Abstract:
A connector arrangement for tapping off current from a plurality of insulated input conductors includes a rectangular base member having a horizontal planar upper surface provided with a plurality of parallel seats receiving the insulated conductors, a frame mounted on the base member for supporting a plurality of terminal blocks for vertical displacement over the seats, each terminal block including an insulation piercing contact extending downwardly therefrom, and an eccentric disk arrangement for displacing each terminal block relative to the frame member between an elevated position spaced above the associated conductor seat and a lowered position in which the contact penetrates the insulation layer and engages the conductor, thereby to transmit current to an output conductor via the insulation-piercing conductor, a bus bar, and a tap-off terminal.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     A connector arrangement is provided for tapping off current from a plurality of insulated input conductors and for supplying the same to a plurality of output conductors, including a rectangular base member having a horizontal planar upper surface provided with a plurality of parallel seats receiving the insulated conductors, a frame mounted on the base member for supporting a plurality of terminal blocks for vertical displacement over the seats, each terminal block including an insulation piercing contact extending downwardly therefrom, and an eccentric disk arrangement for displacing each terminal block relative to the frame member between an elevated position spaced above the associated conductor seat, and a lowered position in which the contact penetrates the insulation layer and engages the conductor.  
         [0003]     2. Description of Related Art  
         [0004]     This kind of connection system is known from DE 297 08 222 U1. The connection system shown in that reference is used—just as the connection system of the present invention—to make electricity tap-off branches from a plurality of continuous conductors without having to cut through the continuous conductors. For this purpose, a plurality of groove-like seats are provided on a base plate into which seat 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 put on 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 resilient contacts for connection with output conductors. In this way, one can make in each case two branches on each conductor without having to separate the continuous conductors.  
         [0005]     It is also known that one can arrange conductor connection discs on a shaft in a rotatable manner upon a bottom plate. This design did not work satisfactorily, because the conductors must be inserted sideways so that the arrangement is not suitable for assembly upon already-installed continuous cables.  
         [0006]     The present invention therefore starts with the typical state of the art and seeks to simplify said state of the art with respect to its design structure, whereby a compact structure with ease of operation is achieved.  
       SUMMARY OF THE INVENTION  
       [0007]     Accordingly, a primary object of the present invention is to provide a connector arrangement for supplying to a plurality of output conductors electrical current that is tapped off current from a plurality of continuous insulated conductors, including a base member having a plurality of parallel longitudinal seats for supporting the insulated conductors, a rectangular frame mounted on the base member to enclose the space above the seats, a plurality of terminal blocks connected with the frame for vertical displacement above the seats, respectively, said terminal blocks containing downwardly extending insulation-piercing contacts, respectively, and displacement means for displacing the terminal blocks downwardly relative to the frame to cause the insulation layers of the insulated conductors to be pierced by the contacts. The insulation-piercing contact means are connected by internal bus bar means with output terminals that that supply the tapped-off current to the output conductors connected thereto.  
         [0008]     According to another object of the invention, the frame and terminal block assembly is mounted on the base member by snap fastener means provided on integral posts that extend upwardly from the base member, whereby upon downward displacement of the assembly relative to the base member, the fastener means on the integral posts cooperate with corresponding fastener surfaces on the frame. In a second embodiment, the frame includes pivot lug means that extend from one end of the frame for engagement with corresponding pivot openings contained in the base member, whereby in order to fasten the frame and terminal block assembly to the base member, the frame and terminal block assembly is pivoted downwardly about the pivot lug and opening from an inclined upper position toward a horizontal position above and parallel with the base member, thereby to cause engagement between fastener means carried by integral posts on the base member and corresponding fastener surfaces at the other end of the frame.  
         [0009]     The present invention provides a connection system for tapping off electricity from a plurality of continuous electrical conductors, in particular, a section of cable from which the outer sheath has been stripped, with a base plate provided with a plurality of parallel seats arranged next to each other for the purpose of receiving the conductors of the cable from which the sheathing has been stripped, section by section; a connection module that is arranged on the bottom plate and that preferably can be supported by a modular frame having several receiving chambers for f receiving movably arranged terminal blocks in them with housings made of insulating material, where the terminal blocks have at least one insulation-penetrating contact that is directed at the bottom plate and that serves for contacting one of the conductors, together with at least one branch connection, in particular, for output tap-off conductors.  
