Patent Publication Number: US-6704992-B2

Title: Cable punch assembly

Description:
FIELD OF THE INVENTION 
     The present invention relates to a cable punch assembly. More particularly, the present invention relates to cable punch assembly for inserting multiple cables simultaneously. The cable punch assembly inserts up to four pairs of cables into insulation displacement contacts in a wiring unit. 
     BACKGROUND OF THE INVENTION 
     Due to significant advancements in telecommunications and data transmission speeds over unshielded twisted pair cables or wires, the connectors (jacks, patch panels, cross connects, etc.) have become critical factors in achieving high performance in data transmission systems, particularly at the higher frequencies. Some performance characteristics, particularly near end crosstalk, can degrade beyond acceptable levels at new, higher frequencies in the connectors unless adequate precautions are taken. 
     Often, wiring is pre-existing. Standards define the geometry and the pin definitions for the connectors, making any changes to the wiring and to the connector geometry and pin definitions for improving performance characteristics cost prohibitive. 
     The use of unshielded twisted pair wiring and the establishment of certain standards for connector geometry and pin definitions were created prior to the need for high speed data transmissions. Thus, while using the existing unshielded twisted pair wiring and complying with the existing standards, connectors must be developed that fulfill the performance requirements of today&#39;s higher speed communications in order to maintain compatibility with the existing connectors. Typical connectors are disclosed in U.S. Pat. No. 6,193,526 of John J. Milner, Joseph E. Dupuis, Richard A. Fazio, and Robert A. Aekins, issued Feb. 27, 2001 and entitled “Wiring Unit with Angled Insulation Displacement Contacts”, and to U.S. patent application Ser. No. 09/675,652 of Alan C. Miller, John J. Milner and Raul G. Pereira, filed Sep. 29, 2000, and entitled “Stuffer Cap Mechanism for an Electrical Connector”, the subject matter of each of which is hereby incorporated by reference 
     One problem with attaching the twisted pair wiring to the terminals of a wiring unit for an electrical connector is that only one wire may be attached at a time. Therefore, one wire must be individually attached to a terminal of the wiring unit before a second wire may be attached. This step is repeated for each terminal of the wiring unit. For a typical RJ plug having eight terminals, this process must be performed eight times. Such a process is time consuming and costly. 
     Another problem is that once an existing cable punch is used to attach a single wire to a terminal, a separate device must be used to cut excess wiring from the wiring unit. For the typical RJ plug having eight terminals, sixteen steps must be performed to connect eight wires in the eight terminals. Eight wires must be connected to the eight terminals, which requires eight separate steps. After each wire connecting step, a second separate step is required to cut off excess wire at each terminal. A sixteen step process to wire a wiring unit is time consuming and costly. 
     A need exists for a cable punch assembly that efficiently connects a plurality of wires to terminals of a wiring unit and cuts excess wiring from the wiring unit. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is a primary objective of the present invention to provide an improved cable punch assembly. 
     A further objective of the present invention is to provide a cable punch assembly that connects a plurality of wires to plural insulation displacement contacts. 
     A still further objective of the present invention is to provide a cable punch assembly having blades for cutting excess wire from a wiring unit. 
     The foregoing objects are basically attained by providing a cable punch assembly for connecting a plurality of wires to plural insulation displacement contacts. The cable punch assembly has a rod having first and second ends, and a base having first and second faces. The second end of the rod is connected to the first face. First and second connectors extend from the second face. Each of the connectors includes two laterally spaced wire pusher members that extend axially from the base to receive an insulation displacement contact between the pusher members as the pusher members force a wire into a wire receiving slot of the contact. 
     Each pair of the wire pusher members engages a single wire, so the cable punch assembly may connect a plurality of wires to a plurality of insulation displacement contacts of a wiring unit. Connecting a plurality of wires at a time decreases the amount of time required to wire a wiring unit. 
     Preferably, a blade is positioned proximal each connector allowing a cable punch assembly to cut off excess wire at the same time that the wires are inserted into receiving slots of the contacts, thereby reducing the number of steps and time required to wire a wiring unit. 
     Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Referring now to the drawings that form a part of the original disclosure: 
     FIG. 1 is a perspective view of a cable punch assembly according to the present invention, showing a front face of the base; 
     FIG. 2 is a perspective view of the cable punch assembly of FIG. 1, showing a rear face of the base; 
     FIG. 3 is a side elevational view of the cable punch assembly of FIG. 1 receiving a plurality of wires prior to connecting the wires to a wiring unit; 
     FIG. 4 is a side elevational view of the cable punch assembly of FIG. 1 connecting a plurality of wires to terminals of the wiring unit; 
     FIG. 5 is a perspective view of the base of the cable punch of FIG. 1, showing the bottom face of the base; 
     FIG. 6 is a bottom plan view of the base of FIG. 1; 
     FIG. 7 is a rear elevational view of the base of FIG. 1; 
     FIG. 8 is a side elevational view of the base of FIG. 1; 
     FIG. 9 is a front elevational view of the body of the base of FIG. 1; 
     FIG. 10 is a rear elevational view of the insert of the base of FIG. 1; 
     FIG. 11 is a top plan view of the base of FIG. 1; 
     FIG. 12 is a top plan view of the insert of the base of FIG. 1 without the body; and 
     FIG. 13 is a front elevational view of a second end of a rod of the cable punch assembly of FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As shown in FIGS. 1-13, the present invention relates to a cable punch assembly  11  for terminating wires at a wiring unit. The cable punch assembly  11  has a handle  13  for wielding the cable punch assembly by a user. A rod  21  has first and second ends  23  and  25 , respectively. The first end  23  is connected to the handle  13 . A base  31  has first and second faces  35  and  37 , respectively. The second end  25  of the rod  21  is connected to base  31  at first face  35 . At least two connectors  51  extend from the second face  37  of the base  31 . 
     As shown in FIGS. 1 and 2, the handle  13  may be of any suitable shape to be wielded by a user. Preferably, the handle is shaped to conform to a user&#39;s grip and has a rubber outer layer to facilitate a user&#39;s grip. 
     The rod  21  may be of any suitable shape, but is preferably cylindrical. As shown in FIG. 13, the rod  21  may have first and second portions  27  and  29 , respectively. The first portion  27  has a larger diameter than the second portion  29 . The first portion  27  has an axial groove  22  that has a first end  24  proximal the transition between the first and second portions of the rod and extends axially along the first portion of the rod to a second end  26 . A recess  28  in the rod  21  is located approximately 90 degrees around the circumference of the rod from the axial groove  22 . A circumferential groove  32  extends from the axial groove  22  to the recess  28 . 
     Preferably, the base first face  35  is opposite its second face  37 . The first face  35  of the base  31  receives the rod  21 . Preferably, the base  31  has a body  33  and a removable insert  41  received by the body. Although, the base can have a body  33  and an insert  41  that are separately formed and assembled, the base may be a single piece. 
     As shown in FIG. 9, the body  33  of the base has a first face  34  and a second face  36 . Preferably, the first face  34  is opposite the second face  36 . A passageway  38  extends from the first face to the second face for receiving the rod  21 . As shown in FIG. 11, a ball  20  is located in passageway  38  to facilitate retention of the base  31  on the rod  21 . First and second arms  61  and  63  extend outwardly from second surface  36 . Preferably, first and second arms  61  and  63  extend substantially perpendicularly from opposite edges of the second surface  36  of the body  33 , as shown in FIG.  5 . Preferably, arms  61  and  63  extend beyond insert  41  to protect all parts of the cable punch assembly during use, including insert  41 , wire pusher members  91  and  93 , blades  52 , and first and second insert shoulders  47  and  49 . First and second recesses  65  and  67  in the first and second arms  61  and  63 , respectively, receive the insert  41 . Preferably, body  33  is made of a metal. 
     As shown in FIGS. 5,  7  and  10 , the insert  41  has first and second faces  43  and  45 . Preferably, the first face  43  is opposite the second face  45 . An opening  42  in first face  43  receives tip  29  of rod  21 , as shown in FIG.  12 . First and second arms  44  and  46  extend substantially perpendicularly from a third face  50  of insert  41 . A groove  48  is formed between the first and second arms for receiving and aligning with a wiring unit, as shown in FIGS. 2,  3  and  7 . First and second shoulders  47  and  49  extend along fourth and fifth faces  71  and  72 , respectively, of the insert  41 . Cavities  73  and  74  extend along second face  45  of the insert  41 . Preferably, insert  41  is made of a plastic. 
     As shown in FIGS. 1-4, connectors  51  receive wires for connecting to insulation displacement contacts  18  of a wiring unit  17 . The wiring unit  17 , insulation displacement contacts  18 , and stuffer cap  19  are described in U.S. Pat. No. 6,193,526 to Milner et al. and U.S. patent application Ser. No. 09/675,652 of Miller et al. First, second, third, fourth, fifth, sixth, seventh and eighth connectors  75 ,  76 ,  77 ,  78 ,  79 ,  80 ,  81  and  82 , respectively, extend from second surface  45  of the insert  41 . Preferably, four connectors  51  extend from each of first and second cavities  73  and  74  in the second face  45  of the insert  41 . Preferably, each of the connectors  51  is non-perpendicular to any edge of the second face of the base  31  and insert  41 , as shown in FIGS. 5-6. 
