first side 32 ofthe base module 28 and the protection module 30 attaches to the second side 34 ofthe base module 28. When the modules 26, 28, 30 are assembled to form the terminal block assembly 20 as shown in FIGS. 1 and 2, the terminal block 0 assembly 20 can be attached to the rod frame system 22 or to the U-shaped frame 24 without using any additional mounting components as required with some prior art devices. As shown in FIGS. 1 and 2, rod-mounting stmctures 36 are provided on the 5 protection module 30 for attaching the assembly 20 to a rod frame mounting system 22. The present invention also provides frame mounting stmctures 38 which in the form of Line positioning guide stmctures 88 are positioned on both sides ofthe channel 68 between the entry end 80 and the well 84 and the strain relief 82 in the well 84. The guide stmctures 88 quickly and efficiently guide a line 52 into the channel 68 with the strain relief stmcture 82 positively retaining the line 52 in the channel 68. The strain relief stmctures 82 are formed of a non-conductive material and are intended not to contact the conductor 89 within the line 52. The strain relief stmctures 82 also positively retains dressed lines in place as other lines are being dressed into the base module. The feature permits numerous lines to be dressed and then generally simultaneously connected. In the present invention 10 pairs of lined may be retained in the base module and generally simultaneously connected when the connector module is attached to the base module. An alignment post 90 extends upwardly from the first side 32 to provide a positive positioning and alignment guide. The alignment post 90 engages an alignment groove 92 formed in the underside ofthe connector module 26. The combination ofthe trimming stmcture 78 engaging the well 76 for trimming the ends ofthe lines 52 and the post 90 engaging the groove 92 as well as end tabs 94 engaging end apertures 96 provides positive alignment ofthe connector module 26 with the base module 28. These positive positioning stmctures provide efficient and reliable connection between these modules 26, 28. The trimming stmctures 76 are formed with varying degrees of extension from the underside ofthe connector module 26 so as to sequentially trim the lines as the modules 26, 28 are assembled. The incremental trimming ofthe lines reduces the forces that are required such that only a portion ofthe total number of line 52 are trimmed as the modules 26, 28 are engaged. This trimming arrangement helps reduce the trimming 14 corresponding service connection assembly 56 ofthe connector module 26. In this regard, when the connector module 26 is attached to the base module 28, each pair of lines or wire dressing stmctures 64 will be placed in connection with a corresponding service connection assembly 56. This also positions the pairs of wire dressing stmctures 64 for connection with corresponding half-tap assemblies 60 which may be attached to corresponding half-tap areas 65. Locking fingers 66 on the base module 28 engage and retain the connector module 26 in connection with the base module 28. With reference to FIG. 4, the wire dressing stmctures 64 include a wire receiving channel 68 extending transversely through the first side 32 ofthe base module 28. FIG. 4 shows two distribution lines 52 placed in corresponding wire receiving channels 68 and two channels 68 in which distribution clips 72 are positioned transversely to the channels 68 for engaging a wire placed therein. It should be noted that wires have not been included in the channels over which the distribution clip 72 have been positioned in the interest of clarity. Positioned at a terminal end 74 ofthe channel 68 is a well 76. The well 76 receives a trimming stmcture 78 formed on an abutting side ofthe connector module 26 (see FIG. 5). An opposite end ofthe channel 68 is an entry end 80. Spaced between the entry end 80 and the terminal end 74 is a strain relief stmcture 82 and a clip receiving well 84. As can be seen in FIG. 4, the distribution clips 72 have insulation displacement fingers 86 (hereinafter referred to as "IDC fingers 86") which straddle the channel 68 to displace insulation 87 surrounding the lines 52 and conductively engage a conductor 89 within the lines 52. The IDC fingers 86 are received in the clip receiving well 84. protection module 30, further reference is made to FIGS. 6-17. FIG. 6 provides an enlarged, top, perspective view ofthe connector module 26. As shown, the connector module 26 includes the service connection assembly 56 and the half-tap assembly 60. The service connection assemblies 56 include a cavity 100 formed in the connector 5 module 26 and an actuator 102 which slidably engages the cavity 100. The half-tap assembly 60 includes a half-tap housing 104 and an actuator 102. It should be noted that the same actuator 102 is used with the service connection assembly 56 and the half-tap assembly 60. The half-tap assembly 60 may be selectively attached to the connected module 26 as a second line, coupled to, but independent from, the service line. Similarly, 10 the half-tap assembly 60 may be removed from the connector module 26 if the second line is no longer needed. A plurality of connector assemblies 56 and half-tap assemblies 60 are positioned along the connector assembly 26 in an orientation which prevents the half-tap assembly 15 60 from interfering with the connector assembly 56. In other words, the half-tap assembly 56 is not carried on and does not obstruct access to the connector assembly 56. Positioning the half-tap assemblies 60 on the same side ofthe connector module as the connector assemblies 56 in a back-to-back orientation also reduces a height dimension 105 ofthe modular assembly relative to the mounting frame (see FIGS. 1 and 2). 