Patent Abstract:
A termination tool for terminating multiple wires to a two part electrical connector assembly composed of a wire arrangement manifold and a jack housing is provided by the present disclosure. The termination tool includes a main tool body having a termination housing provided thereon including a first cavity, a second cavity and a passage extending between the first and second cavities. The first cavity has an open side to receive and is shaped to removably retain a wire arrangement manifold, the second cavity having an open side to receive and being shaped to removably retain a jack housing, and the passage being sized to allow, in use, the wire arrangement manifold to pass therethrough from the first cavity to the second cavity and having cutting means provided on opposing sides of its end proximate to the first cavity.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of International Application No. PCT/GB2009/000520 filed on Feb. 25, 2009, which claims the benefit of GB 0804043.8, filed Mar. 4, 2008. The disclosures of the above applications are incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to a termination tool and corresponding male and female connectors. 
     BACKGROUND 
     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
     Termination tools exist in many different forms, with the desirable characteristics including portability, ease of assembly, ease of use and reliable termination of the connector to communication wires. 
     US Patent Publication No. 2006/0230608 describes a termination tool for use with network jack plugs and sockets such as CAT 5e, CAT 6, etc. The tool is designed to work in two distinct stages. An electrical connector wire arrangement manifold is prepared by inserting wires into the relevant connector slots on said wire arrangement manifold and placing the cap into a cavity on one side of the tool. Adjacent to said cavity are cutting means, mounted such that upon actuation of a trigger mechanism the cutting means are urged astride the prepared wire arrangement manifold, severing any excess wires protruding thereon and driving the wires securely into the connector slots. A second, separate cavity is provided on the other side of the tool into which the trimmed wire arrangement manifold and a jack housing are inserted adjacent each other. Actuation of the trigger mechanism urges a ram against the wire arrangement manifold, pressing it into engagement with the jack housing, whereupon the wires in the wire arrangement manifold make electrical contact with connection terminals in the jack housing, thus securing the wire arrangement manifold within the jack housing, and terminating wire arrangement manifold and housing sections of the electrical connector. 
     However, this device suffers from the disadvantage of requiring two distinct operations to be performed; the trimming of wires protruding from the prepared wire arrangement manifold and then the repositioning of said wire arrangement manifold such that a ram may be used to urge the wire arrangement manifold into engagement with a jack housing. 
     SUMMARY 
     According to the present disclosure there is provided a termination tool for terminating multiple wires to a two part electrical connector assembly composed of a wire arrangement manifold and a jack housing, the termination tool comprising a main tool body having a termination housing provided thereon including a first cavity, a second cavity and a passage extending between the first and second cavities, the first cavity having an open side to receive and being shaped to removably retain the wire arrangement manifold, the second cavity having an open side to receive and being shaped to removably retain the jack housing, and the passage being sized to allow, in use, the wire arrangement manifold pass therethrough from the first cavity to the second cavity and having cutting means provided on opposing side of its end proximate to the first cavity, the termination tool further comprising a ram aligned with the passage and actuatable to move between a retracted position in which the ram is withdrawn from the first cavity and a second position in which the ram extends through the passage so as, in use, to press the wire arrangement manifold from the first cavity, through the passage and into engagement with the jack housing located in the second cavity, the cutting means severing any overhanging wire tails from the sides of the wire arrangement manifold as it enters the passage. 
     A termination tool is thus provided where corresponding male and female connectors are arranged such that in one motion the tool is used to cut multiple electrical connector wires and then terminate wire arrangement manifold and housing sections of an electrical connector. A termination tool in accordance with the present disclosure has the advantage that the whole termination operation is performed in a single operation, increasing efficiency. 
     In one form, the first cavity is of complementary shape to and a close tolerance fit with the wire arrangement manifold such that, in use, the wire arrangement manifold is constrained against lateral movement in the first cavity. Similarly, the second cavity is of complementary shape to and a close tolerance fit with the jack housing such that, in use, the jack housing is constrained against lateral movement in the second cavity. In this way, the wire arrangement manifold and jack housing are accurately aligned with each other so as to ensure reliable termination upon actuation of the tool. 
     In one form, the first cavity includes a groove in each side surface thereof adjacent the cutting means at the mouth of the passage in which, in use, tails of wires inserted into the wire arrangement manifold are received so as to align them for trimming by the cutting means upon operation of the tool. This has the further advantage that the longitudinally asymmetric configuration of the grooves prevents insertion of the wire arrangement manifold into the first cavity in the wrong orientation since the wire tails will then not align with the grooves and hence the close tolerance fit of the wire arrangement manifold in the first cavity will prevent entry of the wire arrangement manifold into the first cavity. 
