Abstract:
A splicing enclosure is comprised of a base portion and a lid portion, with a grounding contact positioned in both halves. The grounding contacts include a plurality of grounding contact portions to receive shielded cable in a transverse relation thereto. The enclosure is provided with a removable ferrule, which can be slidably received between the shielding and inner sheath of a shielded cable to enhance the strain relief on the cable between the cable and the grounding contact. The grounding contact is designed so as to accommodate a plurality of shielded cable configurations. The enclosure is also provided with a progressive latch, which cooperates upon rotation of the lid relative to its base portion to take off the load from the integrated hinge to prevent breakage of the hinge.

Description:
FIELD OF THE INVENTION 
     The present invention relates to the field of electrical connections and more particularly to enclosures for spliced cable connections such as telephone wires. 
     BACKGROUND OF THE INVENTION 
     It is common in the telephone industry, where cable splices need to be made along the path of distribution, that splices be made which will include some type of an electrical connection to splice the individual wires of the cable and environmentally seal them in a connection enclosure to prevent degradation to the connection. This type of splice could be either a so-called drop wire splice or could be a buried splice in the case of underground cable. It is also common to have both six and twelve pairs of twisted wire, which comprise the telephone cable. 
     As in almost any electrical connection device, where a cable is involved, and where an individual wire or a plurality of wires are interconnected to terminals or like wires, a so-called strain relief mechanism is desirable, such that tension or force outwardly on the cable is not transmitted to the electrical connection of the wires, but rather the force as transmitted to a housing into which the cable is being terminated. Various strain relief mechanisms exist in the marketplace and in the prior art for transferring the forces to the connector housings. 
     One such device is shown in the Tyco Electronics (AMP Division) commercial product known as the CERTI-SEAL wire splice enclosure (for 2- to 6-pair buried drop wire splice) where the housing is formed as a shell of two similar halves, where one of the halves includes grounding contact. The cables to be spliced are brought in from opposite ends and the cables are stripped to expose the individual wires to be spliced, and a section of the shielding. The two wires are positioned in the grounding contact to common or ground the two shields. Splice connection blocks known as TEL-SPLICE (also a commercial of Tyco Electronics) then interconnect the individual wires to one another for making the individual wire splices. 
     While the above-mentioned connection assembly is adequate for its intended use, it would be, however, advantageous to provide such a splice enclosure, which can accommodate more than one cable size, in order that the enclosure can accommodate at least 6-pair and 12-pair cable. it would also be advantageous if the enclosure could accept three cables, such that the enclosure could terminate combinations of cable, for example, two 6-pair; two 12-pair; or a 12-pair to two 6-pair. 
     SUMMARY OF THE INVENTION 
     The objects of the invention have been accomplished by providing an electrical splicing enclosure for splicing a plurality of shielded cables, which comprises an insulating housing having a first housing member and a second housing member, where the first housing member is hinged to the second housing member so that the first housing member and second housing member are movable from an open position to a closed position. The first housing member and the second housing member overlie each other, with the first housing member and the second housing member each having a base wall, and a peripheral wall, the peripheral walls conforming to provide an enclosure when in the closed position. At least two cable receiving openings are provided through the housing for the cables to be spliced. Grounding contacts, carried by the first and second housing members, comprise cable receiving slots having gripping edges to grip shielding of the shielded cables to be spliced, and the grounding contacts being profiled for overlapping contact with the cables, so as to trap the cable there between, and to provide strain relief thereto. 
     Preferably, the grounding contacts are comprised of a unitary member having multiple cable receiving slots. The grounding contacts are comprised of a base contact portion having upstanding wall sections extending from marginal edges thereof, with the cable receiving slots are formed in the upstanding wall sections. The cable receiving slots are comprised of upwardly facing openings in opposing walls of the upstanding wall sections, such that the cables are terminated transversely of the upstanding wall sections. The grounding contacts have at least one central cable-receiving slot and an end cable-receiving slot on opposite sides of the central cable-receiving slot. The end cable-receiving slots are profiled to accept a plurality of wire sizes. The base contact portions of the grounding contacts are deformable through a line parallel with the slots. 
     Also preferably, a ferrule is insertable under the shielding of the cables to be spliced, to enhance the strain relief effect on the cable. 
     In another embodiment of the invention, an electrical splicing enclosure for splicing a plurality of shielded cables comprises an insulating housing for enclosing cables to be spliced having at least two cable receiving openings provided therethrough for the cables to be spliced. The enclosure has at least one grounding contact carried by one of the housing members, the grounding contact comprising cable receiving slots having gripping edges to grip shielding of the shielded cable to be spliced. A ferrule is included which is profiled to be receivable beneath the shielding of cables to be spliced to rigidify the connection and strain relief of the cable with the grounding contact. 