     Each connector  51  includes two laterally spaced wire pusher members  91  and  93  that extend axially from the base to receive an insulation displacement contact  18  between the pusher members as the pusher members force a wire into a wire receiving slot  14  of the contact  18 . As shown in FIG. 5, inner most edge  58  of wire pusher member has a rounded edge  58  to prevent damaging wire with a sharp edge. Preferably, each connector  51  is substantially U-shaped, such that each wire pusher member  91  and  93  forms a leg with a slot  92  therebetween for receiving an insulation displacement contact. 
     A blade  52  may be positioned proximal each pair of connectors  51 . First blade  83  is positioned proximal first and second connectors  75  and  76 . Second blade  84  is positioned proximal third and fourth connectors  77  and  78 . Third blade  85  is positioned proximal fifth and sixth connectors  79  and  80 . Fourth blade  86  is positioned proximal seventh and eighth connectors  81  and  82 . The blades  52  are positioned proximal each pair of connectors so that any excess wiring is cut by the blade, thereby forming a neatly wired wiring unit. 
     Assembly and Disassembly 
     As shown in FIG. 7, the insert  41  is received by the body  33  to form the base  31 . First and second shoulders  47  and  49  are received by the first and second recesses  65  and  67  in the body  33 . When properly inserted, the opening  42  in the first face  43  of the insert is aligned with the passageway  38  of the body  33 . The rod  21  is then inserted through passageway  38  in the body  33  and into the insert  41 . The tip  29  of rod  21  is received by the opening  42  in first face  43  of insert  41 . Ball  20  in passageway  38  travels along axial groove  22  in the rod  21  as the rod passes through the body  33  and into the insert  41 . When rod  21  is fully inserted, ball  20  is aligned with circumferential groove  32 . The base  31  is then rotated approximately 90 degrees, so that the ball travels along circumferential groove  32  until coming to rest in recess  28  in rod  21 , thereby locking insert  41  to body  33 . The tip  29  of rod  21  prevents insert  41  from being slid horizontally out of the body. The upper ends  94  and  95  of arms  61  and  63  prevent insert  41  from being removed vertically from body  33 . 
     To remove insert  41  from body  33 , base  31  is rotated so that ball  20  of body  33  is in the axial groove  22 . Base  31  may then be vertically slid from rod  21 . Once base  31  has been removed from rod  21 , insert  41  may be removed from body  33 . 
     Once base  31  has been secured to rod  21 , a wire  95  may be inserted in any of the slots  14  in the wiring unit  19 . The wiring unit  19  shown in FIGS. 3 and 4 is a typical RJ plug having eight insulation displacement contacts, and, therefore, eight slots  14 . Each slot  14  may receive a wire  95 , thereby allowing up to eight wires to be terminated in wiring unit  19 . A wire  95  is held in slot  14  of an insulation displacement contact. Wire  95  enters wiring unit  19  from first end  98 . Wire  95  is then bent less than 90 degrees and positioned in any open slot  14  of wiring unit  19 . Excess wire extends over the sides of wiring unit  19 , as shown in FIG.  3 . Once all the desired wires  95  have been inserted into slots  14  of insulation displacement contacts  18  of wiring unit  19 , the cable punch assembly may be used to connect the wires to insulation displacement contacts  18  of wiring unit  19 . 
     The cable punch assembly  11  is aligned with the wiring unit  17 , such that groove  48  is aligned with shoulder  97  of the wiring unit. Once groove  48  of base  31  is aligned with shoulder  97  of the wiring unit, the base slides down so that wires  95  are pushed deep into slots  14  of insulation displacement contacts  18 . Both wire pusher members  91  and  93  of connector  52  contact wire  95 , and force the wire down into slot  14  of insulation displacement contact  18 , such that when the cable punch assembly is pulled up the wires are kept behind by the insulation displacement contacts of the wiring unit  17 . Slots  92  of connectors  52  receive insulation displacement contacts  18  as wire  95  is inserted into the insulation displacement contacts. 
     When wire pusher members  91  and  93  of cable punch assembly  11  have inserted wire  95  into insulation displacement contact  18 , blades  52  contact surface  99  of wiring unit  17 . Any excess wire  96  extending over the edge of wiring unit  17  is cut by the blade, as shown in FIG. 4, thereby providing a neatly wired wiring unit. 
     While advantageous embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined in the appended claims.