         [0010]     As regards design, the arrangement is further simplified when, compared to the state of the art, the invention uses tool-free connectable IDC contacts, in particular, contacts for wiring purposes. The module frame is well suited for absorbing the force, especially during wiring. In the process, the connection module as such already creates a unit that can be pre-assembled by the manufacturer, and that unit, in itself, already absorbs the major wiring forces without excessively stressing the bottom plate. It is thus possible in a simple manner to contact both the continuous conductors and the branching conductors (at any rate, when one uses direct plug contacts). As a result, there is no need to insert individual terminal blocks, although each of the conductors can be wired individually.  
         [0011]     The continuous insulated conductors, for instance, can be the continuous conductors of a flat 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 section are inserted in the seats of the bottom plate. For contacting purposes, one then merely needs to put on the terminal blocks, to displace them toward the engaged position, and then to insert the conductor ends of the output tap-off conductors. In this way, one can also quickly and subsequently assemble a output conductor to an already-installed cable.  
         [0012]     Preferably, the terminal blocks, and thus especially also the insulation-penetrating contacts arranged thereupon, are guided in a purely vertically movable manner in the respective chambers so as to ensure a clearly defined piercing contact normal to the axis of the conductors. In this way, one can advantageously avoid pivotal movement of the contacts during the severing of the insulation layer of the conductor.  
         [0013]     Preferably, actuation devices are associated with the terminal blocks for the purpose of movement, in particular, the vertical displacement of the terminal blocks in their respective chambers. In this manner, the terminal blocks are displaced simultaneously as a group in their respective module chambers; this ensures large-surface sliding bearing and defined guidance of the IDC contacts during the contacting of the conductors. Here, it is particularly advantageous when the actuation devices are made as eccentric disks because the latter facilitates high force transmission in a narrow space. 
     
    
     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  is an exploded view of a first embodiment of the connector arrangement of the present invention;  
         [0016]      FIG. 2   a  is a perspective rear view of the terminal block of  FIG. 1 , and  FIG. 2   b  is an exploded view of the terminal block of  FIG. 2   a;    
         [0017]      FIG. 3  is an exploded view illustrating the manner of mounting the support frame assembly upon the base member, and  FIGS. 4 and 5  are corresponding perspective views illustrating the frame mounted on the base member with the terminal blocks in their elevated inoperable position and lowered operable insulation-piercing position, respectively;  
         [0018]      FIGS. 6 and 7  are longitudinal sectional views illustrating the manner of operation of the apparatus to displace the frame and terminal block assembly from the elevated inoperable position to the lowered insulation-piercing position, respectively;  
         [0019]      FIGS. 8 and 9  illustrate a modification of the apparatus of  FIG. 4  contained within the outer housing with the lid removed and with the lid added, respectively;  
         [0020]      FIG. 10  is a perspective view of the cable-to-conductor separating means of  FIG. 8 ;  
         [0021]      FIG. 11  is a perspective view of a modification of the housing arrangement of  FIG. 9 ;  
         [0022]      FIGS. 12-14  are perspective views illustrating base members having various conductor seat arrangements;  
         [0023]      FIG. 15  is an exploded view of a modification of the apparatus of  FIG. 1 ;  
         [0024]      FIG. 16   a  is a rear perspective view of the terminal block of  FIG. 15 , and  FIG. 16   b  is an exploded view of the terminal block of  FIG. 16   a;    
         [0025]      FIG. 17  is a perspective view of a partially assembled connector arrangement corresponding to  FIG. 15 ;  
         [0026]      FIGS. 18 and 19  are perspective views illustrating the assembled apparatus of  FIG. 15  with the terminal blocks in the elevated inoperative and lowered operative insulation-piercing positions, respectively;  
         [0027]      FIGS. 20 and 21  are longitudinal sectional views illustrating the operation of the apparatus of  FIG. 15  when in the lowered operative and elevated inoperative positions, respectively;  
         [0028]      FIG. 22  is a perspective view of another modification of the base member conductor seat arrangement;  
         [0029]      FIG. 23  is a perspective view of the apparatus of  FIG. 16  mounted within the lower housing section, with the lid removed;  
         [0030]      FIGS. 24 and 25  are perspective views of various modifications of the housing of  FIG. 23 ;  
