Abstract:
A dual-sided IDC connector for use in connecting electrical components to field wiring is described. One side of the IDC connector may be factory-wired to an electrical component. A second side of the IDC connector may be field-wired in an end-wiring or a through-wiring configuration. The second side of the IDC connector may have multiple covers to minimize the effort required by a field technician to terminate the field-wiring. The IDC connector may be easily mounted to existing raceways, outlet strips, and junction boxes.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
   This application claims priority from U.S. Provisional Patent Application No. 60/939,425, filed May 22, 2007, the entire disclosure of which is hereby incorporated by reference. 

   FIELD OF THE INVENTION  
   The present invention relates generally to electrical connectors and, more particularly, to a dual-sided insulation displacement contact (“IDC”) connector for use in field-wiring and factory-wiring, capable of being installed in a raceway, outlet strip, and other electrical field installations. 
   BACKGROUND OF THE INVENTION  
   Electrical connectors are used to connect many types of insulated wires, and enable technicians to connect insulated wires without having to strip and crimp the wires. Typically, an IDC connector may be a housing with channels for wires to pass through, a cover, and one or more IDC&#39;s. IDC&#39;s comprise an electrically conductive material, and may have a “U” shape on one or more sides. IDC&#39;s may pierce through the wire insulation when a force is applied between the wire and the IDC. After the IDC pierces the wire insulation of a first wire, the IDC contact may make electrical contact with the first wire. The opposite end of the IDC from the end in contact with the first wire may be positioned around or along a second wire, and force may be applied between the second wire and the IDC. The IDC may pierce the insulation of the second wire, and electrical contact may be made between the first and second wires through the IDC. 
   One problem that exists when terminating wires using an IDC connector is that a great deal of force may be required for the field technician to properly push down the cover onto the connector and thereby terminate the connections. Pushing down on a cover of an IDC connector may create the force between the wire and the IDC contact needed for the IDC to pierce the wire insulation. However, the force required to pierce the wire insulation may be large, so that it is uncomfortable or inconvenient for the field technician to terminate the contacts. 
   An additional problem is that, typically, the field technician must install a connector on each side that is to be terminated. For instance, a first wire or set of wires may be installed into one side of the housing corresponding to one end of one or more IDC&#39;s, and a second wire or set of wires may be installed into a second side of the housing corresponding to the opposite end of one or more IDC&#39;s. This takes time and, as previously stated, may require a great deal of physical effort on the part of the technician to properly terminate the wires. 
   Another problem is that alter terminating the IDC, it may be desirable to place the connector in a field configuration, i.e., on a raceway, in an electrical box, in an outlet strip, or another configuration. Connectors that are not adapted to be easily installed in such field configurations may require extra time from the field technician to complete the installation. 
   SUMMARY OF THE INVENTION  
   A dual-sided IDC connector for use in connecting electrical components to field wiring is described. One side of the IDC connector may have wires from an electrical component that are terminated and installed in the factory. A second side of the IDC connector may be field-wired in an end-wiring or a through-wiring configuration. 
   Terminating the electrical component wiring to the IDC connector in the factory or at a time before field installation of the electrical component may reduce the time and labor necessary to install and terminate IDC connectors. Because the factory wiring may be already installed in a first side of the IDC connector, the field technician may only need to install the field wiring in a second side of the IDC connector. 
   The IDC connector may be easily mounted to existing raceways, outlet strips, and junction boxes. This may increase efficiency, as less time is required to install the connectors after the wiring has been terminated. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a front upper right exploded view of an IDC connector, in accordance with an embodiment of the present invention; 
       FIG. 2  is a front upper right perspective view of an IDC connector having factory wiring and field through-wiring, in accordance with an embodiment of the present invention; 
       FIG. 3  is a front upper right perspective view of an IDC connector having factory wiring and field end-wiring, in accordance with an embodiment of the present invention; 
       FIG. 4  is a front upper right perspective view of the IDC connector, with the field-wired cover open, in accordance with an embodiment of the present invention; 
       FIG. 5  is a front view of the IDC connector showing one of the field-wired covers in the open position, and another field-wired cover rotated over the field housing before being coupled to the field housing, in accordance with an embodiment of the present invention. 
