Patent Publication Number: US-8122585-B2

Title: Spanner plate

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority under 35 U.S.C. §119(e) to U.S. provisional patent application No. 60/902,550 filed Feb. 20, 2007 which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an electrical connector tool and, more particularly, to a spanner plate for an electrical connector tool. 
     2. Brief Description of Prior Developments 
     Electrical connector tools having audible and tactile features are known in the art. For example U.S. Provisional Patent Application No. 60/851,724, filed on Oct. 13, 2006, discloses audible (such as a “pop” for example) and tactile (such as a vibratory effect for example) features utilized with a hydraulic crimping tool wherein the audible and tactile features are actuated when a predetermined hydraulic pressure is met. Additionally, U.S. Pat. Nos. 6,564,610 and Re. 33,714 disclose electrical connector tools having various audible and tactile features. There is a problem with conventional audible and tactile features in that these indications may not be sufficiently loud (or tactile) in various environments and the user may not realize that the desired crimping force was achieved. As customers demand dependable tools that are easy to operate in various working environments, there is a need to provide audible and tactile indicating features having robust and reliable configurations. It is, therefore, desirable to provide an improved configuration which indicates to the user that a completed crimping operation has been performed. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the invention, an electrical connector tool spanner plate is disclosed. The electrical connector tool spanner plate includes a first section and a second section. The first section includes an aperture and a first opening. The aperture extends along a majority of a length of the first section. The spanner plate is configured to surround an electrical connector tool cam mechanism at the aperture. The second section includes a second opening. The second section extends from the first section in a general cantilevered fashion. The second opening is proximate a free end of the second section. The aperture is between the first opening and the second opening. 
     In accordance with another aspect of the invention, an electrical connector tool is disclosed. The electrical connector tool includes a frame, a jaw, a first handle, a spanner plate, a cam member, and a resilient member. The frame includes a first end and a second end. The jaw is connected to the first end of the frame. The first handle extends from the second end of the frame. The spanner plate includes a first end and a second end. The first end is connected to the jaw. The spanner plate is configured to transfer a force between the first handle and the jaw. The cam member is between the first end and the second end of the spanner plate. The cam member is supported within the frame. The resilient member is connected between the first handle and the second end of the spanner plate. 
     In accordance with another aspect of the invention, a method of manufacturing an electrical connector tool is disclosed. A frame comprising a first end and a second end is provided. The frame includes a first handle extending from the second end of the frame. A jaw is movably connected to the first end of the frame. A spanner plate is supported within the frame. The spanner plate includes a first end and a second end. The first end is connected to the jaw. The spanner plate is configured to transfer a force between the first handle and the jaw. A cam member is connected to the frame. The cam member is between the first end and the second end of the spanner plate. A resilient member is connected between the first handle and the second end of the spanner plate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawings, wherein: 
         FIG. 1  is a side elevational view of a crimping connector incorporating features of the present invention; 
         FIG. 2  is an exploded perspective view of the crimping connector shown in  FIG. 1 ; 
         FIG. 3  is a top plan view of a spanner plate used in the crimping connector shown in  FIG. 1 ; 
         FIG. 4  is a side elevational view of the spanner plate shown in  FIG. 3 ; 
         FIG. 5  is a partial enlarged view of the spanner plate shown in  FIG. 3 ; and 
         FIG. 6  is an elevational top side view (relative to a first section of the spanner plate) of the spanner plate shown in  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , there is shown a side elevational view of a crimping tool  10  incorporating features of the invention. Although the invention will be described with reference to the exemplary embodiment shown in the drawings, it should be understood that the invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used. 
     The crimping tool  10  includes a frame  12 , a first jaw  14 , a second jaw  16 , a first handle  18 , a second handle  20 , and a housing  22 . The jaws  14 ,  16  are pivotally connected to each other and are attached to a first end  24  of the frame  12 . The first jaw  14  comprises a groove  26 . The second jaw  16  comprises an indentor  28 . The first handle  18  extends from a second end  30  of the frame  12 . The second handle  20  is pivotably attached to the frame  12 . The housing  22  extends between the second jaw  16  and the second handle  20 . The crimping tool  10  is configured to crimp an electrical connector (not shown) between the jaws  14 ,  16  upon manipulation of the handles  18 ,  20 . Additionally, the disclosed crimping tool  10  provides an audible and tactile indication subsequent to the crimping operation. 