         [0031]      FIGS. 26   a,    26   b  and  26   c  are partially assembled, fully assembled, and exploded perspective views, respectively, of another terminal block embodiment; and  
         [0032]      FIGS. 27   a,    27   b  and  27   c  are partially assembled, fully assembled, and exploded perspective views, respectively, of a further terminal block embodiment. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0033]     Referring first more particularly to  FIGS. 1, 2   a,  and  2   b,  the connector tap-off arrangement  1  of the present invention includes a base member  2  that supports a rigid frame  3  that is formed from a suitable electrically insulating material and that contains a plurality of chambers  6  that are open at their upper and lower ends and within a plurality of terminal blocks  4  are respectively arranged for vertical movement as guided by rib and slot means  69 . The apparatus is operable to tap off electrical current from a plurality of insulated conductors  21  of a cable  22  that are exposed upon the removal of a section of the cable sheath, thereby to define a pair of cable sheath ends  24 . The cable is supported at each end of the base member  2  by integral cable support means  23 , and the individual insulated conductors are mounted in separate longitudinally extending cable seats  20  that are integral with the base member. As will be explained in greater detail below, when the frame  3  is mounted on the base member  2  as shown in  FIGS. 3 and 4 , eccentric disks  16  on the terminal blocks  4  are operated to displace the terminal blocks downwardly relative to the frame, thereby to effect piercing of the insulation layers on the conductors  21  by a piercing contacts  8 , on the terminal blocks, whereby electrical current is tapped off from the conductors  21  and supplied to output conductors  70   a  and  70   b  connected with the various terminal blocks  4 .  
         [0034]     As shown in  FIGS. 2   a  and  2   b,  each of the terminal blocks  4  includes a terminal block body  7  that is formed from a suitable electrically insulating synthetic plastic material, and within which is mounted a conductive bus bar  10 . At one end, the bus bar  10  is connected with the insulation-piercing fork contact  8  that is connected with the first output contact means  9   a  in the form of a resilient contact  11 . At its other end, the bus bar  10  is connected with the second output contact means  9   b,  which comprises a vertical plug contact  13 . The terminal body  7  has a first access opening  12  for receiving the bare end of an output conductor  70   a  that engages the resilient contact  11 , and the other end the terminal body contains a second access opening  35  for receiving the plug connector  65  of a second output conductor  70   b.  Thus, as will be described in greater detail below, when a given insulation-piercing contact  8  pierces the insulation layer of one of the conductors  21  to engage the conductor thereof, electrical current is transmitted both to the first output conductor  70   a  via the resilient contact means  11 , and to the second output conductor  70   b  via the bus bar  10 , the plug contact  13 , and the plug connector  65 . As is known in the art, the resilient contact  11  comprises a reversely bent resilient portion  56  terminating in an end extremity  55  that is adapted to engage the bare conductor end of the output conductor  70   a  that is inserted via opening  12 . In order to stabilize and support the insulation-piercing contact  8  relative to the bus bar  10 , a resilient U-shaped protective cover  34  is provided having a base portion that is connected with the bus bar  10 , and a pair of leg portions that extend downwardly on opposite sides of the insulation-piercing contact  8 .  
         [0035]     Arranged for rotation within cam chambers  14  contained in the upper portion of the terminal block housings  7  are a plurality of eccentric disks  16 , respectively, said disks containing axially-aligned radially-offset openings  17 . Extending through these aligned offset openings is a mounting shaft  37  the ends of which are supported by opposed openings  36  contained in the side walls of the frame  3 . The side walls of the terminal housings  7  contain opposed vertical slots  18  through which the mounting shaft  37  extends. The eccentric disks  16  also carry at each end central axially-extending pegs  32  that extend within corresponding opposed slots  33  contained in the side walls of the housing  7 . Also mounted on the operating disks are spring-biased buttons  53  that are arranged to engage corresponding stop openings  54   a  and  54   b  contained in the housing side walls when the terminal blocks are in their elevated and lowered positions, as will be described below. The housing  7  contains a first access opening  12  for receiving the first output conductor  70   a,  and a second access chamber  35  for receiving the connector of the second output conductor  70   b.    