     Preferably, the housing comprises a first housing member and a second housing member, the first housing member being hinged to the second housing member so that the first housing member and second housing member are movable from an open position to a closed position where the first housing member and the second housing member overlie each other. The first housing member and the second housing member each having a base wall, and a peripheral wall, the peripheral walls conforming to provide an enclosure when in the closed position. The two grounding contacts are carried by the first and second housing members, the grounding contacts comprising cable receiving slots having gripping edges to grip shielding of the shielded cables to be spliced, and the grounding contacts are profiled for overlapping contact with the cables, so as to trap the cable there between, and to provide strain relief thereto. The grounding contacts are comprised of a unitary member having multiple cable receiving slots. The grounding contacts are comprised of a base contact portion having upstanding wall sections extending from marginal edges thereof, and the cable receiving slots are formed in the upstanding wall sections. The cable receiving slots are comprised of upwardly facing openings in opposing walls of the upstanding wall sections, such that the cables are terminated transversely of the upstanding wall sections. The grounding contacts have at least one central cable receiving slot and an end cable-receiving slot on opposite sides of the central cable-receiving slot. The end cable-receiving slots are profiled to accept a plurality of wire sizes. The base contact portions of the grounding contacts are deformable through a line parallel with the slots. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of the subject enclosure in the open state; 
     FIG. 2 is an isometric view similar to that of FIG. 1 taken from a different perspective; 
     FIG. 3 is an upper plan view of the enclosure housing of FIGS. 1 or  2  with the grounding contacts removed; 
     FIG. 4 is a side plan view of the grounding contact shown in FIGS. 1 or  2 ; 
     FIG. 5 is an isometric view of the grounding contact of FIG. 4; 
     FIG. 6A is an upper plan view of the strain relief ferrule utilized in the subject invention; 
     FIG. 6B is a side plan view of the strain relief ferrule of FIG. 6A; 
     FIG. 6C is an end view of the strain relief ferrule of either of FIGS. 6A or  6 B; 
     FIG. 7 is an upper plan view similar to that of FIG. 3 showing the grounding contacts in position; 
     FIG. 8 is a perspective view of the enclosure illustrating two 12-pair cables spliced together, poised for receipt in the enclosure; 
     FIG. 9 shows the configuration of two 12-pair cables in a butt splice configuration; 
     FIG. 10 shows two 12-pair cables in an in-line configuration; 
     FIG. 11 shows the incorporation of the strain relief ferrule with a 6-pair cable; 
     FIG. 12 shows a perspective view of the enclosure for use with the 6-pair cable; and 
     FIGS. 13A-13C show various diagrammatical views showing the incorporation of spliced cable. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With respect first to FIGS. 1 and 2, the invention will be described in greater detail. As shown, a splicing enclosure is shown generally as reference  2 , which incorporates a housing comprised of a first housing portion, or base portion  4 , and a second housing portion or lid  6 . The enclosure  2  further comprises grounding contact members shown at  8 , which common the shielding of spliced shielded cables as will be described in further detail. Finally, the enclosure  2  includes removable strain relief ferrules  10 , which as shown in FIGS. 1 and 2, are shown in a stored position. With reference now to FIGS. 1 through 3, the housing member comprised of first and second housing portions  4  and  6  will be described in greater detail. 
     With respect first to FIG. 3, the base portion  4  is comprised of a base wall  12  provided with a plurality of strengthening ribs shown at  14 . The base wall  12  includes an outer peripheral wall  16 , which forms the concavity of the enclosure and further includes two spaced-apart and opposing walls at  18 . The base portion  4  further includes a receiving nest  20  to receive the associated grounding contact  8  as shown in FIGS. 1 and 2. As shown best in FIG. 3, the nest  20  is comprised of a first wall  22 , intermediate walls  24 , and an outer wall  26 . The nest  20  is bounded on its inner end by an upstanding wall at  28  as best shown in FIGS. 2 or  3 . As also best viewed in FIG. 3, locking ribs  30  and  32  project upwardly to form locking surfaces for the grounding contact as will be described in greater detail. Locking rib  30  extends integrally upwardly from both the base wall  12  and the wall  28 . Locking rib  32  extends upwardly from the base member  12  and integrally from an inner surface  34  of the peripheral wall  16 . 
