Abstract:
An electrical connector arrangement taps off electrical current from a plurality of coplanar parallel input insulated conductors and supplies the same to a plurality of output conductors, respectively. A rectangular base member is provided having a horizontal upper surface that supports a plurality of parallel coplanar longitudinally-extending input conductors, respectively. A pair of pivot members are connected with the ends of the base member for pivotal movement about transverse horizontal pivot axes, respectively. As the pivot members are pivoted from disengaged positions toward engaged positions parallel with and directly above the base member top surface, bifurcated insulation-piercing knives on the pivot members pierce the insulation layers of the insulated conductors and electrically engage the conductors. Junction blocks fastened to the pivot members include output contacts connected with the insulation piercing knives via bus bars, which output contacts are connected with the output conductors, respectively.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     An electrical connector arrangement for tapping off electrical current from a plurality of coplanar parallel input insulated conductors and supplying the same to a plurality of output conductors, respectively, includes a rectangular base member having a horizontal upper surface that supports a plurality of parallel coplanar longitudinally-extending alternately-staggered input conductors, respectively, and a pair of pivot members connected with the ends of the base member for pivotal movement about transverse horizontal pivot axes, respectively. As the pivot members are pivoted from disengaged positions relative to the base member toward engaged positions parallel with and directly above the base member top surface, bifurcated insulation-piercing knives on the pivot members pierce the insulation layers of the insulated conductors and electrically engage the conductors. Junction blocks fastened to the pivot members include output contacts connected with the insulation piercing knives via bus bars, which output contacts in turn are connected with the output conductors, respectively.  
         [0003]     2. Description of Related Art  
         [0004]     It is well known in the patented prior art to provide connectors with insulation piercing contacts, as shown, for example, by the prior U.S. patents to Gaertner et al U.S. Pat. No. 6,120,315, Lux No. U.S. Pat. No. 6,135,804, Stuckmann et al U.S. Pat. No. 6,478,605, and Huiskamp et al U.S. Pat. No. 6,692,292, among others. It is also known to provide quick-fastening terminal blocks and junction blocks having one-way resilient contacts for automatically engaging and retaining a bare conductor end that is inserted through an access opening, as shown by the patents to Beege et al U.S. Pat. Nos. 6,280,233 and 6,712,641, and Fricke et al U.S. Pat. No. 6,796,855, among others.  
         [0005]     In the German patent No. DE 297 06 750 U1, an electrical connector is disclosed in which a plurality of taps are provided for tapping off electrical current from an insulated conductor. For this purpose, a plurality of groove-like seats are provided on a base plate into which seats one can insert a flat cable or a plurality of electrical conductors that are parallel with respect to each other. Then an upper part is displaced in order to slacken the conductors or the flat cable. Upon this preassembled unit, which is provided with separating walls, one then locks clamp-like bodies in a pivotal motion, which bodies in each case are provided with an insulation-penetrating contact that is connected via a bus bar with, in each case, two traction spring clamps for connection of branching conductors. In this manner, one can make in each case two branches on each conductor without having to separate the continuous conductors.  
         [0006]     It is also known that one can arrange connection devices on a shaft that is rotatably mounted on a bottom plate. This design did not prove effective because the conductors must be inserted sideways so that the arrangement is not suitable for assembly on already installed continuous cables.  
         [0007]     The present invention therefore is an improvement over the typical state of the prior art and seeks to simplify said state of the art with respect to its design structure. A compact structure and easy handling are also to be achieved as a result.  
       SUMMARY OF THE INVENTION  
       [0008]     Accordingly, a primary object of the present invention is to provide a connector arrangement in which a plurality input insulated conductors are supported in parallel, spaced, alternately-staggered coplanar arrangement on a rectangular base member, whereupon pivot members pivotally connected with opposite ends of the base member are pivoted downwardly to cause insulation piercing contacts thereon to pierce the insulation layers of alternate insulated conductors, respectively. A plurality of bus bars connect the piercing contacts with the output contacts of junction boxes that are rigidly fastened to the pivot members, respectively. The output contacts are preferably of the quick-fastening one-way resilient contact type that automatically engage the bare end of an output conductor that is inserted through an access opening in the junction block.  