     It should be understood that although the first jaw  14  and the second jaw  16  terminate in the groove  26  and the indentor  28 , respectively, the first jaw  14  and the second jaw  16  may comprise reverse configurations wherein the first jaw terminates in an indentor and the second jaw terminates in a groove. Additionally, it should be noted that alternate embodiments may comprise any type of compression or forming jaws including removable crimps or cutting dies. 
     Referring now also to  FIG. 2 , the crimping tool  10  further comprises a toggle mechanism  32  and a cam mechanism  34  disposed within the frame. The toggle mechanism  32  is connected to the first end  24  of the frame  12  and comprises a plurality of links  36 ,  38 , pivot pins  40 , and other supporting hardware. The toggle mechanism  32  pivotably connects the first jaw  14  and the second jaw  16  to each other and to the frame  12 . The cam mechanism  34 , comprising a cam member  42  and other supporting hardware, is supported within the frame  12 , by a pin  44  for example, between the first end  24  and the second end  30  of the frame  12 . The cam member  42  is in contact with a cam follower  46  which is pivotally connected to, and forms a portion of, the toggle mechanism  32 . 
     The cam member  42  is rotated by any suitable mechanism such as a ratchet mechanism comprising a ratchet wheel  48  and pawl  50  driven by multiple strokes of the second handle  20 . As the cam member  42  rotates, a force is exerted by the cam member  42  on the cam follower  46  to actuate the toggle mechanism  32  and the crimping jaws  14 ,  16 . An increasing radius of the cam member  42  builds up the force to a maximum crimping force exerted by the cam member  42 . When the cam member  42  rotates from its lowest radius to its highest radius, the jaws  14 ,  16  are in a closed or crimping position. When the cam member  42  rotates from its highest radius to its lowest radius, the jaws  14 ,  16  are in an open position. The cam member  42  may comprise a shape allowing for a rapid or sudden release of the crimping force as the cam member  42  rotates from its highest radius to its lowest radius (end of crimping cycle). 
     The crimping tool  10  also comprises a spanner plate  52  (best illustrated in  FIGS. 3-6 ). The spanner plate  52  is disposed within the frame such that the spanner plate  52  surrounds the cam member  42 . Additionally, a first end  54  of the spanner plate  52  is connected to the toggle mechanism  32  and a second end  56  of the spanner plate  52  is connected to the first handle  18 . The spanner plate  52  may be fabricated from any suitable material, such as stainless steel (304) or cold roll steel, hardened to Rc (Rockwell C-scale hardness number) about 50 to about 55, for example. The spanner plate  52  is configured to create an audible and tactile “pop” at the end of the crimping cycle in the crimping tool  10 . 
     The spanner plate  52  comprises a first section  58  and a second section  60 . The first section  58  comprises an aperture  62  suitably sized and shaped to fit around the cam member  42  and cam mechanism  34  (as well as other crimping tool  10  components) with a clearance gap therebetween. The aperture  62  extends along a majority of the length of the first section  58 . The aperture  62  may comprise a generally rectangular shape which provides a sufficient clearance envelope around the cam member  42  and the cam mechanism  34  such as to not interfere with the operation of the crimping tool  10 . 
     The first section  58  also comprises an opening  64  extending through a width of the first section  58  proximate the first end  54 . The first end  54  is suitably sized and shaped to be fitted, or sandwiched, between two links  36  (shown in  FIG. 2 ) of the toggle mechanism  32 . The opening  64  is suitably sized and shaped to receive a pin  66  (shown in  FIG. 2 ) of the toggle mechanism  32 . The opening  64  extends through the first section  58  in a generally substantially perpendicular orientation to the aperture  62 . The opening  64  is aligned with pin holes  67  of the links  36 . This allows for the pin  66  to extend through the opening  64  with ends of the pin fitted within the pin holes  67 . The opening  64  allows for the first end  54  of the spanner plate  52  to be pivotably attached to the links  36  (through pin  66 ) of the toggle mechanism  32  connected to the second jaw  16 . 