20 Further, the independent attachment ofthe half-tap assembly 60 to the connector module 26 in the half-tap area 65 prevents having to disturb both lines to carry out an operation on one ofthe lines. In contrast, while some prior art devices may provide half-tap assemblies, these 25 prior art half-tap assemblies interfere with or are directly connected to the primary service line. Also, some prior art devices may provide a half-tap assembly integral with 16 forces required thereby making it easier for the tradesperson to assemble the modular assembly system and to prevent assembly errors. The asymmetry of abutting portions of the connector module 26 and the base module 28 require that the modules 26,28 be in proper alignment for assembly thereby preventing any chance of assembling the modules 26, 28 in an incorrect position. It should also be noted, that the present invention provides a high degree of environmental protection for the distribution line 52 retained in the base module 28 and connected to the connector module 26. Environmental protection is provided by means of a suitable gel, grease or other non-conductive environmentally protecting material of known composition. Preferably a non-conductive material referred to as "grease" is used with present invention. Grease is used because it is less expensive, easier to use during the manufacturing process and readily available and easy to use in the field for maintenance or repairs. The environmental protection material is not illustrated in the figures in the interest of clarity. In use, the material is positioned in the well 76, the clip receiving well 84, and the cavity 100 ofthe connector module 26 and a cavity 101 ofthe half-tap assembly 60. These wells or cavities 76, 84, 100, 101 are the areas in which the conductive components ofthe lines 52, 54, 58 will be exposed or might be exposed. By providing a non-conductive environmental protection material in these areas, the lines 52 are protected against the detrimental environmental effects such as moisture and particulates and the resulting corrosion. Turning now to a more detailed discussion ofthe connector module 26, the assemblies attached thereto, and the interconnection with the base module 28 and The isolation legs 112, 114 are curved spring biased components which are integrally formed with the respective clips 110, 72. The clips 110, 72 are oriented with the convex portions ofthe isolation legs 112, 114 in abutting contact. The clips 110, 72 are positioned to place the isolation legs 112, 114 to contact with a slight spring biasing action so that the spring biased stmcture ofthe isolation legs 112, 114 provides a secure conductive engagement ofthe service clip 110 and the distribution clip 72. Referring to FIGS. 3, 4, 10 and 11, it can be seen that all ofthe service and distribution clips 110, 72 are inserted into and retained in the connector module 26 from the same side. Distribution clips 72 shown on the base module 28 in FIG. 4 are provided only for illustrative purposes; these clips 72 are actually retained in the connector module 26. FIGS. 10 and 11 show barbs 156 on the clips 110,72 which dig into the abutting surfaces ofthe connector module 26 to retain the clips 110, 72 therein. The IDCs 86, 116 are exposed to respective, opposite sides ofthe connector module 26 for attachment to respective lines. Same side assembly ofthe clips 110, 72 in the connector module 26 makes the connector module easier to assemble and easier to automate the assembly thereof, thus further increasing the efficiencies ofthe present invention. An important feature ofthe present invention is that it can be assembled without the need for any special tools. In contrast, many prior art devices require the use of a specialized tool for the connection of lines to and assembly of terminal blocks. Prior art devices have profited from proprietary tools for terminal block assembly use. However, it is more advantageous to the tradesperson to not have to use specialized tools. For example, a tradesperson cannot carry out their assembly tasks if such a specialized tool is unavailable, damaged or lost. Additionally, such proprietary tools add additional expense to terminal block products. 