         [0009]     According to a more specific object of the invention, insulation means are provided for electrically isolating the pivotally displaceable junction blocks from each other. In one embodiment, insulation plates are mounted on the adjacent sides of the junction blocks. In another embodiment, each pivot member and junction block that pivot as a unit at one end of the base member is contained within the chamber of an insulating jacket that is mounted on the base member. At the other end, a similar insulating jacket is provided having chambers for receiving the pivot units, respectively.  
         [0010]     In terms of design, the connector arrangement is further simplified when compared to the state of the art because the invention uses tool-free connectable IDC contacts, in particular, insulation layer penetrating fork contacts for wiring purposes. In spite of the use of the IDC contacts with the greater width due to its design—especially in the version as fork contacts—it produces a very narrowly structured arrangement consisting of connecting devices, which furthermore in a simple manner makes it possible in an extremely simple fashion without the use of any tools to contact both the continuous conductors and the branching conductors (at any rate, when direct plug contacts are used).  
         [0011]     The continuous conductors, for example, can be the continuous conductors of a flat cable or any other cable—for example, a round cable—whose cable sheath was removed in the area of the connection system, whereby the continuous conductors in this sheath-stripped area are inserted in the recesses of the bottom plate. For contacting purposes, one then merely needs to put on the connection disc, to swing them, and then to insert the conductor ends of the branch conductors. In this way, one can also quickly and subsequently assemble a branching on an already installed cable.  
         [0012]     It is also desirable that, in any event, the IDC contacts of neighboring connection discs in the chosen staggered arrangement are located relatively far removed from each other, something that definitely reduces any disadvantageous effects such as the occurrence of undesirable leakage currents.  
         [0013]     An advantageous development that can also be considered as an independent invention of its own is given in the second embodiment including insulating jacket means, whose object is distinguished by a particularly simple handling coupled with a furthermore particularly good insulation of the individual conductors from each other.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     Other objects and advantages of the invention will become apparent from a study of the following specification, when viewed in the light of the accompanying drawing, in which:  
         [0015]      FIG. 1   a  is a front perspective view of a first embodiment of the connector arrangement of the present invention when in the partially assembled condition, and with certain parts broken away;  
         [0016]      FIG. 1   b  is an exploded perspective view of the apparatus of  FIG. 1   a;    
         [0017]      FIG. 1   c  is a perspective view of the apparatus of  FIG. 1   b  with the conductors inserted in the base member;  
         [0018]      FIG. 1   d  is a perspective view of the apparatus of  FIG. 1   c  with the pivot means in the connected condition;  
         [0019]      FIG. 1   e  is a perspective view of the apparatus of  FIG. 1   d  with the pivot members and the junction blocks in the fully assembled condition;  
         [0020]      FIG. 2  is a side elevation view of the apparatus of  FIG. 1   a  with certain parts removed;  
         [0021]      FIG. 3  is a top plan view of the apparatus of  FIG. 2 ;  
         [0022]      FIG. 4   a  is a front perspective view of a second embodiment of the invention when in a partially assembled condition;  
         [0023]      FIG. 4   b  is an exploded perspective view of the apparatus of  FIG. 4   a;    
         [0024]      FIG. 4   c  is a perspective view of the apparatus of  FIG. 4   b  with the conductors inserted in the corresponding seats contained in the base member;  
         [0025]      FIG. 4   d  is a perspective view of the apparatus of  FIG. 4   c  with the insulating jackets connected with the base member;  
         [0026]      FIG. 4   e  is a perspective view of the apparatus of  FIG. 4   d  when in the fully assembled condition;  
         [0027]      FIG. 5  is a partially sectioned side elevation view of the apparatus of  FIG. 4   a ; and  
         [0028]      FIG. 6  is a top plan view of the apparatus of  FIG. 5 .  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0029]     Referring first more particularly to  FIG. 1   a , the connector apparatus of the present invention includes a generally rectangular base member  1  having an upper surface containing a plurality of parallel longitudinally extending seats  13  for receiving a plurality of parallel alternately-staggered insulated conductors  10 . Pivotally connected with the ends of the base member  1  by pivot means  8   a  and  8   b  are a plurality of pivot members  3 . As will be explained in greater detail below, to each pivot member  3  is fastened by fastening means  24  to a junction block  2 , thereby to define a rigid pivot unit. The pivot units defined by the assembly of the pivot member  3  and the junction block  2  are pivotally movable between a disengaged condition angularly inclined relative to the base member  1  (as shown in  FIG. 1   d ), and an engaged condition in which the units are pivoted to positions parallel with the base member  1 , as shown in  FIG. 1   e.    
