Abstract:
A cable terminating apparatus for terminating a cable having a plurality of wires with a connector, the cable terminating apparatus includes a housing having a plurality of slots arranged for positioning the plurality of wires in a fixed spaced relationship relative to each other. A connector has a plurality of terminals corresponding to the plurality of wires. A squeezing tool has a recess configured for receiving the housing and the connector. The squeezing tool has a moveable plate for urging the connector and the housing against a support wall and into engagement with each other to electrically connect the plurality of terminals with the plurality of wires.

Description:
FIELD OF THE INVENTION  
         [0001]    The invention relates to an apparatus and method for terminating an electrical cable with a connector.  
         BACKGROUND OF THE INVENTION  
         [0002]    To terminate a cable containing a plurality of wires with a connector containing a plurality of terminals, such as, a cable used for telecommunication applications, each of the wires is inserted one at a time into each of the terminals with a tool made of plastic. The wires are then pressed into engagement with the terminals and free ends of the wires are removed with a tool, such as pliers. This conventional method of termination, however, is difficult to perform and has several drawbacks, particularly in instances where the cable contains a significant number of small diameter wires. For example, the method of cutting the free ends of the wires with pliers results in the free ends having variable lengths. Because the length of the free ends is inconsistent, the free ends may come into contact with a metal shielding member. Additionally, because the tools are made of plastic, the tools are not durable.  
         SUMMARY OF THE INVENTION  
         [0003]    It is, therefore, an object of the invention to provide a method and device that facilitates the termination of a cable having a plurality of wires with a connector having a plurality of terminals. It is another object of the invention to provide a method and device that cuts wire ends proximate to terminals of the connector in a convenient manner and ensures that the wire ends are removed from the connector in such a way that the wire ends do not protrude from the connector and impede the application of a strain relief member to the connector. It is still a further object of the invention to provide a method and device that inserts the wires into terminals of the connector to a uniform controlled depth.  
           [0004]    This and other objects are solved by a cable holding device for terminating a cable having a plurality of wires with a connector comprising a housing having a plurality of slots arranged for positioning the plurality of wires in a fixed spaced relationship relative to each other, and an inner surface configured for guiding a complementary surface of the connector into electrical engagement with the plurality of wires.  
           [0005]    This and other objects are further solved by a cable terminating apparatus for terminating a cable having a plurality of wires with a connector. The cable terminating apparatus includes a housing having a plurality of slots arranged for positioning the plurality of wires in a fixed spaced relationship relative to each other. A connector has a plurality of terminals corresponding to the plurality of wires. A squeezing tool has a recess configured for receiving the housing and the connector. The squeezing tool has a moveable plate for urging the connector and the housing against a support wall and into engagement with each other to electrically connect the plurality of terminals with the plurality of wires.  
           [0006]    This and other objects are further solved by a method of terminating a cable having a plurality of wires with a connector having a plurality of terminals wherein the plurality of wires are positioned in a housing in a fixed spaced relationship relative to each other. A connector is aligned with the housing by engaging an inner surface of the housing with a complementary surface of the connector. The connector and the housing are pressed against a support wall to urge the connector further into engagement with the housing to electrically connect the plurality of terminals with the plurality of wires. Free ends of the plurality of wires are simultaneously severed with a cutting device. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    The invention will now be described by way of example only with reference to the accompanying drawings, in which:  
         [0008]    [0008]FIG. 1 is a top perspective view of a cable holding device of the present invention;  
         [0009]    [0009]FIG. 2 is a top perspective view of the cable holding device in an open state;  
         [0010]    [0010]FIG. 3 is an exploded perspective view of the cable holding device;  
         [0011]    [0011]FIG. 4 is a bottom plan view of the cable holding device;  
         [0012]    [0012]FIG. 5 is a bottom perspective view of the cable holding device;  
         [0013]    [0013]FIG. 6 is a perspective view of a cutting blade of the cable holding device;  