       FIG. 6  is a front upper right perspective view of the IDC connector with the field-wired cover closed, in accordance with an embodiment of the present invention; 
       FIG. 7   a  is a top plan view of an IDC connector having field end-wiring with the field covers in the open position, in accordance with an embodiment of the present invention; 
       FIG. 7   b  is a top plan view of an IDC connector having field end-wiring with the field covers in the closed position, in accordance with an embodiment of the present invention; 
       FIG. 8   a  is a top plan view of an IDC connector having field through-wiring with the field covers in the open position, in accordance with an embodiment of the present invention; 
       FIG. 8   b  is a top plan view of an IDC connector having field through-wiring with the field covers in the closed position, in accordance with an embodiment of the present invention; 
       FIG. 9  is an illustration of a typical installation of the IDC connector to an outlet, in accordance with an embodiment of the present invention; 
       FIG. 10  is an illustration of a typical installation of the IDC connector to a receptacle-type outlet, in accordance with an embodiment of the present invention; 
       FIG. 11  is an illustration of a typical installation of the IDC connector to an outlet strip base mounted to a wall, in accordance with an embodiment of the invention; 
       FIG. 12  is an illustration of a typical installation of the IDC connector to a surge suppressor, in accordance with an embodiment of the present invention; 
       FIG. 13   a  is an illustration of a typical field-wiring of the IDC connector in a raceway with a faceplate, in accordance with an embodiment of the present invention; 
       FIG. 13   b  is an illustration of a typical placement of an IDC connector in a raceway with a faceplate, in accordance with an embodiment of the present invention; 
       FIG. 13   c  is an illustration of a typical placement of an installed IDC connector into a raceway with a faceplate, in accordance with an embodiment of the present invention; and 
       FIG. 13   d  is an illustration of a typical installation of the faceplate over an IDC connector in a raceway, in accordance with an embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
     FIG. 1  is a front upper right expanded view of an insulation displacement contact (“IDC”) connector  101 . The IDC connector  101  has a factory housing  105 , a factory cover  103 , a field housing  111 , field covers  115 , and IDC&#39;s  321 . 
   The factory housing  105  may have two side walls, a front wall  333 , and an end wall  311 . One or more factory wire apertures  303  may be located on the front wall  333  and the end wall  311  of the factory housing  105 . 
   The factory housing  105  is shown in  FIGS. 1-13   d  as having factory wire apertures  303  only on the front wall  333 . Frequently, wires from electrical components may be installed into an IDC connector in an end-wiring configuration. In this case, it may be desirable to have a solid end wall  311 , as shown in  FIGS. 1-13   d.    
   Alternatively, factory wire apertures  303  may be located on the end wall as shown with respect to the front wall  333 . Wiring from the electrical component may be installed in a through-wiring configuration, and the wires may pass through the factory wire apertures  303  on the front wall  333  and the end wall  311 . 
   The factory wire apertures  303  hold the factory-installed wiring as it enters the factory housing  105 . Factory guide walls  309  are located inside the factory housing  105 . The factory guide walls  309  are shown in  FIG. 1  as being interrupted by the factory IDC guides  305 . The number and location of the interruptions in the length of the factory guide walls  309  may depend on the number, size, and location of IDC&#39;s  321  and the IDC apertures  313 . The factory guide walls  309  may be parallel to the side walls of factory housing  105 . The factory guide walls  309  may separate and guide the factory-installed wiring to the desired position. IDC apertures  313  may be located on the bottom surface of the factory housing  105 , and may allow the IDC&#39;s  321  to pass through the bottom surface of the factory housing  105  in order to make electrical contact with the factory wiring. 
