Patent Publication Number: US-6210205-B1

Title: Spacer for IDC termination

Description:
FIELD OF THE INVENTOR 
     The present invention relates to a spacer, and more particularly to a spacer for use with an IDC connector for ensuring termination between conductors of cables and insulation displacement section of terminals. 
     DESCRIPTION OF PRIOR ART 
     Conventionally, terminals are assembled to passageways defined in a housing through interferential fit therebetween. In order to securely assemble the terminal to the corresponding passageway, a body portion of the terminal is formed with barbs which anchor to walls of the passageway. In the very beginning, the pitch between two adjacent terminals provides enough room which effectively prevent a short circuit therebetween. For example, the width of the terminal is about 0.4 mm and the height of the barbs formed thereon is 0.1 mm. If the pitch is 1.27 mm, then the spacing between sides of the terminals equals to 1.27−0.2−0.2=0.87 (mm) [0.2 is a half of the width of the terminal], while the spacing measured from two adjacent barbs equal to 0.87−0.1−0.1=0.67 (mm). The terminals can be assembled to the corresponding passageways through interferential fit and the arrangement can pass the Direct Withstanding Voltage Test. However, the barbs or the likes formed on the body portion of the terminal will increase the insertion force. In addition, when the pitch reduces to 0.8 mm (very high density [VHD] connectors), then the spacing between two adjacent terminals equals to 0.8−0.2−0.2=0.4 (mm). In this case, it is impossible to assemble the terminals to the corresponding passageways through interferential fit because the spacing between two adjacent barbs equals to 0.4−0.1−0.1=0.2 (mm). The arrangement can not pass the Direct Withstanding Voltage Test because short circuit between two adjacent terminals will occur. 
     One of the solutions for such VHD connector is by insert molding which features high precision, reliability, and low labor cost. Furthermore, the body portion of the terminal can be formed with dimples to increase the retention within the enclosed housing. However, alignment of each terminal within a mold cavity is a problem which complicates the molding process as well as the mold configuration. 
     U.S. Pat. No. 5,761,805 discloses a plurality of channels ( 138 ) formed adjacent to the insulation displacement sections ( 32 ,  34 ). The conductive wires ( 24 ) are seated in the channels ( 138 ) after termination. However, during termination the insulation displacement sections ( 32 ,  34 ) are not well supported and vulnerable to fall down when excessive forces are experienced. 
     U.S. Pat. No. 6,062,896 issued May 16, 2002 assigned to the same assignee, entitled to “Method For Terminating Connector” describes a spacer used to terminate conductors to IDC sections of terminals. The specification is enclosed for reference. The disclosed spacer includes a base having a plurality of retaining slots for retaining conductive wires therein for facilitating reliable termination. Even each insulation displacement section is well supported, the retaining force provided by the open slot is still not enough during termination. If the conductive wires are not securely retained, termination thereof will displace the conductive wire. 
     SUMMARY OF THE INVENTION 
     An objective of this invention is to provide a spacer for terminations wherein conductors of wires are securely arranged in the spacer and during the terminations, insulation displacement section of terminals are well supportably guided thereby preventing the insulation displacement section from falling down. 
     In order to achieve the objective set forth, a carrier for terminating conductors of conductive wires to insulation displacement sections of terminals molded in a housing of a connector by assembling said carrier carrying conductive wires therein to a terminating face of said housing, comprises an elongate base defining upper, lower, front and rear faces. An array of channels extends between the front and rear faces. An array of slits is defined in the lower face in a direction traverse to the channels and each communicates a corresponding channel. An array of retaining slots defined in the lower face and each retaining slot is in alignment with a corresponding one of the channels. During termination between the conductors and the insulation displacement sections, each insulation displacement section is securely supported within the corresponding slit before the insulation displacement sections engage with the cables thereby facilitating reliable termination therebetween. 
     These and additional objects, features, and advantages of the present invention will become apparent after reading the following detailed description of the preferred embodiments of the invention taken in conjunction with the appended drawing. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a perspective view of a spacer in accordance with the present invention; 
     FIG. 2 is an exploded view of a connector core and two spacers; and 
     FIG. 3 is similar to FIG. 1 viewed from a reverse direction and with conductive wires assembled therein; 
     FIG. 4 is an assembled view of FIG. 3; 
     FIG. 5 is a sketch view showing terminating status between the spacer and insulation displacement sections. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENT 
     Referring to FIGS. 1 and 2, a spacer  1  in accordance with the present invention comprises an elongate base  10  defining an upper face  10   a , a lower face  10   b  opposite the upper face  10   a , and front and rear faces  10   c  and  10   d . An array of channels  11  is defined in the front face  10   a . In the instant embodiment, the channels  11  extend about two third of the width of the base  10 . An array of retaining slots  12  is defined in the lower face  10   b  and each in alignment with the corresponding channel  11 . The inner diameter of the channel  11  is dimensioned such that a conductive wire  30  can snugly insert therein. However, the width of a front end  12   a  of the retaining slot  12  is slightly smaller than an outer diameter of the conductive wires  30 , therefore when the conductive wire  30  extends through the channel  11 , a free end of the conductive wire  30  can be securely retained by the front end  12   a  of the retaining slot  12 . As a result, the conductive wire  30  will not be displaced during terminations. An array of slits  13  is defined in the lower face  10   b  and each communicates a corresponding channel  11 . In the instant embodiment, there are two rows of slits  13  and which are offset from each other. By this arrangement, two adjacent channels  11  are corresponding respective slits  13  in different rows. 
     The base  10  further forms a pair of guiding posts  14  and a pair of latches  15  for engaging with holes  25   a  and hooks  25   b  of a connector core  25  of a connector. Description of function of the guiding posts  14  and the latches  15  are detailedly described in the co-pending application and no description is given therefor. By the provision of the guiding posts  14  and the latches  15 , the spacer  1  can be assembled to the connector core  25 . The connector core  25  has a terminating face  26  on which an array of insulation displacement section  27  extending therethrough. Please refer to the co-pending application for details. 
     Referring to FIGS. 3 and 4, the conductive wires  30  are firstly assembled to the channels  11 , then the spacer  1  is assembled to the termination face  26  whereby the conductors  30   b  of the conductive wires  30  are terminated with the insulation displacement section  27  of the connector core  25 . 
     Referring to FIG. 5, when the latch  15  of the spacer  1  is located at the first position of the hook  25   b , a top portion  27   a  of the insulation displacement section  27  extends into the corresponding slit  13  and is in contact with the insulation layer  30   a  of the conductive wire  30 . When the spacer  1  is moved further downward, the latch  15  is moved from the first position to the second position such that the insulation displacement section  27  pieces through the insulation layer  30   a  and makes an electrical contact with the conductor  30   b.    
     The advantage of the instant application is since the conductive wires  30  are completely received in the channels  11 , termination can be effectively performed. This is also beneficial for later over-molding process. In addition, the insulation displacement sections  27  are supportably received in the corresponding slits  13 , during the terminating process, the insulation displacement sections  27  are well protected without any deformation thereby benefiting reliable termination between the insulation displacement sections  27  and the conductive wires  30 . 
     While the present invention has been described with reference to a specific embodiment, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications to the present invention can be made to the preferred embodiment by those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.