     As shown in FIG. 3, walls  24  and  26  are disposed in a parallel relation to each other and define a gap  36  therebetween. It should also be appreciated that the walls  24  and  26  are profiled to receive cables transversely thereof, see particularly FIG. 1 with contoured surfaces  40 ,  42 ;  44 ,  46 ; and  48 ,  50 . It should also be appreciated that the opposing wall  18  and peripheral wall  16  are also profiled to receive a cable transversely therethrough, the opposing wall  18  and peripheral wall  16  including openings  52 ,  54 ;  56 ,  58 ; and  60 ,  62 , as shown in FIG.  2 . It should be appreciated that in comparing FIGS. 1 and 2, the pair of openings  52 ,  54  are aligned with the openings  40 ,  42 ; the openings  56 ,  58  are aligned with the openings  44 ,  46 , and that the openings  60 ,  62  are aligned with the respective openings  48 ,  50 . It should also be appreciated that the openings  52 ,  54 ;  40 ,  42 ; and  60 ,  62 ;  48 ,  50  are profiled to receive the same sized cable, and in the preferred embodiment of the invention are sized to receive a 12-pair shielded cable. As shown in FIG. 1, wall  22  also includes contoured surfaces to allow for a cable entrance, and includes surfaces  64 ,  66 , and  68 . With reference now to FIG. 2, contoured surfaces  70 - 80  are provided in walls  16  and  18  which are aligned with the surfaces  64 ,  66 , and  68 , that is, surfaces  70  and  72  are aligned with surface  64 ; surfaces  74 ,  76  are aligned with surface  66 ; and surfaces  78 ,  80  are aligned with surface  68 . As shown best in FIG. 3, a support for the contact  8  is formed by a plurality of transversely extending ribs  84  extending intermediate the walls  22 ,  24 . Finally, support walls  88  provide structural rigidity to the contact nest  28  and include a transverse wall portion  90  and a plurality of upstanding posts at  92 . As shown in FIG. 3, a ferrule storage area is shown at  94  having an upstanding wall at  96  and upstanding posts at  98 . The opposing walls  18  further comprise gel relief ports at  100 , as shown in FIG.  1 . 
     With respect to FIG. 3, the lid  6  includes a base wall  102  having structural ribs at  104 . The lid  6  further includes a peripheral wall at  106  and opposing walls at  108 . Upstanding walls  112  and  114 , together with end wall  116 , provide a secondary contact-receiving nest  110 . In a like manner as the contact receiving nest  20 , contact receiving nest  110  further includes retaining ribs  120  and  122  (FIG.  3 ); contoured surfaces  124 ,  126 ,  128 , and  130  (FIGS.  1  and  2 ); and transversely extending ribs  132 . As also shown in FIGS. 1 and 2, the outer peripheral wall  106  and the opposing wall  108  further include cable-receiving openings similar to items  52 - 62 , and  70 - 80 . As shown in FIG. 2, openings  140 ,  142  cooperate with openings  52 ,  54 ; openings  144 ,  146  cooperate with openings  56 ,  58 ; and openings  148  and  150  cooperate with openings  60 ,  62 , to complete the cable receiving openings. Similarly, openings  152 ,  154  cooperate with openings  70 ,  72 ; openings  156 ,  158  cooperate with openings  74 ,  76 ; and openings  160 ,  162  cooperate with openings  78 ,  80 . The opposing walls  108  further comprise gel relief ports at  168 , (FIG.  1 ). 
     With respect again to FIGS. 1 through 3, the housing portions  4  and  6  are shown as integrally molded about their edges, that is, about a hinge  170  formed between support walls  172  and  174 . An edge latching system is comprised of projections  176  and complementary openings  180 , as best shown in FIG.  2 . Each of the projections  176  includes a curved wall portion  182  (FIG. 2) and an upstanding support rib  184  (FIG.  1 ). Each of the openings  180  is comprised of a T-shaped slot including an elongate portion  186  and a transverse portion at  188  (FIG.  3 ). It should be appreciated that each of the projections  176  is receivable in sliding engagement with a corresponding opening  180  as will be further described herein. 
     With respect now to FIGS. 4 and 5, the grounding contact  8  will be described in greater detail. The contact  8  is comprised of a base portion  200  having generally upstanding wall sections at  202  and  204 . The wall sections  202  and  204  define a plurality of grounding contact portions at  206 ,  208 , and  210 . Each of the contact portions  206 - 210  is comprised of side edges  212 ,  214 , and  216 , respectively, having serrated edges at  220 ,  222 , and  224 . Also with respect to FIG. 4, due to the cut-out sections  230 , the base portion  200  of the contacts  8  are bendable at  232 , at both ends as will be described in greater detail herein. Finally, as shown in FIGS. 4 and 5, the contact member  8  includes a locking lance  236  which has been struck from the base portion  200  to lock the contact in place in the housing as will also be described in greater detail herein. 
     With respect now to FIGS. 6A and 6C, the ferrule  10  is disclosed as including a substantially cylindrical barrel portion  252  formed from rolling to include top edges at  254 . The ferrule  10  further includes a front leading edge at  256  and a rear edge at  258 . A gripping tab  260  extends integrally from the rear edge  258  as will be described in further detail. 