     The cutting means, in one form, comprises a pair of blades, one on either side of the mouth of the passage. Further advantageously, the position of the cutting means is related to the thickness and spacing of wires in the wire arrangement manifold, such that, in use, the leading edge of the cutting means engages with, and subsequently severs, the wire tails sequentially, rather than simultaneously. This has the advantage of reducing the force required to operate the tool and therefore, for example, reducing a required actuator pivot length or the like. The sequential severing of the wire tails could be achieved by offsetting the cutting means either side of the mouth of the passage relative to each other, by inclining the cutting edge of the cutting means relative to the direction of movement of the wire arrangement manifold or by a combination of the two. Preferably the wire tails are severed in pairs and further advantageously the cutting means is positioned such that the severance of a pair of wire tails by the cutting means is completed before the next pair of wire tails is subsequently engaged by the leading edge of the cutting means. The width of the passage is also advantageously equal in width to the first cavity. 
     The passage may include a longitudinally extending rib on the top of each side, which reduces the width of the passage at the top and thereby prevents the wire arrangement manifold from being removed from the passage during operation of the tool. 
     In one form, the second cavity includes one of a projection and a recess in a side thereof, in particular the side opposite the passage, and the jack housing includes a complementary other of a projection and a recess which aligns with the one of the projection and the recess when the jack housing is correctly oriented with respect to the second housing. This has the advantage that it ensures proper alignment of the jack housing upon insertion since it will be prevented from entering the second cavity if wrongly oriented. In a preferred embodiment, the jack housing includes a tab, which engages in a slot, which extends from the open side of the second cavity. 
     The open sides of the first and second cavities are on the same side of the tool in one form of the present disclosure. 
     The depth of the first cavity is preferably such that when the wire arrangement manifold is fully inserted therein, it aligns with the passage. Similarly, the depth of the second cavity is preferably such that, when the jack housing is fully inserted therein, an opening in the jack housing in which the wire arrangement manifold engages for effecting termination is aligned with and facing the passage. 
     In one form, the tool is hand operated, including trigger which is connected to the ram so as to effect longitudinal movement of the ram from its retracted position to its extended position. A ratchet mechanism is advantageously integrated with the trigger mechanism, which operates to prevent retraction of the ram, once operative movement has commenced, until the ram has reached its fully extended position. This has the advantage that it ensures that proper termination occurs between the wire arrangement manifold and the jack housing. Other means may also be provided which prevents operation of the trigger until a wire arrangement manifold has been properly inserted into the first cavity and a jack housing has been properly inserted into the second cavity. 
     The trigger may be spring-loaded to effect return of the ram to its retracted position once the termination stroke has been completed. 
     The present disclosure further provides a wire arrangement manifold for use with a termination tool according to the disclosure, comprising a body having an end surface with an opening therein through which, in use, a cable formed of a plurality of separate wires is insertable, a front face having a plurality of notches formed therein proximate to at least one side of the wire arrangement manifold, each notch size to retain one of the wires of the cable therein, and a passage extending from the opening in the end surface to the front face for channelling the wires to the notches. 
     In one form, the notches in the front face of the wire arrangement manifold are arranged in two rows, one extending along each side of the body, with the notches being equi-spaced along the body. In particular, the end housing has eight notches arranged in two rows of four. 
     The body in one form is rectangular in shape, at least when viewed in the direction of the front face. The opening in the end face is preferably open to the back of the end housing, the passage taking the form of a through opening which extends from the back to the front face of the body. 
     The present disclosure still further provides a jack housing for matingly engaging with the wire arrangement manifold of the disclosure, the jack housing comprising a body having a socket formed in a front end therein containing a plurality of contacts, an opening in a top side of the body and a plurality of termination jaws upstanding from the bottom of the opening, each termination jaw being electrically connected to an associated one of the contacts, the opening being of complementary size and shape to the wire arrangement manifold such that, in use, the wire arrangement manifold is insertable into the opening from the top thereof such that each wire located in one of the notches in the wire arrangement manifold engages between one of termination jaws, effecting electrical contact therewith. 
     In one form, the back wall of the opening in the jack housing has a slot formed therein extending from the top edge, the cable extending from the wire arrangement manifold, in use, being received in the slot as the wire arrangement manifold engages in the opening. 
