Patent Publication Number: US-8533939-B2

Title: Compression tool

Description:
BACKGROUND OF THE INVENTION 
     The subject matter herein relates generally to compression tools for terminating wires to electrical connectors. 
     Compression tools are known for terminating wires to electrical connectors such as connectors. The connectors are loaded into the compression tool and a handle is squeezed to press the connector onto the wires to make electrical connection therebetween. For example, the connector may include insulation displacement contacts (IDCs) that are pressed onto the wires to make electrical connection therebetween. The compression tools typically include a ram connected to the handle that is actuated when the handle is squeezed. The ram engages the connector and presses the connector onto the wires. 
     Known compression tools are not without disadvantages. For instance, the compression tools have a fixed relationship between the ram and the handle such that the compression tools have a single shut height. In other words, the ram is pressed to the same final position every time the handle is squeezed to the closed position. However, typically different sized connectors are known and in use. In order for the tool to be used with different sized connectors, the connector includes a family of spacers that may be placed in the space between the ram and the connector to change the shut height of the compression tool. The spacers are separate components and may be easily lost, and increase the overall cost of the compression tool. 
     In some situations, when long connectors are being terminated, the operator uses the tool by only partially closing the handle to an intermediate, rather than fully closed, position to reduce the shut height of the compression tool to accommodate the longer connector. However, such use of the compression tool requires a skillful operator and extra time as the operator must estimate the amount of closing needed to fully terminate the connector to the wires. Partial termination may occur, leading to a defective connector. Additionally, over-closing may lead to damage to the connector. 
     A need remains for a compression tool that can terminate different sized electrical connectors. A need remains for a compression tool that allows the ram to be variably positionable with respect to the handle to define different shut heights for the compression tool. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one embodiment, a compression tool is provided for terminating wires to a connector. The compression tool includes a frame that has a receiving space configured to receive the connector. A handle is rotatably coupled to the frame. A ram is held by the frame. The ram has an engagement end within the receiving space that is configured to engage the connector. The ram is movable between an initial position and a final position. A link is coupled between the ram and the handle. The link is variably positionable with respect to at least one of the handle or the ram to change the final position of the ram within the receiving space to control a shut height of the compression tool. 
     In another embodiment, a compression tool is provided for terminating wires to a connector that includes a frame that has a receiving space configured to receive the connector. A handle is rotatably coupled to the frame. A ram is held by the frame. The ram has an engagement end within the receiving space that is configured to engage the connector. The ram has an actuation end opposite the engagement end. The ram has at least two ram cradles in the actuation end. The ram is movable between an initial position and a final position. A link is coupled to the handle. The link has a ram end configured to be selectively received in the ram cradles. The final position of the ram within the receiving space is controlled based on the ram cradle in which the ram end is received. 
     In a further embodiment, a compression tool is provided for terminating wires to a connector that includes a frame that has a receiving space configured to receive the connector. The frame has at least two frame slots that define different travel paths. A handle is rotatably coupled to the frame. A ram is held by the frame. The ram has an engagement end within the receiving space that is configured to engage the connector. The ram is movable between an initial position and a final position. A link is coupled to the handle. The link has a selector configured to be selectively received in the frame slots and traveling along the corresponding travel path during actuation of the handle. The final position of the ram within the receiving space is controlled based on the frame slot in which the selector is received. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of a compression tool formed in accordance with an exemplary embodiment. 
         FIG. 2  is a rear perspective view of the compression tool with a portion removed for clarity. 
         FIG. 3  is a side section view of the compression tool with a portion removed for clarity. 
         FIG. 4  illustrates two section views of the compression tool, showing the compression tool in a large shut height position and in a small shut height position. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  is a front perspective view of a compression tool  10  formed in accordance with an exemplary embodiment. The compression tool  10  is used for terminating wires (not shown) to a connector  12 . Optionally, the wires may be laced into a wire organizer integrated into the connector  12  and terminated to the connector  12  when the connector  12  is compressed within the compression tool  10 . Alternatively, a separate lacing feature, which is part of the compression tool  10 , may be provided and used with the compression tool  10  to terminate the wires to the connector  12 . 