   Factory IDC guides  305  are located inside the factory housing  105  over the IDC apertures  313 . The factory IDC guides  305  may guide the IDC&#39;s  321  into position and may prevent the IDC  321  from bending in response to forces exerted on the IDC  321  from the wiring as the IDC  321  pierces the wire insulation to make contact with the wire. The IDC apertures  313  and factory IDC guides  305  are preferably staggered to allow the IDC connector  101  to be narrower.  FIG. 1  shows the IDC&#39;s  305  staggered so that the IDC&#39;s  321  progressively move from left to right in a direction away from the front wall  333 . However, the IDC&#39;s  305  may be located in any configuration. Additionally,  FIG. 1  shows an IDC connector  101  with positions for three wires; however, any number of wires and IDC&#39;s  321  may be used. 
   A factory cover  103  may be sized to fit over the factory housing  105 . The factory cover  103  may have factory cover wire restraints  307  positioned to align with the factory wire apertures  303 . The factory cover wire restraints  307  may prevent the factory wiring from moving away from the factor wire apertures  303  when the factory cover  103  is installed. 
   The field housing  111  has two side walls, a front wall  335 , and a back wall  337 . One or more field wire apertures  323  may be located on the front wall  335  and the back wall  337  of the field housing  111 . Field wiring may commonly be installed in an end-wiring or in a through-wiring configuration. One or more field wire apertures  323  may be located on the front wall  335  and back wall  337 . The field wire apertures  323  may hold the factory-installed wiring as it enters the field housing  111 . 
   Field guide walls  405 , discussed further with respect to  FIG. 4 , are located inside the field housing  111 . The field guide walls  405  may be parallel to the side walls of the field housing  111 . The field guide walls  405  may separate and guide the field-installed wiring to the desired position. 
   IDC apertures  331  are located on the bottom surface of the field housing  111 , and allow the IDC&#39;s  321  to pass through the bottom surface of the field housing  111  to make electrical contact with the field wiring. 
   Field IDC guides  403 , discussed further with respect to  FIG. 4 , may be located inside the field housing  111  over the IDC apertures  331 , and may guide the IDC&#39;s  321  into position and prevent them from dislocating or bending excessively after they are inserted into IDC apertures  313 ,  331 . The IDC apertures  331  may be staggered to allow the IDC connector  101  to be narrower, and may be aligned with the IDC apertures  313  of the factory housing  105 . 
   A field cover face  327  may be located on one or more sides of one or more field covers  115 . The field cover face  327  may secure the field-installed wiring and may also prevent unwanted dust and other particles located in the environment outside the raceway IDC connector  101  from entering the field housing  111 . 
   Latches  329  may be located on each of the field covers  115 . The latches  329  may couple the field covers  115  to the field housing  111 , discussed further with respect to  FIGS. 4 and 5 . Alternatively, the field covers  115  may be coupled to the field housing  111  by gluing, a retention clip, or by another coupling method known in the art. 
   The field housing  111  shown in  FIG. 1  has three field covers  115  attached to the field housing  111  by three field hinges  113 . The number of field covers  115  may vary, and may depend on the number of wires in the field housing  111 , although the number of field covers  115  and the number of wires in the field wiring do not necessary need to be equal. For instance, a single field cover  115  may push down one or more wires onto one or more IDC&#39;s  321 . 
   The IDC&#39;s  321  may be inserted into the IDC apertures  331  of the factory housing  105 . The field housing  111  may be placed on top of the factory housing  105 . The opposite ends of the IDC&#39;s  321  may inserted into the IDC apertures  313  of the factory housing  105 . The factory IDC guides  305  and the field IDC guides  403 , discussed further with respect to  FIG. 4 , may guide the IDC&#39;s  321  into position and may prevent them from dislocating or bending excessively after they are inserted into IDC apertures  313 ,  331 . The field housing  111  and the factory housing  105  may be attached by ultra-sonic welding, gluing, a retention clip, or another coupling method known in the art. 