     The bottom of the body advantageously has a guide tab thereon of narrower width than the main body, which, in use, aligns with and engages in a complementary shaped recess formed in the second cavity when the jack housing is correctly oriented with respect to the second cavity and prevents entry of the jack housing into the second cavity in the wrong orientation. The guide tab is advantageously formed as a mounted hook for latching the jack housing in place in a patch panel, wall mounting or the like. 
     In one form, the opening includes eight termination jaws arranged in two rows of four to complement the arrangement of the notches in the wire arrangement manifold, each jaw being composed of a pair of metal prongs with a space between them which narrows towards the base of the opening such that as a wire is pressed therebetween, the jaws progressively cut through the insulation on the wire and make electrical contact with the core of the wire. 
     Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which: 
         FIG. 1  is a side view of an apparatus according to the invention, showing the insertion of a jack housing and wire arrangement manifold; 
         FIG. 2  is an exploded perspective view of the apparatus of  FIG. 1 ; 
         FIGS. 3(   a ),  3 ( b ) and  3 ( c ) are partial perspective views of the apparatus of  FIG. 1 , showing extension of the ram; 
         FIGS. 4(   a ) and ( b ) are overhead views of the first and second cavities at retracted and extended positions of the ram, showing the shape of each cavity; 
         FIG. 5  is a perspective view of the apparatus of  FIG. 1 , showing the apparatus fully engaged; 
         FIG. 6  is a perspective view of the apparatus of  FIG. 1 , showing retraction of the ram and subsequent removal of the electrical connection assembly; 
         FIG. 7  is a perspective view of the jack housing and wire arrangement manifold; 
         FIG. 8  is a perspective view of the wire arrangement manifold cover; 
         FIG. 9  is a perspective view of the assembled jack housing, wire arrangement manifold and cover; and 
         FIG. 10  is a perspective view of the assembled jack housing, wire arrangement manifold and cover showing the jack socket. 
     
    
    
     The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. 
     Referring first to  FIGS. 1 ,  2  and  3 , there is shown a hand-held termination tool  100  for effecting automated termination of an wire arrangement manifold  101  into a jack housing  102  for providing electrical connection between wires  103  mounted in the wire arrangement manifold  101  and contact jaws  104  provided in the jack housing  102 . The termination tool  100  has a main tool body  105  with a handle  106  fast with the body  105  and a trigger  107  pivotally attached to the body  105  and operably moveable towards the handle  106  in order to effect movement of a ram  108  as described hereinafter. Biasing means such as a spring (not shown) is connected to the trigger  107 , which urges the trigger  107  away from the handle  106 . Attached to the front portion of the main tool body  105  is a termination housing  109  having a pair of spaced apart cavities  110  and  111  formed therein, each of which extends to the top  109   a  of the termination housing  109 , and a passage  112  which extends between the first and second cavities  110 ,  111  so as to allow movement of an element from the first cavity  110  to the second cavity  111  as described below. 
     As shown in  FIG. 3   c , the first cavity  110  is generally rectangular in cross section and is sized to enable the wire arrangement manifold  101  to be engaged end on into the cavity from the top side  109   a  of the housing  109  with a close tolerance fit such that the wire arrangement manifold  101  is restrained from lateral movement within the first cavity  110 . The first cavity  110  furthermore includes a pair of side wing slots  113 , one formed in each side wall of the cavity proximate to the end where it meets the passage  112 , each slot  113  extending from the top side  109   a  of the housing  109  substantially the full depth of the first cavity  110 . 
     The second cavity  111  is similarly generally rectangular in cross section but is of a larger cross section and depth compared with the first cavity  110  to accommodate the larger size of the jack housing  102 . As with the first cavity  110 , the cross section of the second cavity  111  is sized to enable the jack housing  102  to be slid end on into the second cavity  111  from the top side  109   a  of the housing  109 , there being a close tolerance fit between the jack housing  102  and the sides of the second cavity  111  so as to prevent lateral movement of the jack housing  102  and hence accurately locate the jack housing  102  laterally therein. The depth of the first and second cavities  110 ,  111  are furthermore set so that when the wire arrangement manifold  101  and jack housing  102  are fully inserted into their respective cavities, they are accurately longitudinally located relative to each other as well as relative to the passage  112 . 