18 the service line assemblies and thus do not allow for selective addition or removal of half-tap assemblies. The prior art devices do not provide the ease of access as does the present invention, nor do such prior art devices provide the selective modularity ofthe present invention. FIG. 7 provides an enlarged, partial fragmentary, top plan view ofthe connector terminal block assembly system 20 as shown in FIG. 2. The cross sections therethrough provide additional details ofthe various stmctures and functions ofthe assembly system 20 ofthe present invention. A modular test probe assembly 107 is shown in FIGS. 7 and 9. The test probe assembly 107 has been removed from FIG. 8 in the interest of showing the assembly 20 without the test probe assembly 107. Turning now to FIG. 8, the connector module 26 is shown attached to the base module 28, and the base module 28 is shown attached to the protection module 30. An electrical connection is made between the service connection assembly 56 and the distribution clip 72 by a service clip 110. The service clip 110 and the distribution clip 72 are retained in the connector module 26 for engagement with the lines retained on the base module 28. An isolation leg 112, 114 is provided on both the service clip 110 and the distribution clip 72, respectively. Each ofthe clips 110, 72 have insulation displacement connector portions 116, 86 on ends opposite the isolation arms 112, 114. In fact, the present invention uses the same clip stmcture ofthe service clip 110 and the distribution clip 72. By using the same clip for each ofthe clips 110, 72 efficiencies are gained by reducing the number and type of parts, such as fewer individual types of parts to inventory, manufacture and track. With further reference to FIGS. 8, 9, and 12, it can seen that the half-tap assembly 60 includes the actuator 102, the housing 104 and a pair of half-tap clips 136. Each clip 136 includes an insulation displacement connector portion 138, a forked connector portion 140 and a shaft 142 therebetween. It should be noted that the clips 5 136 are typically stamped from a desired metallic material. In this regard, the half-tap clips 136 have a shaft 142 which is a twisted portion extending between the IDC portion 138 and the forked connector 140. This is desirable because this arrangement permits the half-tap clips 136 to be oriented in a direction which will allow engagement with the IDC 138 in the same orientation as the service connection assembly 56 while engaging a 0 similarly aligned portion ofthe distribution clip 72. As shown more clearly in FIGS. 9 and 10, the forked connector 140 engages an aligned leg 144 ofthe distribution clip 72. Line 9-9 in FIG. 7 is offset slightly through a small portion ofthe assembly 20 in order to show in FIG. 9 the forked connector 140 5 coupled to the top portion of an aligned leg 144 ofthe corresponding distribution clip 72. In FIG. 9 a portion of a wall 145 has been broken away to reveal the connection therebehind. In this manner, a half-tap assembly 60 can be connected to each ofthe distribution lines 52 to add a second line. 0 More particularly, the half-tap assembly 60 is connected to the connector module 26 by inserting the forked connector 140 through a corresponding access port 146 through the half-tap area 65 ofthe connector module 26. An upstanding pin 150 is also formed in this area for engaging a corresponding slot 152 formed in the half-tap housing 104. As shown in FIG. 9, a rear wall 152 ofthe connector housing 104 is spaced away 5 from a rear wall 154 ofthe service line assembly 56 to allow access to the isolation port 124 therebetween. The access ports 146 act as test probe points if the half-tap connector 20 In use, a service line is positioned in a bore 120 ofthe actuator 102 when the actuator is in an up position. In the up position, the actuator 102 is disengaged from the IDC portion 116 ofthe clip 110. The line is retained in the bore 120. The actuator 102 is moved downwardly to engage the line in the slot 122 forming a conductive connection between the clip 110 and the line. As described hereinabove, the IDC portion 86 ofthe distribution clip 72 is engaged with a line. As such, the distribution line is conductively coupled to the service line through the isolation legs 114, 112, respectively. An isolation port 124 is positioned over the spring biased connection ofthe isolation legs 112, 114. As shown in FIG. 9, an isolation plug 126 may be inserted through the isolation port 26 to separate the isolation arms 112, 114. With the arms 112, 114 separated by the isolation plug 126, the distribution line is disconnected from the service line. Further, test ports 128 are provided on top ofthe actuators 122 to provide a conductive path to contact the IDCs 116 positioned in the actuator 102. As such, test probes 130, 132 may be inserted into the test ports 128 to test the lines. It should be noted that the plug 126 does not have to be part of a test probe assembly 107, but may be an independent component which may be used in the absence ofthe test probes 130, 132. As noted above, the distribution clip 72 and the service clip 110 are identical clips oriented in different direction so that the isolation