   The factory wiring may be installed into the factory housing  105  by laying the factory wires along factory guide walls  309 . In an end-wiring configuration, the factory end wall  311  may be solid in order to protect the ends of the factory-installed wiring that are exposed after they are cut for installation into factory wire apertures  303  of the factory housing  105 . Alternatively, in a through-wiring configuration, the factory end wall  311  may have factory wire apertures  303  through which factory wiring may pass. 
   The factory housing  105  and the factory cover  103  may be attached by ultra-sonic welding, gluing, a retention clip, or by any other suitable coupling method known in the art. When the factory cover  103  is pushed down onto the factory housing  105  during attachment, the factory cover wire restraints  307  may exert pressure on the wire insulation. The pressure from the factory cover  103  during installation may cause the IDC&#39;s  321  to pierce through the insulation of the factory-installed wiring and to make electrical contact with the factory-installed wires. 
   The raceway IDC connector  101  may be included within a factory terminated device, for example, in the electrical or control box on the device. The field wiring may be installed by a field technician into the field housing  111  when the device that includes the IDC connector  101  is installed in the field. 
   The field wiring may be installed into the field housing  111  by laying the field wires along the field guide walls  405 , discussed further with respect to  FIGS. 4 and 5 . In an embodiment in which the field covers  115  are attached to the field housing  105  with flexible plastic hinges, the field covers  115  may be individually rotated into position over the field housing  111  and pushed down over the field housing  111  to couple the field housing  111  to the field covers  115 . When the field covers  115  are pushed down onto the field housing  111 , the field cover wire restraints  315 , discussed further with respect to  FIG. 4 , may exert pressure on the wires, causing the IDC&#39;s  321  to pierce through the insulation of the field-installed wiring and to make electrical contact with the field-installed wires. 
   The IDC connector  101  may be sized to fit into standard-sized electrical raceways for convenient field installation. 
     FIG. 2  is a front upper right perspective view of an IDC connector having factory end-wiring and field through-wiring, in accordance with an embodiment of the present invention. The through-wiring configuration shown in  FIG. 2  has factory wiring entering the IDC connector  101  and the coupled field wiring extending from both sides of the IDC connector  101 . 
   The factory housing  105  houses the factory wiring, made up of, for example, three power wires of either 120 VAC or 230 VAC. The factory cover  103  and the factory guide walls  309  may hold the factory wiring in place. 
   The field covers  115  may be placed over the field housing  111  and coupled to the field housing  111  to secure the field wiring. The through-wiring tab  407 , discussed further with respect to  FIGS. 4 and 5 , may be crushed when the field covers  115  are coupled to the field housing  111 . Alternatively, the through-wiring tab  407  may be removed before the field wiring is laid into the IDC connector  101  by the field technician, for example, by pinching the through-wiring tab  407  with pliers and pulling the tab off the IDC connector  101 . The through-wiring tabs  407  may have perforations to aid the field technician in removing the through-wiring tabs  407 . 
     FIG. 3  shows an end-wiring configuration, whereby the field wiring is terminated inside the field housing  111 , and extends from only one side of the IDC connector  101 , in accordance with an embodiment of the present invention. The end-wiring configuration may be installed similarly to the through-wiring configuration discussed with respect to  FIG. 2 , except that the field wiring may be terminated within the field housing  111 . The through-wiring tabs  407 , discussed further with respect to  FIGS. 4 and 5 , may remain intact and may protect the field wiring from dust and other particles in the environment of the IDC connector  101 . 
     FIG. 4  is a front upper right perspective view of the IDC connector  101 , with the field-wired cover open. The factory wiring is not shown in  FIG. 4 ; however, in a typical installation the factory wiring would extend from the factory wire apertures  303 . 