     The compression tool  10  is operated to press the connector  12  onto the wires to terminate the wires to the connector  12 . For example, the connector  12  may include insulation displacement contacts (IDCs) that are pressed onto the wires to terminate the wires to the connector  12 . Optionally, the wires may be twisted wire pairs that are terminated to the connector  12 . 
     The connector  12  includes a housing  14  along a longitudinal axis  15  extending between a cable end  16  and a mating end  18 . A cable, including a plurality of the wires, is fed into the connector  12  through the cable end  16 . The cable may be terminated to the connector  12  inside of the housing  14 , or alternatively may be terminated to the connector  12  at the cable end  16 . The tool provides compression in a direction along the longitudinal axis  15  to terminate the wires to the connector  12 . 
     The compression tool  10  includes a frame  20  having a receiving space  22  that receives the connector  12 . The compression tool  10  also includes a handle  24  rotatably coupled to the frame  20  and a ram  26  held by the frame  20  and actuated by the handle  24 . The ram  26  has an engagement end  28  positioned within the receiving space  22  that is configured to engage the connector  12 . The ram  26  is moveable between an initial position and a final position to compress the wires into the connector  12  the wires to terminate the connector  12 . The ram  26  is moveable within the receiving space  22  in a direction parallel to the longitudinal axis  15  to press the connector  12  onto the wires. 
     In an exemplary embodiment, and as describe in further detail below, the ram  26  is variably positionable with respect to the handle  24  to selectively change a shut height of the compression tool  10 . The shut height is defined as a distance between the engagement end  28  of the ram  26  and an end wall  30  of the frame  20  that defines an end of the receiving space  22 . The connector  12  is pressed against the end wall  30 , and the end wall  30  defines a stop for the connector  12  during compression of the compression tool  10 . 
     During use of the compression tool  10 , the handle  24  is rotated or squeezed toward the frame  20  to a closed position. In the closed position, the handle  24  engages the ram  26  to stop the closing action of the handle  24 . As the handle  24  is squeezed closed, the handle  24  presses the ram  26  in a compression direction, shown by the arrow A, in which the engagement end  28  of the ram is pressed toward the connector  12  along the longitudinal axis  15 . The ram  26  is pressed from the initial position to the final position, and the final position of the ram  26  corresponds with the closed position of the handle  24 . In an exemplary embodiment, the ram  26  has more than one final position, such that the engagement end  28  of the ram  26  is positioned different distances from the end wall  30 , defining different shut heights. 
     The compression tool includes a link  32  that extends between the handle  24  and the ram  26 . Closing movement of the handle  24  is transferred to the ram  26  by the link  32 . In an exemplary embodiment, the link  32  is variably positionable with respect to at least one of the handle  24  or the ram  26  to change the final position of the ram  26  within the receiving space  22  to control the shut height of the compression tool  10 . The link  32  is variably positionable with respect to at least one of the handle  24  or the ram  26  to control an effective position of the handle  24  with respect to the ram  26  to define at least two final positions of the ram  26 . In the illustrated embodiment, the link  32  is variably positionable with respect to the ram  26  at a separable interface to change the shut height. Alternatively, the link  32  may be variably positionable with respect to the handle  24  to change the shut height. 
     The frame  20  includes a right shell  34  and a left shell  36  coupled together. The handle  24 , ram  26  and link  32  are received in the frame  20  between the right and left shells  34 ,  36 . The frame  20  includes an opening  40  having at least two frame slots  42 ,  44 , representing an upper frame slot  42  and a lower frame slot  44  with a connecting section  46  therebetween. Optionally, the frame  20  includes a J-shaped opening defining the upper frame slot  42  and a J-shaped opening defining the lower frame slot  44 . The upper frame slot  42  extends to a back end  43 . The lower frame slot  44  extends to a back end  45  (shown in phantom). Optionally, the back end  45  may be positioned further rearward than the back end  43 . The frame slots  42 ,  44  define different travel paths. In an exemplary embodiment, the frame slots  42 ,  44  define travel paths having different lengths. The link  32  includes a selector  48  that is received in the opening  40 . The selector  48  is positionable in one of the frame slots  42  or  44  to change the position of the link  32  with respect to the ram  26 . During actuation of the handle  24 , the selector  48  travels along the travel path defined by either the upper frame slot  42  or the lower frame slot  44 . A travel distance of the selector  48  may be different when traveling along the travel path defined by the upper frame slot  42  as opposed to the travel path defined by the lower frame slot  44 . The different lengths of travel correspond to different lengths of travel of the ram  26  within the receiving space  22 . 