     The passage  112  which extends between the two cavities  110 ,  111  is sized laterally to be a close tolerance fit with the wire arrangement manifold  101  so that the wire arrangement manifold  101 , once fully inserted into the first cavity  110 , can move longitudinally through the passage  112  and into the second cavity  111  and has the same depth as the first cavity  110 . A cutting blade  114  is located on each side of the mouth of the passage  112  at the intersection with the first cavity  110  in alignment with the wing slots  113 , the blades  114  extending substantially the entire depth of the passage  112  and being laterally spaced apart such that the wire arrangement manifold  101  is a close tolerance fit therebetween. The cutting blades  114  are cutting means for cutting wires. 
     Although not shown in the illustrated embodiment, the passage  112  may optionally have a rib extending longitudinally along each side proximate to the top, which forms a constriction in the cross section, preventing the wire arrangement manifold  101  from moving vertically as it moves through the passage  112 . 
     Ram  108  is mounted in the main body  105  in alignment with the passage  112  and is pivotally connected to the end of the trigger  107  so that when the trigger  107  is operated, the ram  108  is moved forwards into the termination housing  109  from a retracted position (shown in  FIG. 2 ) in which it is fully withdrawn into the main body  105  and out of the first cavity  110 , and an extended position in which it is moved longitudinally through the first cavity  110  and into the passage  112 , projecting into the second cavity  111  as shown in  FIG. 4   b . Guides  115  channel the path of the ram  108  so as to constrain it to move only in the longitudinal direction. The trigger  107  also includes a ratchet mechanism  120 , which controls the forward movement of the ram  108  and prevents it from being withdrawn back into its retracted position until it has reached its fully extended position. Such mechanisms are within the practical knowledge of the skilled person and will not, therefore, be described here in greater detail. 
     The wire arrangement manifold  101 , shown in more detail in  FIG. 7  comprises a generally rectangular body  101   a  having a through opening  101   b  therein which links to an opening  101   c  in the rear end of the body. A series of notches  116  are formed in the opposing sidewalls extending from the bottom edge thereof, in the illustrated embodiment four equi-spaced notches  116  in each sidewall, in each of which is engageable a single wire of a cable bundle. As shown in  FIG. 2 , the cable  117  is fed through the rear opening  101   c  and the wires  103  are fed through the opening  101   b  to the bottom of the wire arrangement manifold  101 . Each wire  103  is then located in its allotted notch  116 , identified by colour coding or the like provided on each side of the body  101   a  in alignment with the notches  116 , with the free end of the wire  103  extending laterally from the sides of the wire arrangement manifold  101 . 
     The jack housing  102 , also shown in  FIG. 7 , again comprises a generally rectangular body  102   a  having a jack socket  102   b  in its front face (shown in  FIG. 10 ) with a plurality, in particular eight contacts therein. The top  102   c  of the body  102   a  has a rectangular opening  102   d  formed therein in the bottom  102   e  of which are upstanding a plurality, in particular eight, contact jaws  104 , each of which is electrically connected to one of the contacts of the jack socket  102   b . The jaws  104  are of the type known in the art which are self-terminating with an inserted wire, that is they automatically cut through any insulation on an appropriately sized wire pressed between the jaws so as to make electrical contact with the inner core of the wire, and they are arranged in two spaced apart rows of four jaws corresponding to the pattern of the notches  116  in the wire arrangement manifold  101 . The opening  102   d  is bound by opposing sidewalls; a front wall and a rear wall, which has a through opening, formed therein which extends to the top of the opening  102   d . The opening  102   d  is sized such that the wire arrangement manifold  101  is a press fit therein through the open top of the opening  102   d  with the tail of a cable which extends from the wire arrangement manifold  101  locating in the through opening in the rear wall of the opening  102   d , each notch  116  in the wire arrangement manifold  101  aligning the wire  103  located therein with one of the jaws  104  so that as the wire arrangement manifold  101  is pressed fully into the opening  102   d , each wire  103  engages in its associated jaw  104  and makes electrical contact therewith. 
     A cover  121 , as shown in  FIGS. 8 and 9 , fits over the wire arrangement manifold  101  and secures into the jack housing  102  at the opening  102   d  so as to protect the terminated wires  103  and provide an enclosed casing in which the wire arrangement manifold  101  is held. A recess  102   f  surrounding the opening  102   d  in the jack housing  102  is sized such that the cover  121  is a press fit therein. An opening  121   a  in the cover  121  allows the cable  117  to be fed through. 