legs 112, 114 are in engagement. Efficiencies gained in the present invention by use of identical parts is extended by the use of identical actuators 102 for the service connector assemblies 56 and the half-tap assemblies 60. This similarity of parts helps reduce the number of specialized parts required for the present invention which decreases problems which may be associated with additional unique components. protectant material in the bores 120 so as to provide a non-conductive environmental protectant around a connection between the lines and the corresponding IDC clips 116, 138, 86. With reference to FIGS. 12 and 13, the actuator 102 is shown in FIG. 13 in the raised position. The actuator 102 can be forced downwardly into the housing to engage a line retained in a bore 120 to engage the line with the IDC clip 138. The service connector assembly 56 and the half-tap assembly 60 include captivating means 162. While the half-tap assembly 60 is shown in FIG. 13, it should be understood that the same captivating means 162 may be employed with the service connection assembly 56. The captivating means 162 includes a protmsion 164, a captivating notch 166 and a engaging notch 168 which are positioned along a rearside ofthe actuator 169. The protmsion 164 extends into the captivating notch 166 to captively retain the actuator 102 in the housing 104. It should be noted that the protmsion 164 has a generally peφendicular edge surface 170 which abuts a corresponding generally perpendicular surface 172 ofthe captivating notch 166. When the surfaces 170, 172 abut, the actuator 102 is prevented from being disengaged from the housing 104. Both the engagement notch 168 and the captivating notch 166 have sloped surfaces 174, 176, respectively. The sloped surfaces 174, 176 allow the actuator 102 to travel upwardly and downwardly relative to the protmsion 164. In this regard, the protmsion 164 has a sloped surface 178 which allows the sloped surface 176 ofthe captivating notch 166 to ride thereover when the actuator 102 is moved downwardly. Similarly, once the actuator 102 is moved downwardly, the protmsion 164 engages the engagement notch 168. The generally peφendicular surface 170 on the protmsion 164 tends to resist disengagement ofthe protmsion 164 from the notch 168. However, when 22 assembly 60 is not connected to the connector module 26. However, if a half-tap assembly 60 is connected to the connector module 26, test access is provided by the test ports 128 formed through the actuator 102 ofthe half-tap assembly 60. The half-tap assembly 60 is easily attached or removed from the connector assembly in a pressed manner. The clips 136 are retained inside the housing 104 by means of barbs 156 formed on the outer perimeter ofthe clips 136. The clips 136 are inserted between slots 158 formed in the housing with the barbs 156 engaging the corresponding surface in the slots 158. As such, the half-tap assembly 60 is provided as a single assembled component with captive elements thereof for attachment to and disengagement from the connector module 26. As will be described in greater detail hereinbelow, the actuator 102 is connected to the housing 104 and captively retained therein. Due to the modular nature ofthe half-tap assembly 60, the assemblies need only be attached when a second line is required and may be removed once a second line is no longer needed. This modular constmction helps maintain only the connections that are needed and reduces the possibility for interconnection errors. Interconnection errors are reduced because the half-tap assembly 60 may be removed when no longer inserted thereby preventing an accidental connection thereto. With further reference to FIGS. 9 and 10, it should be understood that the primary cavity 160 ofthe base module 28 and the connector cavities 100 ofthe connector module 26 may be filled with a non-conductive environmental protectant such as the "grease" in order to provide further environmental protection ofthe connections retained therein. Further, each ofthe actuators 102 employed in the service connection assemblies 56 and the half-tap assembly 60 may be provided with environmental as found in some prior art devices. For example, the protection module 30 ofthe present invention has a single piece body for the housing 31. The single piece housing eliminates special, independent stmctures for mounting the module 30 to a rod frame system. Further, the housing 31 includes a plurality of compartments 196 for retaining individual protector devices 198 (as shown in FIG. 3) which eliminates special independent cartridges or cassettes for holding protection devices. Additional efficiencies are gained from the single piece constmction ofthe protection module housing 31 because additional parts are eliminated and a single type of housing 31 can be used regardless of the mounting frame system. It should be noted that the protector devices 198 as shown in FIG. 3 are three element gas tube type protector devices of a known constmction. It is within the scope ofthe present invention to substitute two element