     In the illustrated embodiment, the upper frame slot  42  is shorter than the lower frame slot  44 . The upper frame slot  42  is positioned forward of the lower frame slot  44 . When the selector  48  is in the upper frame slot  42 , the link  32 , and thus the ram  26 , is configured to be moved further forward such that the engagement end  28  is pressed further into the receiving space  22 . When the selector  48  travels along the travel path defined by the lower frame slot  44 , the link  32 , and thus the ram  26 , do not travel as far forward and thus the engagement end  28  does not travel as far forward into the receiving space  22 . The compression tool  10  is configured to accommodate longer connectors  12  when the selector  48  is in the lower frame slot  44 . The compression tool  10  accommodates shorter connectors  12  when the selector  48  is in the upper frame slot  42 . 
       FIG. 2  is a rear perspective view of a portion of the compression tool  10 , with the left shell  36  (shown in  FIG. 1 ) removed for clarity. The right shell  34  is illustrated in  FIG. 2 , along with the handle  24 , the ram  26  and the link  32 . 
     The handle  24  includes an arm  60  extending between a fixed  62  and a free end  64 . The fixed end  62  includes posts  66  that extend outward and are received in pockets (not shown) of the frame  20 . A pivot axis  68  is defined through the posts  66 . The handle  24  is rotated about the pivot axis  68 . The posts  66  hold the handle  24  within the frame  20 . The arm  60  may be pushed or pulled between open and closed positions. In  FIG. 2 , the arm  60  is shown in a closed position, while the open position is shown in  FIG. 1 . The arm  60  includes a handle stop  70  extending from a bottom thereof. In the illustrated embodiment, the handle stop  70  is L-shaped. The handle stop  70  defines a latch that is configured to engage the ram  26  to hold the handle  24  in the closed position, such as for storage of the compression tool  10 . 
     The link  32  extends between a ram end  72  and handle end  74 . The ram end  72  engages the ram  26 . The handle end  74  engages the handle  24 . In the illustrated embodiment, the handle end  74  is fixedly coupled to the handle  24 . In the illustrated embodiment, the handle end  74  is rotatably coupled to the handle  24  using a pin  76 . As the handle  24  is moved between the open and closed position, the link  32  rotates about the pin  76 . 
     The ram end  72  is separably coupled to the ram  26 . The ram end  72  may be variably positionable with respect to the ram  26  to control the shut height of the compression tool  10 . For example, the ram  26  may be disengaged from the ram end  72  such that the link  32  may be repositioned with respect to the ram  26 , and then ram  26  may reengage the ram end  72  at a different portion of the ram  26 . The selector  48  is coupled to the link  32  at the ram end  72 . 
     The selector  48  may extend from one or both sides of the link  32  such that the selector  48  may be received in the opening  40  and/or a corresponding opening in the left shell  36  (not shown). 
     The ram  26  includes a body  80  extending between the engagement end  28  and an actuation end  82 . A portion of the body  80  extends into the receiving space  22 , while another portion of the body  80  is held internal of the frame  20 . In an exemplary embodiment, the ram  26  is spring loaded by a spring  84  that forces the ram  26  in a rearward direction. The force of the spring  84  may be overcome by closing the handle  24  to push the ram  26  forward into the receiving space  22 . The spring force  84  may also be overcome by pulling on finger grips  86  at the engagement end  28  to pull the ram  26  forward. 