   Retaining rims  409  are located on the side wall of the field housing  111 . Latches  329 , shown in further detail in  FIG. 5 , may couple with the retaining rims  409  to hold the field covers  115  in place, in accordance with an embodiment of the present invention. 
   The field guide walls  405  are shown in  FIG. 1  as being interrupted by the field IDC guides  403 . The number and location of the interruptions in the length of the factory guide walls  309  may depend on the number, size, and location of IDC&#39;s  321  and the IDC apertures  331 . 
   The through-wiring tabs  407  may be located inside the field wire apertures  323  on the field front wall  335 . The through-wiring tabs  407  may preferably be made of a plastic that may be crushed by the pressure of the field Wiring when the field covers  115  are installed over the field housing  111 . Alternatively, as discussed with respect to  FIG. 4 , the through-wiring tabs  407  may be made of a plastic that may be removed by a field technician. For example, the through-wiring tabs  407  may have perforations to aid the field technician to remove the through-wiring tabs  407 . The through-wiring tabs  407  may prevent unwanted dust and other particles located in the environment outside the IDC connector  101  from entering the field housing  111  in the end-wiring configuration discussed with respect to  FIG. 2 . 
     FIG. 5  is a front view of the IDC connector showing one of the field-wired covers in the open position, and another field-wired cover in the closed position, before being coupled to the field housing  111  by the field technician. The field cover face  327  may be tapered to guide the cover into place after it has been rotated over the field housing  111 . Saddle guides  503  may guide the field cover  115  over the wires as it is rotated over the field housing  111 . 
   The front field cover  115  is shown in  FIG. 5 , positioned over the field housing  111 . In order to couple the field cover  115  to the field housing  111 , the field technician may push the field cover  115  onto the field housing  111  using channel lock pliers or an equivalent tool. The latch  329  may snap over the retaining rim  409 , thereby coupling the field cover  115  with the field housing  111 . As discussed with respect to  FIGS. 1-3 , the field covers  115  may also be coupled in other ways. 
   Using a plurality of field covers  115  may reduce the physical effort required by the field technician to couple each field cover  115 , because the field technician may be piercing through fewer wire insulations each time a field cover  115  is coupled to the field housing  111 . Any number of field covers  115  may be used, and the number may be as many as the number of wires contained in the field housing  111 . 
     FIG. 6  is a front upper right perspective view of the IDC connector  101  with the field covers  115  coupled to the field housing  111 . In this view, the field covers  115  have all been rotated over the field housing  111  and locked into place by the field technician. Field cover recesses  325  are shown on the field covers  115 . Field cover recesses  325  may assist the field technician in coupling the field covers  115  to the field housing  111 . The field wiring and the factory wiring are not shown. 
     FIG. 7   a  is a top perspective view of an IDC connector  101  having field end-wiring with the field covers in the open position. The field wiring may be cut to fit within the length of the field housing  111 . The field wiring may be laid into the field housing  111  and pushed down under the wire retainers  305 . The field covers  115  may each be rotated over the field housing  111 . The field technician may couple each field cover  115  individually using Channel Lock® pliers or an equivalent tool.  FIG. 7   b  shows the IDC connector  101  having field end-wiring with the field covers  115  coupled to the field housing  111 . 
     FIG. 8   a  is a top perspective view of an IDC connector  101  having field through-wiring with the field covers in the open position. The field wiring may be laid into the field housing  111  and pushed down under the wire retainers  305 . The field wiring may be placed within the field wire apertures  323  on the field back wall  337 , and over the through-wiring tab  407 . The field covers  115  may each be rotated over the field housing  111 . The field technician may couple each field cover  115  individually using Channel Lock® pliers or an equivalent tool. The pressure from the wires may crush the thin wall of the through-wiring tab  407 , allowing the field wiring to extend from both ends of the field housing  111 . Alternatively, as discussed with respect to  FIG. 4 , the through-wiring tabs  407  may be removed by the field technician.  FIG. 8   b  shows the IDC connector having field through-wiring with the field covers  115  coupled to the field housing  111 . 