protector devices, as well as solid state protectors in the protection module 30. These devices 198 are conductively coupled to the modular terminal block assembly system 20 ofthe present invention as set forth hereinabove. The protector devices 198 include three leads 200, 202, 204 which are engaged in corresponding grippers 194, 206, 194, respectively. It should be noted that the ground bar stmcture 48 includes a plurality of grippers 206 one each corresponding to a pair of ring clip and tip clip grippers 194. In other words, the lead 202 engages the ground bar gripper 206 and with the leads 200, 204 each, respectively, engaging a ring clip or tip clip gripper 194, 194. In FIG. 17, the cross-sectional view taken along line 17-17 in FIG. 16 shows the engagement ofthe leads 200, 202, 204 with the corresponding grippers 194, 206, 194, respectively. With reference to FIG. 16, a partial fragmentary portion ofthe protection module 30 is shown with the ring clip 188, tip clip 190, as indicated by the grippers 194, and the 24 suitable force is applied to the actuator 102, it can be upwardly disengaged from the housing 104 with the sloped surface 174 riding against the generally peφendicular surface 170 thereby allowing the actuator 102 to move upwardly. As such, the engagement notch 168 allows the actuator 102 to be forcibly disengaged from the protmsion 164. Also, the captivating notch 166 positively retains the actuator and prevents the actuator 102 from being disengaged from the protmsion 164 once the actuator 102 is positioned in the housing 104. With reference to FIGS. 11, 14, 15, 16 and 17, it can be seen that the present invention includes a protection module 30. The protection module 30 includes a protection module housing 31 from which depends the rod mounting stmcture 36 and which include a plurality of chambers 186. In each chamber is a ring clip 188 and a tip clip 190. The ring tip clip and the tip clip are also shown in FIG. 3 and include a forked connector 192 on one end of each clip 188, 190 and a gripper 194 formed on the opposite end of each clip 188, 190. The ring clip 188 and tip clip 190 are arranged so that the forked connectors 192 are axially aligned. This axial alignment allow the forked connectors 192 to engage corresponding arms ofthe distribution clip 72 IDC arms 86. The engagement ofthe forked connectors 192 ofthe ring clip 188 and tip clip 190 is more clearly illustrated in FIG. 10 which shows the forked connectors 192 engaging the arms 86 ofthe distribution clips 72. With further reference to FIG. 15, a partial fragmentary, perspective view ofthe underside ofthe protector module housing 31. This partial fragmentary, underside view is shown in order to illustrate the single piece, unitary constmction ofthe housing 31 including the rod mounting stmctures 36 on the ends thereof. This single piece constmction is advantageous because it eliminates numerous pieces and sub-assemblies connections may be made to and removed from the service connection assemblies 56 and any half-tap assemblies 60 while maintaining constant protection on the assembly 20. The present invention assures that tradespersons and equipment will be protected by the protection module 30 at all times. Additionally, the present invention 20 is a modular design which allows the protection module 30 to be added after the distribution lines are connected to the base module 28 and the connector module 26. Further, the protection module 30 provides for removal ofthe protection devices 198 after a failure has occurred. This allows the fault to be corrected and a new protector 198 inserted into the corresponding compartment 196. The protection module 30 allows different types of protectors 198 to be inserted in order to retrofit an existing assembly 20 or other types of protection devices such as a solid state protection device 198. While a preferred embodiment ofthe present invention is shown and described, it is envisioned that those skilled in the art may devise various modifications and equivalents without departing from the spirit and scope ofthe appended claims. The invention is not intended to be limited by the foregoing disclosure. 26 ground bar 48 in position. A body portion 208 ofthe protection device 198 is retained in a corresponding compartment 1 6 with the body positioned against a wall 210 dividing compartment 196 into several portions. The secondary walls 212 are positioned between each protection device 198 so as to segregate or isolate the protection devices 1 8 from 5 one another. As shown in FIGS. 1, 2, 3, and 10 the grounding bar stmcture 48 is constmcted to be compatible with both the rod frame stmcture 22 and the u-shaped frame stmcture 24. The grounding bar 48 is a single piece component which is retained in the housing 10 31 having the biases portion 46 and the grippers 206 extending therefrom. The biased portion 46 biases against an outside surface 213 ofthe rod frame 22 or against the wall 50 ofthe u-shaped frame 24. In this manner, the biased portion maintains conductive contact with the conductive surface ofthe