         [0030]     In accordance with a characterizing feature of the present invention, each pivot member  3  is provided with a bifurcated insulation piercing fork  4  that is adapted to pierce the insulation layer  10 ′ of a given conductor, thereby to effect electrical engagement between the insulation piercing member  4  and the inner conductor member  10 ″ of the insulated conductor  10 . The insulation piercing fork  4  is connected by means of a bus bar  6  contained within the junction block  2  to a pair of outlet contacts  5   a  and  5   b  that are arranged beneath access openings  7   a  and  7   b  contained in the top wall of the junction block  2 . The bare ends of output conductors  30  are adapted for insertion within the access openings  7   a  and  7   b  for engagement with the contacts  5   a  and  5   b , respectively, thereby capping off a portion of the current from the conductor  10  for supply to the output conductors  30 .  
         [0031]     Referring to  FIG. 1   b , it will be seen that the pivot members  3  are provided at their lower corners with outwardly facing laterally spaced hook portions  12  that are arranged for engagement with corresponding inwardly directed hook portions  11  integral with the base member  1 . As shown in  FIG. 1   b , the insulated conductors  10  are staggered in such a manner that the cable ends of alternate cables  10   a ,  10   c ,  10   e , and  10   g  extend in one direction relative to the base member  1 , and the ends of the alternate insulated cables  10   b ,  10   d , and  10   f  extend in the opposite direction relative to the base member  1 . Similarly, the associated pivot units defined by the pivot members  3  and the junction blocks  2  fastened thereto are spaced in a comb-like fashion, whereby the junction blocks  2   a ,  2   c ,  2   e , and  2   g  are spaced to receive the junction blocks  2   b ,  2   d , and  2   f . Thus, after the insulated conductors  10  are inserted within their respective conductor seats  13  as shown in  FIG. 1   c , the hook portions  12  of the pivot members  3  are connected with the corresponding hook portions  11  on the base plate  1 , as shown in  FIG. 1   d , where upon the pivot units are pivoted downwardly toward the fully engaged positions of  FIG. 1   e.    
         [0032]     Referring now to  FIG. 2 , when the pivot unit comprising the pivot member  3  and the junction block  2  is pivoted downwardly about the hinge means  8   a , the knife edges of the bifurcated fork  4  will sever the insulation layer  10 ′ of the insulated conductor  10   a . As the pivot unit is progressively pivoted downwardly toward the fully engaged position, the knife edges of the bifurcated fork  4  come into electrical contact with the inner conductor of the insulated cable  10   a . Current is transmitted to the two branch contacts  5  via the bus bar  6 . As shown in  FIG. 2 , a mechanical advantage is provided by the pivot radius r, which is the distance between the pivot means  8   a  and the knife edges of the bifurcated fork  4 . As shown in  FIGS. 1   b  and  3 , the sides of the junction blocks are covered by cover plates  15  that are formed from an electrically insulating synthetic plastic material, thereby to isolate the contacts of one junction block from the output contacts of the other junction blocks.  
         [0033]     Referring to  FIGS. 1   c  and  1   d , the base member  1  is provided with friction catches  14  that engage the sides of the junction blocks  2 , thereby to retain the same in the engaged position shown in  FIG. 1   e . Support bridges  19  may be provided for supporting the junction blocks relative to the base plate  1 .  