         [0036]     The support shaft  37  is normally non-rotatably connected with the eccentric disks  16 , whereby the eccentric discs are operated simultaneously as a unit. Alternatively, the disks could be rotatably mounted on the shaft for individual selective operation. The base member  2  contains a row of inspection openings  30  beneath the conductors  21 , respectively, thereby to permit an observer to determine if the conductors are properly in place. The base member also includes a plurality of vertically projecting integral mounting studs  25  to which the frame  3  is fastened when mounted on the base member  2 , as shown in  FIGS. 3 and 4 . Catch fasteners at the upper ends of the vertical projections  25  engage corresponding catch projections on the frame  3  when it is lowered to the mounted position of  FIG. 4 .  
         [0037]     Referring now to  FIG. 6 , once the assembly of the frame  3  and the terminal blocks  4  is lowered onto the base member  2 , the tip of an operating tool such as a screwdriver  40  is inserted within a corresponding slot  42  contained in the outer periphery of the eccentric disk  16 , whereupon the disks  16  are simultaneously rotated about the support shaft  37  that extends through the opening  17  contained in the eccentric disks, and the vertical slots contained in the side walls of the terminal blocks. Owing to the cooperation between the outer circumferential cam surface of the eccentric disk  16  and the adjacent wall surface of the cam recess  14 , together with the forces produced by the radial pegs  32  extending through the slots  33  contained in the side walls of the housing  7 , the frame assembly is displaced downwardly relative to the base member  2  from the elevated inoperative position of  FIG. 3  to the lower operable position of  FIG. 7 . At this time, the knife edges of the bifurcated fork piercing member  8  sever the insulation layer of the associated conductor  21 , whereupon the conductor within the insulated conductor is electrically connected with the first and second contact means  9   a  and  9 b at opposite ends of the terminal block. The retaining button  53  on the opposite ends of the eccentric disk  16  then engages the corresponding position-establishing opening  54   b  ( FIG. 2   b ), thereby to maintain the eccentric disks  16  in place relative to the terminal blocks upon removal of the operating tool  40 .  
         [0038]     To disengage the frame and terminal block assembly from the base member  2 , the operating tool  40  is again introduced into the slot  42 , whereupon the eccentric disks  16  are rotated in the counterclockwise direction to their initial disengaged positions of  FIG. 6 . In this state, the button  53  on each end of the eccentric disk  16  engages the position opening  54   a  contained in the side walls of the terminal block housing  7 .  
         [0039]     Referring now to  FIGS. 8 and 9 , following the mounting of the frame and terminal block assembly on the base member  2 , the resulting assembly is inserted downwardly within the chamber contained within an outer housing  26 , with the cable extending through resilient seals mounted in the end walls of the outer housing  26 . The output conductors  70  are directed out of the chamber of the outer housing  26  via a lateral opening  28  contained in the opposed side walls of the outer housing  26 . The seal that normally closes the opening  28  is fractured to permit the output conductors to extend there through. If desired, a cable support element  43  ( FIG. 10 ) may be provided containing a circular opening  45  at one end for receiving the cable  22 , and a plurality of openings  44  for receiving the respective insulated conductors  21 . The lower housing element  26  is closed by an upper lid closure member  27 , as shown in  FIG. 9 . In the modification of  FIG. 11 , the opening  48  contained in the seal member  47  at each end of the housing  26  has an oval configuration for receiving a flat cable having a plurality of insulated conductors enclosed with an outer sheath layer.  