         [0014]    [0014]FIG. 7 is a perspective view of the cable holding device with a cable installed therein;  
         [0015]    [0015]FIG. 8 is a perspective view of the cable holding device of FIG. 7 partly engaged with a connector;  
         [0016]    [0016]FIG. 9 is a perspective view of the cable holding device and the connector loaded into a squeezing tool;  
         [0017]    [0017]FIG. 10 is a plan view of the connector with a metal shielding member;  
         [0018]    [0018]FIG. 11 is a perspective view of the cable holding device and the connector being loaded into the squeezing tool;  
         [0019]    [0019]FIG. 12 is a perspective view of the cable holding device relative to the squeezing tool during a first squeezing operation;  
         [0020]    [0020]FIG. 13 is a perspective view of the cable holding device relative to the squeezing tool during a second squeezing operation;  
         [0021]    [0021]FIG. 14 is a perspective view of the separation of the cable holding device from the connector;  
         [0022]    [0022]FIG. 15 is a perspective view of the disengagement of the cable holding device from the cable; and  
         [0023]    [0023]FIG. 16 is a perspective view of the cable terminated with the connector and a strain relief device. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0024]    [0024]FIG. 9 shows a cable terminating apparatus according to the invention. The apparatus includes a cable holding device  2  and a squeezing tool  4  for terminating a cable  6  with a connector  8 . As shown in FIGS. 1 and 2, the cable holding device  2  may be formed from metal and includes a housing having first and second housing parts  18 . Hinge lugs  24  project from the first and second housing parts  18 . Each of the hinge lugs  24  has a through-hole  22 . The through-holes  22  are aligned for receipt of a pivot pin  20  to hingeably mount the first housing part  18  to the second housing part  18  such that the first and second housing parts  18  may be rotated between an open position shown in FIG. 2 and a closed position shown in FIG. 1. Locking lugs  26  are formed on a side opposite from the hinge lugs  24 . Each of the locking lugs  26  has a through-hole  28 . The through-holes  28  are aligned for receipt of a locking pin  30  that secures the first and second housing parts  2  in the closed position.  
         [0025]    Between the hinge lugs  24  and the locking lugs  26 , each of the first and second housing parts  18  has a hemi-cylindrical cable gripping recess  32 , as best shown in FIG. 5. As shown in FIG. 2, each of the cable gripping recess  32  is defined by an inner side wall  36  having U-shaped inner wall slots  40  for guiding or lacing wires  10  of a cable  6 . The inner wall slots  40  open toward a front end  34  of the first and second housing parts  18 . An opposite or outer side of each of the first and second housing parts  18  is defined by an. outer side wall  38  that includes outer wall slots  42  for guiding or lacing the wires  10  of the cable  6 . The outer wall slots  42  open toward the front end  34  of the first and second housing part  18 . Each of the inner wall slots  40  is aligned with a corresponding outer wall slot  42 . The inner and outer wall slots  40 ,  42  have a width that snugly accommodates the wire  10  and its insulation covering. Wire support structures  44  extend perpendicularly to the inner and outer side walls  36 ,  38  and adjacent to each pair of the inner and outer wall slots  40 ,  42 . Each of the wire support structures  44  includes a U-shaped slot  46  for receiving a terminal, such as an insulation displacement terminal  14 , as described in more detail below.  
         [0026]    As shown in FIG. 1, an indicator panel  64  extends along each of the outer side walls  38  and adjacent to the outer wall slots  42 . The indicator panel  64  includes indicia corresponding to colors of the insulation covering of the wires  10  to designate which of the wires  10  is to be inserted into each of the outer wall slots  42 .  
         [0027]    As shown in FIG. 4, each of the first and second housing parts  18  includes a blade slot  48  positioned close to and parallel to each of the outer side walls  38 . An end of each of the blade slots  48  has a first curved portion  66  with a relatively large radius of curvature and a second curved portion  68  with a relatively small radius of curvature. As shown in FIGS. 5 and 6, a cutting device, such as a blade  50  having a cutting edge  52 , is slidably received in each of the blade slots  48 . The cutting edge  52  is formed so that when a rear end  54  of the blade  40  is moved flush with a rear face  56  of the corresponding first or second housing part  18 , the cutting edge  52  severs the wires  10  extending through the wire guiding slots  42 . As shown in FIG. 3, sides of the blades  50  have first and second radiused portions  67 ,  69  that correspond with the first and second curved portions  66 ,  68 . The first and second radiused portions  67 ,  69  ensure that the blades  50  can only be installed in one direction so that when the cutting edge  52  cuts the wires  10 , a minimal amount of the cutting edge  52  projects through terminals  14  in the connector  8 .  