         [0034]     In the illustrated first embodiment of  FIGS. 1   a - 3 , the resilient contacts  5  of the junction blocks are of the one-way leaf spring type arranged for locking engagement with the bare end of the output conductors  30 , as is known in the art. Thus, as the output conductor is axially inserted into the access opening  7 , the base conductor bends the resilient leaf spring contact  5  downwardly until the edge of the leaf spring engages the outer circumferential surface of the bear output conductor  30 . To release the output conductor, a suitable tool, such as the tip of a screwdriver, is inserted within the release opening  32 , as is known in the art. Of course, other types of contacts, such as screw contacts, or the like, could be provided for connection with the output conductors  30 .  
         [0035]     Referring again to  FIG. 3 , it will be seen that the width of the pivot bodies  3  is wider than the width of the junction blocks  2 , whereby owing to the interspersion of the narrow junction blocks  2 , a compact relatively narrow connector arrangement is provided.  
         [0036]     Referring now to the second embodiment of the invention illustrated in  FIGS. 4   a - 4   e , in order to provide positive isolation between the respective junction blocks  2 , a pair of insulating jackets  16   a  and  16   b  are provided that are respectively connected with opposite ends of the base member  1 ′. The jacket  16   a  is provided with a plurality of open ended chambers  16   c  that receive the pivot units at the left-hand end of the base member, and the right-hand jacket  16   b  contains a plurality of open-ended chambers  16   d  that receive the pivot units that are connected with the right-hand end of the support member  1 ′. The protective jackets  16  are formed of a suitable electrically insulating synthetic plastic material for isolating the junction blocks  2  from each other. As shown in  FIG. 4   b , when the insulated conductors  10   a - 10   g  are inserted within their respective conductor seats  13 , the positions shown in  FIG. 4 , the assembly of the pivot units carried by the jacket  16   a  are lowered to the position shown in  FIG. 4   d , whereupon the jacket  16   a  is displaced to the right, thereby to cause the hook members  22  on the jacket  16   a  to come into engagement with the corresponding hook members  23  integral with the base member  1 ′, thereby to securely fasten the elements together as shown in  FIG. 4   d . Similarly, the right-hand protective jacket  16   b  is lowered relative to the base member  1 ′, whereupon the jacket  16   b  is shifted to the left to effective engagement between the inwardly facing hook means  22  thereon and the outwardly facing hook means  23  integral with the base member  1 ′. The insulating jackets  16   a  and  16   b  are thus rigidly fastened to the base member  1 ′ as shown in  FIG. 1   d . In this embodiment, releasable catch means  17  and  18  are provided for retaining the pivot units in the upwardly pivoted disengaged condition, as shown in  FIG. 5 . The catch means includes a male member  17  that is biased outwardly toward engagement with a corresponding aperture  18  contained in a side wall of the jacket  16   a.    
         [0037]     Referring now to  FIG. 5 , it will be seen that the pivot unit consisting of the pivot member  3  and the junction block  2  function in the same manner as in the previous embodiment, since the bifurcated fork  4  is arranged to sever the layer of insulation on the conductor  10   a , thereby to connect the conductor  10 ″ with the output contacts  5  via the insulation piercing fork  4  and the bus bar  6 . Thus, the operation of the connector arrangement of  FIG. 5  is identical to that of the arrangement of  FIG. 2 .  
         [0038]     Referring to  FIG. 6 , it will be seen that the chambers contained in the jackets  16   a  and  16   b  are generally T-shaped, with the transverse portions that receive the pivot members  3  being wider than the longitudinal portions that receive the junction blocks  2 .  
         [0039]     It should also be mentioned that the entire arrangement in FIGS.  1  to  6  can again be set up within a master cover housing. It is also conceivable that one might use them directly for assembly, for example, in the switch cabinet, assuming the bottom plates are corresponding designed with a corresponding fastening. Furthermore, one can make cross-connections and/or markings or the like, for instance, on the connection discs. It is also possible to replace the direct plug connections with other connections using the other connection technique—for example, IDC technique, traction spring technique or screw connection technique—and/or to provide the connection discs with electrical structural elements (again not shown here).  
         [0040]     While in accordance with the provisions of the Patent Statutes the preferred forms and embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that changes may be made without deviating from the invention described above.