     With the components described with respect to FIGS. 1 through 6, the assembly of the apparatus will be described with greater detail. With reference to both FIGS. 3 and 7, the grounding contacts  8  are positioned between respective walls  22  and  24 ; and  112 ,  114 . The contacts are inserted into their respective positions such that the base portions  200  of the grounding contacts  8  contact the transverse wall portions  84  and  132  of the respective receiving nests. This places the locking lances  236  in locking engagement with the respective ribs  30 ,  32 ;  120 ,  122 . It should also be noted that a grease or gel  270  can also be placed in and around the base and lid as shown at  270 , and can be placed in the unit prior to the termination of the various cables, or could be injected afterwards. 
     With respect now to FIG. 8, the application of the enclosure  2  as a splicing member will be described. As shown in FIG. 8, the enclosure can be used to splice two cables  300 ,  302  where each of the cables includes inner shielding  304 ,  306 , which shields individual twisted pair conductors  308 ,  310 . As shown, the cables  300  and  302  have been terminated by a plurality of electrical splicing connectors such as  312 , which could be the TEL-SPLICE connectors as described above. As shown in FIG. 8, cables  300  and  302  are shown as 12-pair cables, and as such, will be positioned in grounding contacts portions  206  and  210  (FIGS. 4 and 5) as will be further described herein. As shown in FIG. 9, the layout of the grounding contact allows for the splicing of the cable to be in a butt splice arrangement, as well as an in-line configuration as shown in FIG.  10 . With respect now to FIGS. 11 and 12, in the event that a smaller cable, for example, a 6-pair shielded cable is to be spliced, such as a cable shown at  320 , the cable is prepared by stripping the insulation back a sufficient portion to expose a length of the shielding sheath  322  for a length similar in length to the strain relief ferrule  10 . As shown in FIG. 11, this should be accomplished by providing an exposed portion of the inner sheath  328 , with the individual twisted pair of conductors  326  extending therefrom. The seam  324  of the shield can be opened to receive the ferrule  10  therein. As the ferrule has a leading edge portion, the ferrule can be grasped by the tab  260 , for example, by a pair of pliers, and be slidably received so as to be positioned between the shield  322  and the inner sheath  328 . The ferrule  10  rigidifies the cable diameter and can now be received in a transverse relation, similar to that shown in FIGS. 9 and 10, but can be received in the center grounding contact portion  208  of the grounding contact  8 . Thus, the 6-pair cable  320  would be positioned either in openings  56 ,  58 , or  74 ,  76  (FIG.  2 ). 
     With reference now to FIGS. 13A-13C, various configurations of spliced cable are shown. With reference first to FIG. 13A, the splice is shown diagramatically to be similar to that of either FIG. 9 or  10 , where two 12-pair cables  300 ,  302  are positioned within ground contacting portions  206  and  210 . As shown in FIG. 13A, the grounding contact  8  is designed such that the distance between adjacent serrated edges  220  (FIG. 5) in the contact portions  206  and  210 , is greater than the outer diameter of the cable-shielded portion of the cables  300  and  302 . This requires that the base portion  200 , labeled  200 A in FIG. 13A, which is proud of the transverse housing ribs  84  deflects downwardly as shown to enlarge the distance between adjacent serrated edges. As shown in FIG. 13A, the same holds true of base portion  200 B of the base portion  200  which receives cable  302 . FIG. 13A represents the splicing of two 12-pair cables in either the in-line or butt splice position. 
     With respect now to FIG. 13B, if a 6-pair cable is terminated, and is prepared as shown in FIG. 11, the cable is terminated in the center contacting portion  208  and in one of the contacting portions  206  or  210 . Due to the smaller diameter of the cable  320 , the deflection of base portion  200 A is less severe, than that previously shown in FIG.  13 A. FIG. 13B represents the splicing of two 6-pair cables in either the in-line or butt splice position. 
     With respect now to FIG. 13C, two 6-pair cables  320  can be spliced and interconnected to a 12-pair cable  300  whereby the 12-pair cable can be positioned in grounding contact portion  206 , one of the 6-pair cables  320  can be positioned in the center grounding contact portion  208 , and the other 6-pair cable can be positioned in grounding contact portion  210 . FIG. 13C represents the splicing of a single 12-pair cable to two 6-pair cables. 
     As described above, the present invention provides for an enhanced strain relief on the interconnection between the shield of a shielded cable and the grounding contact, as well as provides for an increased variety of cable splicing possibilities. Furthermore, as the grounding contacts are provided in both housing portions  4 ,  6 , the strain relief is enhanced. Furthermore, the grounding contacts  8  are laterally offset, as best viewed in FIG. 2, such that the shielding of each cable is captured and sandwiched at four lateral locations along the cable. As the ground contact portion in lid  6 , will fit in the gap  36 , the cables can be adequately held in place along the length.