respective type of frame assembly. For example, if the assembly is attached to a U-shaped frame assembly, the biased portion 46 15 is forced inwardly by the dimensional difference ofthe spacing ofthe U-shaped frame mounting apertures and stmctures. The dimensional difference results in the biased portion 46 being biased outwardly against the wall 50. Altematively, when the assembly 20 is attached to a rod by snap-fitting the rod mounting stmctures 36 over the corresponding rod, the biased portion is forced outwardly by the dimensional difference 0 ofthe spacing ofthe rods and the rod mounting stmctures. The dimensional difference results in the biased portion 46 being biased inwardly against the rod surface 213. There are several advantages ofthe present invention over the prior art with regard to the protection module 30. First, the protection module 30 ofthe present 5 invention is positioned away from the connector module 26 to allow free access to the service connection assemblies 56 and the half-tap assemblies 60. In other words, The Invention Claimed Is: 1. A modular terminal block assembly (20) for connecting at least one distribution line (52) to a corresponding service line (54), said modular terminal block assembly being characterized by: a base module (28) for dressing and retaining distribution lines; a connector module (26) having distribution clips (72) retained thereon for engagement with said distribution lines retained on said base module, and service clips (110) retained thereon for connection of service lines thereto, said service clips and distribution clips being retained on the same side of said connector module and conductively coupled. 2. A modular terminal block assembly (20) as recited in claim 1, being further characterized by: a protection module (30) including protection grippers (206) retained thereon coupled to said distribution clips (72) retained on said connector module (26), protector devices (198) conductively coupled to said protection grippers for providing protection of corresponding ones of said distribution and service lines (52, 54). 28 NOT FURNISHED UPON FILING

Claims: 5. A modular terminal block assembly (20) as recited in claim 1, being further characterized by: an isolation leg (112, 114) connected to each of said service clips (110) and said distribution clips (72), at least one of said isolation legs (112, 114) providing stmcture; and isolation ports (124) in said connector module (26) proximate to said isolation legs (112, 114) of said service clips (110) and said distribution clips (72), said isolation ports being positioned for receiving a non-conductive body (126) therethrough for positioning between said isolation legs of said service clips and corresponding ones of said distribution clips to open the conductive connection formed thereby. 6. A modular terminal block assembly (20) as recited in claim 1, being further characterized by: a plurality of wire dressing stmctures (64) on a side of said base module (28) positioned for abutting and engaging said connector module (26). 7. A modular terminal block assembly (20) as recited in claim 6, being further characterized by: said wire dressing stmctures (64) including a receiving channel (68) for orienting a line therein and a strain relief stmcture (82) positioned proximate to said receiving channel for retaining a portion of a line positioned in said receiving channel. 30 3. A modular terminal block assembly (20) as recited in claim 2, being further characterized by: said base module (28) having a first side (32) and a second side (34), said connector module (26) being attached to said first side of said base module, said protection module (30) being attached to said second side of said base module, said connector module and said base module retaining and conductively engaging distribution lines (52) therebetween and said connector module having service connection assemblies (56) attached thereto for conductively connecting said service lines (54) to said distribution lines (52). 4. A modular terminal block assembly (20) as recited in claim 3, being further characterized by: said protection grippers (206) being positioned generally facing away from said second side (34) of said base module (28) for engaging a protector device (198) in a position spaced away from said service connection assemblies (56) to allow access to said service connection assemblies while maintaining line protection of said lines (52, 54) coupled to said modular terminal block assembly. 11. A modular terminal block assembly (20) as recited in claim 10, being further characterized by: each of said trimming cavities (76) having a non-conductive material retained therein for environmentally protecting a trimmed portion of a line retained in said receiving channel (68). 12. A modular terminal block assembly (20) as recited in claim 1, being further characterized by: at least one half-tap assembly (60) attached to said connector module (26) proximate to a corresponding one of said service connection assemblies (56); and said half-tap assembly including half-tap clips (136) conductively connected to corresponding ones of said distribution clips (72) retained in said connector module for providing a second line connection associated with a corresponding service connection assembly. 