         [0028]    As shown in FIG. 3, a blade retainer  60  that is formed as a slotted spring pin is force fitted in an aperture  62  in the outer side walls  38  of each of the first and second housing parts  18 . The blade retainer  60  passes through an elongated aperture  58  in the blade  50  and prevents the blade  50  from becoming detached from the first and second housing parts  18 . The elongated aperture  58  is configured so that the blade  50  can slide toward and away from the front end  34  of the cable holding device  2 .  
         [0029]    As shown in FIG. 8, the connector has a connector body  104  having a mating face  16  that receives a complimentary connector (not shown) and a connection face  100 . The mating face  16  may include a dust cover  114 . The connection face  100  is provided with a plurality of insulation displacement terminals  14 . Each of the terminals  14  has a corresponding insulation displacement slot  12 . Opposite ends of the terminals  14  are positioned so as to be engageable from the mating face  16  of the connector  8  by means of the complementary connector (not shown).  
         [0030]    As shown in FIG. 10 and as is well known in the art, a metal shielding member  112  may be folded around the connector  8 . An outer surface of the metal shielding member  112  is configured to project a distance  116  of 0.5 mm outside an outer surface of the connector body  104 .  
         [0031]    As shown in FIG. 9, the squeezing tool  4  may be made from metal and includes a handle  74  connected to a trigger  76  by a pivot pin (not shown). Projecting forwardly from the handle  74  is a frame  80 . The frame  80  has a U-shaped recess  84  configured to receive the cable holding device  2  and the connector  8 , as described in more detail below. The frame  80  of the squeezing tool  4  may be adapted to be used with a connector with or without the dust cover  114 . A moveable. plate  88  is mounted in a proximal end of the frame  80  and is displaceable into the recess  84  in a direction shown by arrow A by movement of the trigger  76  towards the handle  74 . A distal end of the frame  80  is a support wall  86  that has a U-shaped slot  82  opening toward a top surface of the frame  80 . The slot  82  is configured to receive the cable  6  and has a width significantly larger than a diameter of the cable  6 , as best shown in FIGS.  11 - 13 . As shown in FIG. 12, a proximal face of the support wall  86  has rebated portions  90  dimensioned to receive the rear ends  54  of the blades  50  when the cable holding device  2  is in a first lateral position relative to the frame  80 . A space formed between the rebated portions  90  correspond to the space between the blades  50 . Laterally adjacent to and on the same side as each of the rebated portions  90  is a support face  94 . The lateral distance between adjacent support faces  94  is the same as the distance between the blades  50 .  
         [0032]    The method of terminating the cable  6  with the connector  8  using the cable holding device  2  and the squeezing tool  4  will now be described in greater detail. As shown in FIG. 16, a strain relief member  96  is slipped over an end of the cable  6 . An outer insulation  98  of the cable  6  is stripped to expose an insulation covering of the wires  10  of the cable  6 , as shown in FIG. 7. The locking pin  30  is removed from the cable holding device  2  so that the cable holding device  2  may be pivoted to the open position, as shown in FIG. 2. The cable  6  is inserted into the cable holding device  2 , and the cable holding device  2  is closed about the cable  6  so that an end portion of the outer insulation  98  is clamped between the cable recesses  32  of the first and second housing parts  18 . The locking pin  30  is re-inserted to secure the first and second housing parts  18  in the closed position such that the cable  6  is firmly gripped in the cable holding device  2 .  
         [0033]    As shown in FIG. 7, each of the wires  10  is laced through one of the inner wall slots  40  in the inner side walls  36  and through the corresponding outer wall slots  42  in the outer side walls  38  according to the indicia on the indicator panel  64 . As the wires  10  are laced, the blades  50  may be inserted into the first and second housing parts  18  so that the rear ends  54 .of the blades  50  project from the rear face  56  of the cable holding device  2 . Alternatively, the blades  50  may be inserted into the first and second housing parts  18  prior to installing the cable  6  in the cable holding device  2 .  
         [0034]    As shown in FIG. 8, the connector  8  used to terminate the cable  6  is partially engaged with the wires  10  by pushing the connection end  100  slightly into the cable holding device  2 . An outer surface of the connector body  104  engages the inner surfaces  105  of the first and second housing parts  18  thereby aligning the terminals  14  with contact portions  106  (FIG. 7) of the wires  10 . As this occurs, the contact portions  106  of each of the wires  10  enter a distal portion of the corresponding insulation displacement slots  12 . The connector body  104  and the internal structure of the cable holding device  2  may be formed so that the connector  8  may only be engaged with the cable holding device  2  in one orientation. Alternatively, the cable holding device  2  may bear a label or other indicator for showing the correct orientation for engagement of the connector  8  with the cable holding device  2 .  