     The first section  58  may comprise a bend  68  along a middle portion of the first section  58 . When viewed from the side (best shown in  FIG. 4 ), the bend  68  forms a generally obtuse angle between portions of the first section  58  extending away from the bend  68 . The bend  68  is provided at lateral sides of the aperture  62  forming a general “V” shape at the edge of the aperture  62 . It should be noted that in alternate embodiments, the bend  68  may be provided at any suitable location along the spanner plate  52 . 
     The second section  60  extends from the first section  58  in a general cantilevered fashion. The second section  60  comprises an elongated generally rectangular shape with an opening  70  proximate the second end  56 . The opening  70  is suitably sized and shaped to receive an end of a resilient member, such as an extension spring  72  (shown in  FIG. 2 ) for example. The opening  70  allows for the second end  56  of the spanner plate  52  to be coupled to the first handle  18  through the spring  72 . The opening  70  proximate the second end  56  is substantially perpendicular to the opening  64  proximate the first end  54 . The spring  72  may be connected to an end of the handle by a pin  74  (shown in  FIG. 2 ) for example. 
     It should be noted that although the figures illustrate the spanner plate  52  as being connected to the tool  10  by the pin  66  at the first end  54  and the spring  72  at the second end  56 , the reverse configuration may be provided wherein a spring is connected to the first end  54  and a pin is connected to the second end  56 . Additionally, any combination of springs and/or pins may be provided. Furthermore, alternate embodiments may comprise any other suitable methods of connecting the spanner plate  52  to the tool  10 . 
     The spanner plate  52  transfers a spring force from the end of the tool handle  18 , around the cam mechanism  34  to the moveable second jaw, or indentor jaw,  16 . As the tool  10  is cycled, a pulling force is transferred through the spanner plate  52 , stretching the extension spring  72 . At the end of the tool&#39;s  10  cycle (rotation of the cam member  42  from its highest radius to its lowest radius) the tension is suddenly released, allowing the indentor jaw  16  to fully retract and open (under the force from the extension spring  72 ) until a back side  76  (shown in  FIG. 2 ) of the indentor jaw  16  impacts a stop feature of the tool  10 . The stop feature may be an end  78  of the second handle  20  for example. However, it should be noted that alternate embodiments may provide any suitable location for the stop feature. Additionally, it should be noted that alternate embodiments may provide for either or both of the jaws  14 ,  16  to impact the housing  22 , the frame  12 , or any other suitable portion of the tool  10 . The impact of the indentor jaw  16  on the stop feature creates the audible and tactile “pop”. 
     The spanner plate  52  provides for an improved crimping tool  10  which gives the user/operator indications that the crimping cycle has been completed. The audible and tactile “pop” allows users to quickly perform crimps on electrical connectors in various environments. The “pop” provides an audible indication of a completed crimp (or a completed tool operation) which can be heard in most industrial environments and maintenance locations. Additionally, the impact also provides a tactile indication which the user can feel at the handles  18 ,  20 . The tactile indication is useful in industrial environments and maintenance locations having increased levels of background noise (where the audible “pop” cannot be heard). The “pop” provides users with an indication that a successful crimp operation has been performed and that the tool  10  has not malfunctioned. 
     The disclosed spanner plate  52  provides further advantages over conventional configurations by allowing a high spring force to be applied to the indenter jaw  16  towards the open position. This creates a significant “snap” that is both audible and tactile at the end of a completed crimp cycle. The absence of a spanner plate does not allow a large force to be applied to the indenter jaw  16  which therefore gives very little indication of a completed crimp. The general opinion of a person operating a tool that has a spanner plate equipped tool is that the audible and tactile “snap” is an appealing signal that the crimp has been completed. The high spring force that the spanner plate  52  applies to the indenter jaw  16  effectively sets the cam  42  in the tool  10  to the same location at the end of each cycle. This ensures that the jaw opening will be consistent between cycles and that the same number of handle strokes will be required for each crimp cycle. 
     It should be noted that although the figures illustrate the disclosed spanner plate  52  as a component within a crimp connector  10 , which may be a Type OH25 HYTOOL™ sold by FCI USA, Inc. (under the FCI-BURNDY® Products line) for example, alternate embodiments may provide the spanner plate  52  within any tool having movable jaws. 
     It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.