13. A modular terminal block assembly (20) as recited in claim 3, being further characterized by: said base module (28) having locking fingers (66) formed on said first side thereof for engagement with an abutting portion of said connector module (26), and said protection module (30) including locking fingers for connection with said second side (34) of said base module. 32 8. A modular terminal block assembly (20) as recited in claim 7, being further characterized by: a connection well (76) formed in said base module (28) proximate to said receiving channel (68) for receiving a portion of said distribution clip (72) therein to connect a line positioned in said receiving channel extending over said connection well with said distribution clip. 9. A modular terminal block assembly (20) as recited in claim 7, being further characterized by: a connection well (76) positioned proximate to said receiving channel (68) between said entry end (80) and said terminal end (74) for receiving a portion of a distribution clip (72) therein for connection to a line retained in said receiving channel (68), said strain relief stmcture (82) being positioned between said connection well and said terminal end of said line receiving channel. 10. A modular terminal block assembly (20) as recited in claim 9, being further characterized by: a trimming stmcture (78) on said connector module (26) and a trimming cavity (76) positioned in said base module (28) proximate to said terminal end (74) of said receiving channel (68), said line trimming stmcture being positioned on said connector module for receipt in said trimming cavity for trimming a terminal end of a line retained in said receiving channel when attaching said connector module to said base module. 17. A modular terminal block assembly (20) as recited in claim 12, said half- tap assembly (60), being further characterized by: means for captivating (162) said actuator (102) in a cavity (101), said captivating means including retaining recesses (166,168) and a protmsion (164), said captivating means having a captivating notch (166) and an engagement notch (168) formed on said actuator and said protmsion formed on an inside surface of said cavity for selectively engaging said engagement notch and said captivating notch, said protmsion and said captivating notch being shaped for positively retaining said actuator in said connection cavity, said engagement notch and said captivating notch being shaped for allowing movement of said actuator relative to said cavity, whereby said protmsion holds said actuator in said connection cavity when engaged with said captivating notch and releasably retains said actuator in an engaged position when engaged with said engagement notch. 34 14. A modular terminal block assembly (20) as recited in claim 2, being further characterized by: a grounding stmcture (48) coupled to said protection module (30), said grounding stmcture comprising a unitary stmcture providing biased grounding contact (46) with a corresponding surface of one of a U-shaped frame mounting system (24) and a rod mounting system (22) to which said modular terminal block assembly is attached. 15. A modular terminal block assembly (20) as recited in claim 1, being further characterized by: a plurality of connection cavities (100) in said connector module (26), said service clips (110) extending into each of said connection cavities; and a connection actuator (102) sized and dimensioned for engagement in corresponding ones of said connection cavities; and means for captivating (162) said actuator in said cavity, said captivating means including retaining recesses (166,168) and a protmsion (164). 16. A modular terminal block assembly (20) as recited in claim 15, being further characterized by: a captivating notch (166) and an engagement notch (168) formed on said actuator (102) and said protmsion (164) formed on an inside surface of said connection cavity (100) for selectively engaging said engagement notch (168) and said captivating notch (166), said protmsion and said captivating notch being shaped for positively retaining said actuator in said connection cavity, said engagement notch and said captivating notch being shaped for allowing movement of said actuator relative to said connection cavity, whereby said protmsion holds said actuator in said connection cavity when engaged with said captivating notch and releasably retains said actuator in an engaged position when engaged with said engagement notch.

Inventors: BASCOM MICHAEL J, BRADSHAW JANET A, DOMINIAK ROBERT M, HAINES WAYNE G, KACZMAREK RICHARD T, LITTLEJOHN KENNETH C, BASCOM, MICHAEL, J., BRADSHAW, JANET, A., DOMINIAK, ROBERT, M., HAINES, WAYNE, G., KACZMAREK, RICHARD, T., LITTLEJOHN, KENNETH, C.
Applicants: RELTEC CORP, RELTEC CORPORATION
Application year: 1996
Main classification: H01R9
IPC codes: H01R9, H04Q1