     The tools operates as follows: 
     The cable  117  is fed through the opening  121   a  of the cover  121  and then through the rear opening  101   c  of the wire arrangement manifold  101 . The wires  103  are then inserted through the through opening  101   b  and each wire  103  pressed into one of the notches  116  with the excess wire  103  overhanging the sides of the wire arrangement manifold  101 . The jack housing  102  is then inserted into the second cavity  111  with the rectangular opening  102   d  in the top thereof facing the first cavity  110 . A mounted hook  118  is provided on the bottom of the jack housing  102  which has a smaller width than the main body  105  and a complementary channel  119  is formed on the side of the second cavity  111  remote from the first cavity  110  such that when the jack housing  102  is inserted into the second cavity  111  in the correct orientation the mounted hook  118  engages in the channel  119 , allowing the jack housing  102  to be fully inserted into the second cavity  111 , whereas if the jack housing  102  is presented to the termination housing  109  in the wrong orientation, the differing width of the second cavity  111  and guide channel  119  prevents the jack housing  102  from being inserted. 
     The wire arrangement manifold  101  is then inserted into the first cavity  110  with the bottom  101   d  facing the second cavity  111  so that the notches  116  open towards the second cavity  111 . When the wire arrangement manifold  101  is aligned with the first cavity  110  in the correct orientation as shown in  FIG. 3   a , the projecting tails of the wires  103  align with the wings slots  113 , providing the extra space to allow the wire arrangement manifold  101  to slide into the first cavity  110 . On the other hand, if the wire arrangement manifold  101  is presented to the first cavity  110  in the wrong orientation, the offset configuration of the notches  116  means that the wire tails  103  do not align with the wing slots  113 , so that the close tolerance fit between the wire arrangement manifold  101  and the first cavity  110  prevents the wire arrangement manifold  101  from entering the first cavity  110 . 
     Once both the wire arrangement manifold  101  and the jack housing  102  are fully inserted into their respective cavities  110 ,  111  the trigger  107  is pressed towards the handle  106 , moving the ram  108  towards the first cavity  110 , engaging the wire arrangement manifold  101  and pressing it towards the passage  112 . As the wire arrangement manifold  101  is engaged by the ram  108 , the tails of the wires  103  overhanging either side of the wire arrangement manifold  101  are pressed against the cutting blades  114 , severing the wires  103  flush with the sides of the wire arrangement manifold  101  and freeing the wire arrangement manifold  101  to move through the passage  112  and into engagement with the aligned rectangular opening  102   d  in the top facing of the jack housing  102  as shown in  FIG. 3   b . Although not shown in the illustrated embodiment the cutting surfaces of the cutting blades  114  are angled with respect to the vertically aligned wires  103  such that they engage with, and subsequently cut, the wires sequentially. The wires  103  opposing each other on either side on the wire arrangement manifold  101  are severed in pairs—the cut of each pair of wires  103  is completed before the leading edge of the cutting blade  114  engages with and then cuts the next pair. 
     As the ram  108  reaches its fully extended position, the wire arrangement manifold  101  is pressed fully into the jack housing  102  shown in  FIG. 3   c , and the wires  103  mounted in the notches  116  are pressed into engagement with the aligned contact jaws  104  upstanding from the base  102   e  of the opening  102   d  in the jack housing  102 , making electrical contacts therewith. The ratchet mechanism  120  prevents the trigger  107  from being released to withdraw the ram  108  back to its retracted position until it has reached its fully extended position, thereby ensuring that the electrical connections are properly made. Once the fully extended position is reached, release of the trigger  107  causes it to move away from the handle  106  under the action of the biasing means, withdrawing the ram  108  from the cavities  110 ,  111  and releasing the jack housing  102  with wire arrangement manifold  101  fastened thereto to be withdrawn from the second cavity  111 . The severed tails of the wires  103  are free to drop out of the wing slots  113  and the tool is ready for the next termination operation. Finally, on removal of the terminated wire arrangement manifold  101  and jack housing  102  from the termination housing  109 , the cover  121  is manually pressed into the recess  102   f  in the jack housing  102  so as to enclose the terminated wires  103 . 
     Thus, the hand-held tool can be used to achieve a terminated connector assembly by the action of one continuous motion; trimming the connector wires and terminating connector halves, without the need to stop to reposition components. 
     It should be noted that the disclosure is not limited to the embodiment described and illustrated as examples. A large variety of modifications have been described and more are part of the knowledge of the person skilled in the art. These and further modifications as well as any replacement by technical equivalents may be added to the description and figures, without leaving the scope of the protection of the disclosure and of the present patent.

Technology Classification (CPC): 8