     FIG. 9  is an illustration of a typical installation  901  of the IDC connector  101  to an outlet  903 . A typical outlet  903  may have factory wiring installed. The IDC connector  101  may be terminated to the factory wiring extending from the outlet  903 . The field wiring may be terminated to the IDC connector  101  in an end-wiring configuration as described with respect to  FIG. 3 . An outlet  903  is shown in  FIG. 9 ; however, any type of electrical receptacle may alternatively be used. 
     FIG. 10   a  is an illustration of a typical installation of the IDC connector  101  to a receptacle-type outlet  1003 . A typical outlet  1005  for installation into an encased outlet strip may have factory wiring and is shown in  FIG. 10   a  installed in outlet strip  1005 . The IDC connector  101  may be terminated to the factory wiring extending from the outlet  1003 . The field wiring may be terminated to the IDC connector  101  in an end-wiring configuration as described with respect to  FIG. 3 . The IDC connector  101  may be inserted into the outlet strip  1005 , as shown in  FIG. 10   b.  Alternatively, the IDC connector  101  may be installed into a junction box. An outlet  1003  is shown in  FIGS. 10   a  and  10   b;  however, another type of electrical receptacle may be used. 
     FIG. 11  is an illustration of a typical installation of the IDC connector  101  to an outlet strip base  1103  mounted to a wall. A typical outlet  1107  for installation into an outlet strip base  1103  may have factory wiring and is shown in  FIG. 11  installed in outlet strip base  1103 . The IDC connector  101  may be terminated to the factory wiring extending from the outlet  1107 . The field wiring may be terminated to the IDC connector  101  in an end-wiring configuration, as described with respect to  FIG. 3 . The IDC connector  101  may be mounted into the outlet strip base  1103 . Alternatively, the IDC connector  101  may be installed into a junction box. An outlet  1107  is shown in  FIG. 11 ; however, any type of electrical receptacle may be used. The outlet strip cover  1105  is mounted over the components installed on the outlet strip base  1103 . 
     FIG. 12  is an illustration of a typical installation of the IDC connector to a surge suppressor. A typical outlet  1107  for installation into an outlet strip base  1103  may have factory wiring and is shown installed in outlet strip base  1103 . A first IDC connector  1201  that may be factory-terminated to an outlet receptacle  1107  and a second IDC connector  101  that may be factory-terminated to a surge suppressor  1203 . The first IDC connector  1201  may be field-wired to a second IDC connector  101  in a through-wiring configuration as described with respect to  FIG. 2 . The first and second IDC connectors  101 ,  1201  may then be mounted into the outlet strip base  1103 . Alternatively, the IDC connectors  101 ,  1201  may be installed into a junction box. An outlet  1107  is shown in  FIG. 12 ; however, another type of electrical receptacle may be used. The outlet strip cover  1105  may be mounted over the components installed on the outlet strip base  1103 . 
     FIGS. 13   a - d  illustrate a typical field-wiring of the IDC connector  101  in a raceway  1311  with a faceplate  1303 . An IDC connector  101  may be factory-wired to an outlet receptacle  903  with a faceplate  1303 . Power wiring  1305  may be field-installed into the power channel  1307  of a raceway  1311 . As shown in  FIG. 13   b,  the IDC connector  101  may be field-installed onto the power wiring  1305  in a through-wiring configuration as described with respect to  FIG. 2 . As shown in  FIG. 13   c,  the assembly of the outlet receptacle  903  and the faceplate  1303  may be mounted onto the power channel  1307 . As shown in  FIG. 13   d,  the power channel cover  1309  may be installed over the power channel  1307  to hide and protect the wiring. 
   It should be understood that the illustrated embodiments are examples only and should not be taken as limiting the scope of the present invention. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents are claimed as the invention.