         [0035]    As shown in FIGS. 9 and 11- 12 , the cable holding device  2  and the connector  8  are then placed in the recess  84  of the squeezing tool  4  with the rear face  56  of the cable holding device  2  facing the support face  94  of the support wall  86  of the frame  80 . When the cable holding device  2  and the connector  8  are placed in the squeezing tool  4 , the moveable plate  88  is in a retracted position (moved towards the handle  74 ). The cable  6  is moved laterally in the slot  82  to the position shown in FIG. 11 where the rear ends  54  of the blades  50  are aligned with the rebated portions  90  in the support wall  86 . The connector  8  and the cable holding device  2  are then moved to insert the rear ends  54  of the blades  50  into the rebated portions  90 , as shown in FIG. 12. The frame  80  may be configured such that the connector  8  and cable holding device  2  may only be placed in the squeezing tool  4  in one orientation.  
         [0036]    The trigger  76  is squeezed so that the moveable plate  88  moves in the direction of the arrow A and forces the connector  8  fully into engagement with the cable holding device  2 . As the connector  8  is engaged with the cable holding device  2 , each of the wires  10  is pushed into the displacement slots  12  and into the insulation displacement terminals  14  associated therewith. The support structures  44  that are arranged adjacent to the contact portions  106  of each of the wires  10  assist in pushing the wires  10  into the insulation displacement terminals  14 . The cable holding device  2  is prevented from moving distally from the frame  80  by the rear face  56  bearing on the support faces  94  of the support wall  86 . Because the rear ends  54  of the blades  50  are accommodated in the rebated portions  90 , no force is applied to the blades  50 .  
         [0037]    The trigger  76  is released and the cable holding device  2  and the connector  8  are moved proximally by a small distance so that the connector  8  and the cable holding device  2  may be laterally displaced to the position shown in FIG. 13 where the rear ends  54  of the blades  50  are aligned with the support faces  94 . The trigger  76  is then squeezed again so that the moveable plate  88  displaces the cable holding device  2  and the connector  8  distally in the frame  80 . As this occurs, the rear ends  54  of the blades  50  are forced into alignment with the rear faces  56  of the cable holding device  2 , and the cutting edges  52  of the blades  50  sever free ends  108  (FIG. 7) of the wires  10  to leave only a minimum amount of the wire  10  projecting outwardly from each of the insulation displacement terminals  14 . The free ends  108  of the wires  10 , which have been severed, are retained in the guiding slots  42  of the cable holding device  2  and may be pulled-out therefrom for disposal.  
         [0038]    The trigger  76  is released, and the cable holding device  2  and the connector  8  are removed from the squeezing tool  4 , as shown in FIG. 14. The terminated cable  6  is removed from the cable holding device  2  by removing the locking pin  30  and pivoting the first and second housing parts  18  to the open position, as shown in FIG. 15. The strain relief member  110  is then slid up the cable  6  and over the connection end  100  of the connector  8 , as shown in FIG. 16. This operation is facilitated by the fact that the free ends  108  of the wires  10  have been severed close to the connector  8 .  
         [0039]    Alternatively, the termination of the cable  6  to the connector  8  may be performed in a single step by omitting the steps shown in FIGS. 11 and 12 and by directly placing the cable holding device  2  in the squeezing tool  4  in the manner shown in FIG. 13.  
         [0040]    The cable terminating apparatus of the invention is preferably adapted to terminate a cable with a shielded or unshielded SL series  110  connector modular jack. Although the cable  6  in the illustrated embodiment is shown as having eight wires, the cable  6  may have any number of wires, and the cable holding device  2  may be adapted to receive any number of wires and the connector  8  may be adapted to have any number of terminals. Additionally, more than one wire could be inserted into a particular terminal and/or not all terminals may be engaged by a wire. Because the cable holding device  2  and/or the squeezing tool  4  is made of metal, the cable holding device  2  and/or the squeezing tool  4  is durable and can withstand repeated use, and the use of the apparatus leads to a very low rejection rate.