     The body  80  includes a ram stop  88  extending from a top of the body  80 . The ram stop  88  defines a latch that engages the handle stop  70  to hold the handle  24  in the closed position. When the ram  26  is released, the spring  84  pushes the ram  26  rearward to hold the ram stop  88  in a blocking position over the handle stop  70 . Pulling on the finger grips  86  pulls the ram  26  forward such that the handle  24  may be released and the handle stop  70  is able to clear the ram stop  88  to move the handle  24  to the open position. 
     The ram  26  includes a plurality of ram cradles  90 ,  92  in the actuation end  82 . The ram cradles  90 ,  92  are configured to receive the ram end  72  of the link  32 . The ram end  72  is selectively received in either the ram cradle  90  or the ram cradle  92  to control the shut height. For example, the ram  26  may be actuated to different final positions within the receiving space  22  based on the ram cradle  90  or  92  in which the ram end  72  is received. The ram cradles  90 ,  92  are open at the actuation end  82 . The ram cradles  90 ,  92  have bottoms  94 ,  96 , respectively, opposite the open ends thereof. The bottoms  94 ,  96  are offset along a ram axis  98  extending between the engagement end  28  and the actuation end  82 . For example, the bottom  94  of the ram cradle  90  is offset forward (e.g., toward the engagement end  28 ) with respect to the bottom  96 . The bottom  96  of the ram cradle  92  is offset rearward (e.g., toward the actuation end  82 ) with respect to the bottom  94 . The ram cradle  90  is positioned above the ram cradle  92 . 
     A separating wall  100  is defined between the ram cradle  90  and the ram cradle  92 . In the illustrated embodiment, the ram cradles  90 ,  92  are curved to receive the selector  48  at the ram end  72  therein. The spring  84  holds the ram  26  against the selector  48  and/or link  32  to hold the selector  48  within the corresponding ram cradle  90  or  92 . The ram cradles  90 ,  92  are sized and shaped to hold the selector  48  therein. The separating wall  100  restricts movement of the selector  48  from one ram cradle  90  or  92  to the other ram cradle  90  or  92 . The separating wall  100  avoids accidental adjustment of the link  32  with respect to the ram  26 . 
     In order to move the link  32  from one ram cradle  90  or  92  to the other ram cradle  90  or  92 , the ram  26  is pulled forward against the spring bias of the spring  84  to a clearing position in which the ram end  72  may be freely moved up or down within the opening  40  to align the selector  48  with the upper frame slot  42  or the lower frame slot  44  (shown in  FIG. 1 ). Once the link  32  is properly positioned, the ram  26  may be released and the spring  84  pushes the ram  26  rearward until the selector  48  is positioned within the corresponding ram cradle  90  or  92 . 
     The ram cradles  90 ,  92  define different driving points on the ram  26  for driving the ram  26 . The driving points are located at different depths from the engagement end  28  to change the final position of the ram  26  within the receiving space  22  to control the shut height of the compression tool  10 . For example, the upper ram cradle  90  defines a driving point position forward of the lower ram cradle  92 . When the selector  48  is positioned in the lower ram cradle  92 , the engagement end  28  is driven further forward within the receiving space  22 . The compression tool  10  accommodates shorter connectors  12  (shown in  FIG. 1 ) when the link  32  is received in the lower ram cradle  92 . When the selector  48  is positioned in the upper ram cradle  90 , the ram  26  is driven less into the receiving space  22 . The compression tool  10  accommodates longer connectors  12  when the link  32  is received in the upper ram cradle  90 .  FIG. 3  is a side section view of the compression tool  10  with the left shell  36  (shown in  FIG. 1 ) removed for clarity.  FIG. 3  illustrates the ram  26  in the clearance position such that the link  32  is freely moveable to the different positions for engaging different ram cradles  90 ,  92 . For example, the link  32  may be lifted upward, such as in the direction of arrow B, or may be pressed downward, such as in the direction of arrow C, to position the selector  48  in alignment with the upper ram cradle  90  or the lower ram cradle  92 . Once the link  32  is positioned, the ram  26  is released and the selector  48  is loaded into the corresponding ram cradle  90  or  92 . 
       FIG. 4  illustrates two section views of the compression tool  10 , showing the compression tool  10  in a large shut height position  102  and in a small shut height position  104 . The left shell  36  (shown in  FIG. 1 ) has been removed for clarity. 