         [0040]     Referring to  FIGS. 12-14 , the connector apparatus may include base members having various configurations and constructions. In the embodiment of  FIG. 12 , the base member  101  is provide with a plurality of conductor seats  20  that are adapted to receive conductors  21   a  and  21   b  having different diameters, respectively. The raised sides of the seats define bridge members  38  are provided with catch hooks  50  that retain conductors  21   a  and  21   b  of different diameters in the insulated conductor seats. In the embodiment of  FIG. 13 , the conductors are retained in separate elastic catch seats  51  that are mounted on a bridge  52  that is fastened to the upper surface of the base member  102 . In the embodiment of  FIG. 14 , the projection  64   a  and  64   b  are arranged in parallel rows and face in opposite directions, thereby to define a labyrinth arrangement for retaining the cables  21   a  and  21   b  of different diameters within the conductor seats  20 .  
         [0041]     In the embodiment of  FIG. 1 , the assembly of the frame  3  and terminal blocks  4  is mounted upon the base member  2  by cooperating snap fastener means on the vertical projections  25  and the corresponding surfaces at the four corners of the frame  3 . In the second embodiment of  FIGS. 15, 16   a,  and  16   b,  the frame and terminal block assembly is fastened to the base member  104  by means of pivot lugs  58  that extend from the rear wall of the frame  3 ′ into a corresponding recess (not shown) contained in the base member  104 , whereupon the frame and terminal block assembly is pivoted from an initial inclined position downwardly about the pivot lug means  58  toward the horizontal position parallel with the base member, thereby to effect engagement between catches  3   d ′ that extend outwardly from the side walls of the frame into corresponding catch openings contained in the vertical protecting portions  25 ′.  
         [0042]     Referring to  FIGS. 15 and 16 , it will be seen that the side walls of the terminal block housing  7  have upper bridge portions  57  that enclose the end portions of the eccentric disks  16 . As before, each disk  16  contains an offset opening  29  that is non-rotatably connected with the operating shaft  37 . The button  53  mounted on each end of the eccentric disk  16  is operable to engage the corresponding position openings  54   a  and  54   b  when the frame and terminal block assembly is in its elevated disengage and lowered engaged positions, respectively. The bus bar arrangement for connecting the piercing contact  8  with the outlet contacts  9   a  and  9   b  is the same in this embodiment as in the first embodiment of  FIG. 1 . Thus, when the eccentric disk  16  of  FIG. 21  is rotated by the tool  40  in the clockwise direction about the axis of support shaft  37  to the position shown in  FIG. 20 , terminal blocks are displaced downwardly to effect piercing of the insulation layer by the fork  8 . In this embodiment, clamp means  59  are provided for clamping the cable  22  to the bottom wall member  104 . As before, the continuous shaft  37  is non-rotatably connected with all of the eccentric disks, whereby the operating disks are displace as a unit. Of course, if desired, the eccentric disks  16  of the embodiments of  FIGS. 1 and 15  could be rotatably connected with the support shaft  37 , whereupon the terminal blocks  4  could be individually displaced relative to the base member, rather than being displaced simultaneously as a group.  
         [0043]     Referring now to  FIG. 22 , the base member embodiment  105  includes resilient supports  51  for retaining conductors  21   a  and  21   b  of different diameters within their respective longitudinally-extending conductor seats  20 . In the embodiment of  FIG. 23 , the apparatus of  FIG. 19  is mounted within the chamber contained in the lower section  26  of an outer housing. At each end, the housing  26  is provided with an opening in which is mounted seal means  47  containing a circular opening  48  for receiving the cable  22 . In the modification of  FIG. 24 , the opening  48 ′ contained in seal means  47 ′ has an oval configuration for receiving a flat cable. The housing  26  is closed by a lid closure member  27 , as shown in  FIGS. 24 and 25 .  
         [0044]     Referring now to  FIGS. 26   a,    26   b,  and  26   c,  it will be seen that the output connector plug  65  that extends within access opening  35  containing the vertical contact  13  that defines the second output contact means  9   b  includes a conductive bifurcated contact  68  having a bifurcated lower end  68   a  that is adapted to receive the upwardly projecting contact  13  when the plug  65  is inserted within the access opening  35 , as shown in  FIG. 26   a.  As shown in  FIG. 27   a - 27   c,  an auxiliary electrical component  65 ′ may be connected with the vertical contact  13  thereby to supply current from the insulation piercing contact  8  to a plurality of output conductors connected with the plug  65 ′.  
         [0045]     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.