     The compression tool  10  is variably positionable between the large and small shut height positions  102 ,  104  by toggling the selector  48  between an up position (corresponding with the large shut height position  102 ) and a down position (corresponding with the small shut height position  104 ). In the large shut height position  102 , the selector  48  is positioned in the upper ram cradle  90 . In the small shut height position  104 , the selector  48  is positioned in the lower ram cradle  92 . In the large shut height position  102 , the compression tool  10  has a first shut height  110  defined between the end wall  30  and the engagement end  28  of the ram  26 . In the small shut height position  104 , the compression tool  10  has a second shut height  112  defined between the end wall  30  and the engagement end  28  of the ram  26 . The second shut height  112  is smaller than the first shut height  112 , with the engagement end  28  of the ram  26  being positioned closer to the end wall  30  to accommodate smaller connectors  12  (shown in  FIG. 1 ). A difference  114  between the first and second shut heights  110 ,  112  is shown in  FIG. 4 . The amount of difference  114  may be different in alternative embodiments. Additionally, more than two different positions may be achieved by the compression tool  10  in alternative embodiments by providing more ram cradles, such as to accommodate more than two different sized connectors  12 . 
     The compression tool  10  has an effective arm length defined between the engagement end  28  and the pivot point between the link  32  and the handle  24 , defined at the pin  76 . The effective arm length determines the shut height. The effective arm length is a function of an effective ram length and an effective link length. The effective lengths are measured linearly along the longitudinal axis of the compression tool  10 . 
     The effective ram length is defined between the engagement end  28  and the bottom  94  or  96  of the ram cradle  90 ,  92  that holds the link  32 . Because the bottoms  94 ,  96  are positioned at different axial positions along the ram axis  98 , the effective ram length is variable based on which ram cradle  90  or  92  in which the link  32  is received. The bottom  94  of the upper ram cradle  90  is positioned forward of the bottom  96  of the lower ram cradle  92  making the effective ram length shorter when the link  32  is received in the upper ram cradle  90  and longer when the link  32  is received in the lower ram cradle  92 . In the illustrated embodiment, in the large shut height position  102 , the effective ram length is represented by a length  120 . In the small shut height position  104 , the effective ram length is represented by a length  122 . The length  122  is longer than the length  120 . 
     The effective link length is defined between the engagement point between the selector  48  and the bottom  94  or  96  and the pivot point at the pin  76 . The effective link length is also controlled based on an angle  124  or  126  of the link  32 . Because the link  32  is rotatable, the angles  124 ,  126  are different, which affects the effective link length. In the illustrated embodiment, in the large shut height position  102 , the effective link length is represented by a length  128 . In the small shut height position  104 , the effective link length is represented by a length  130 . When the link  32  is received in the upper ram cradle  90 , the effective link length  128  is longer. When the link  32  is received in the lower ram cradle  90 , the effective link length  130  is shorter because the angle  126  is greater than the angle  124 . 
     The effective arm length is the sum of the effective ram length and the effective link length. In the illustrated embodiment, in the large shut height position  102 , the effective arm length is represented by a length  132 . In the small shut height position  104 , the effective arm length is represented by a length  134  which is longer than the length  132 . Because the effective arm length  134  is longer than the effective arm length  132 , the shut height  112  is smaller than the shut height  114 . In the small shut height position  104 , the ram  26  is pushed further forward into the receiving space  22  closer to the end wall  30 . 
     The compression tool  10  includes an assembly that allows the shut height to be selectable to accommodate different size connectors  12 . The selector  48  is variably positionable with respect to the ram  26  to change the effective arm length of the ram  26 /link  32 . The ram  26  has different ram cradles  90 ,  92  to receive the selector  48  to vary the position of the link  32  with respect to the ram  26 . The frame  20  has different frame slots  42 ,  44  that accommodate the selector  48  in the different positions. In an alternative embodiment, the link  32  may be variably positionable with respect to the handle  24  in addition to, or in the alternative to, the ram  26  to define multiple shut heights for the compression tool  10 . 
     It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.