Abstract:
A seal for sealing a connector having a test aperture includes a body and a latch formed with the body, the latch including a first deflection beam formed on one side of the body and a second deflection beam formed on an opposite side of the body. The latch also can include a first hook formed with the first deflection beam and a second hook formed with the second deflection beam. The first hook and the second hook are each pivotable between a first latched position and a second unlatched position when the first deflection beam and the second deflection beam are compressed.

Description:
FIELD OF THE INVENTION 
     This invention relates to the field of telephone wire connector blocks and distribution systems, and specifically for a cap or seal for sealing a test channel of a connector. 
     BACKGROUND OF INVENTION 
     In a telephone network, a network cable from the central office is connected to a building entrance protector (BEP) located at the customer site, where the individual telephone lines are broken out line-by-line. The network cable, which consist of a plurality of tip-ring wire pairs that each represent a telephone line, is typically connected to a connector block that forms a part of the BEP. Such connectors may be, for example, mini rocker tool-less insulation displacement (IDC)-type connectors, such as, for example, those sold by A. C. Egerton, Ltd. Other connectors used for telephony wiring applications are described in U.S. Pat. No. 4,662,699 to Vachhani et al., dated May 5, 1987, and in U.S. Pat. No. 3,611,264 to Ellis, dated Oct. 5, 1971. 
     The customer telephone equipment is coupled through such an IDC connector to, for example, a central office telephone line. The connector generally has a top section that includes two wire insertion holes and a bottom section that houses a pair of terminal strips. The wire insertion holes each accommodate one wire of a tip-ring wire pair. The top section pivots about a generally hinged fixed axis located on the side opposite the wire insertion holes and has a movable clasp for maintaining the top section in its closed position. 
     To open the top section, a user releases the clasp member and pivots the top section to its open position. When the top section is in its open position, the terminal strips do not intersect the wire insertion holes, but when the top section is in its closed position, the terminal strips intersect the wire insertion holes. Therefore, to establish an electrical and mechanical connection between the wires and the terminal strips, a user first opens the top section (i.e., pivots the top section to its open position), inserts the pair of wires, and then closes the top section. Upon closing the top section of the connector, the wires are brought into electrical and mechanical contact with the terminal strips. To remove the wires and/or break the electrical connection, the process is reversed. 
     To verify the integrity of a telephone line, the telephone line may be tested at the connector. The size of a connector makes it difficult for a craftsperson to manipulate the connector without the risk of compromising the connection between the wire and the terminal strip within the connector. For this reason, conventional connectors have been designed to afford test access by providing test channels that are open at all times. In this way, the chance of disrupting the electrical connection during testing is minimized. The connector itself, however, is left vulnerable to elements, such as dust or other particles, which can damage the integrity of the connector and the electrical connection. To minimize potential damage to the connector, it is desirable to provide a connector that has test channels that are closed at all times, except when access is required to test a particular connector. 
     SUMMARY OF THE INVENTION 
     The present invention is directed at overcoming the shortcomings of the prior art. A connector can be provided that includes a housing having a test channel, a terminal strip disposed within the housing and in communication with the test channel, and a membrane that seals the test channel. In this way, unlike conventional connectors, which have test channels that are open at all times, the connector of the present invention does not include conventional test channels. Instead, the test channels are closed to outside contaminants by a membrane. 
     In addition, an access tool can be provided that includes a first plier member having a first jaw and a first grip pivotably mounted to the first jaw, a second plier member having a second jaw and a second grip pivotably mounted to the second jaw, and an awl having a first rod pivotably mounted to the first grip, a second rod pivotably mounted to the first rod and to the second grip, and a punch slidably mounted to the first and second jaws for sliding relative to the first and second jaws at a third position. At a first position, the first and second jaws are out of engagement with a cap of a connector; at a second position the first and second jaws are engaged with the cap of the connector, and at a third position, as the first and second grips are squeezed toward one another, the punch moves in a direction away from the tips of the first and second grips to pierce a hole in the membrane covering the test channel access point, thereby permitting the craftsperson to test the connector by inserting a test lead through the now open and accessible test channel and into contact with the terminal strip. 
     In addition, the connector can be provided with a seal that seals the test channel after the connector has been tested. The seal can have a body and a latch movable between a first position wherein the seal is not secured to the connector, and a second position wherein the seal is secured to the connector. In another embodiment, the seal can be a plug that is frictionally fastened within the test channel to seal the channel. Because the connector is generally sealed, the use of sealing gel may be minimized or eliminated. 
     Other objects and features of the present invention will become apparent from the following detailed description, considered in conjunction with the accompanying drawing figures. It is to be understood, however, that the drawings, which are not to scale, are designed solely for the purpose of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawing figures, which are not to scale, and which are merely illustrative, and wherein like reference numerals depict like elements throughout the several views: 
     FIG. 1 is a side elevational view of the test access tool and connector constructed in accordance with the present invention in a first position; 
     FIG. 2 is a side elevational view of the test access tool and connector of FIG. 1 in a second position; 
     FIG. 3 is a side elevational view of the test access tool and connector of FIG. 1 in a third position; 
     FIG. 4 is a front elevational view of the test access tool and connector of FIG. 3; 
     FIG. 5 is a front elevational cross-sectional view of the test access tool and connector taken along line  5 — 5  of FIG. 3; 
     FIGS. 6A and 6B are side elevational views of a seal constructed in accordance with the present invention in a first and second position; 
     FIG. 7 is a front elevational view of the seal of FIG. 6B; 
     FIG. 8 is a side elevational view of a second embodiment of a seal constructed in accordance with the present invention; and 
     FIG. 9 is a front elevational view of the cap of FIG.  8 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Generally speaking, in accordance with the present invention, a connector testing system is provided that provides a more reliable testing configuration, and a connector that is better protected. 
     Referring initially to FIGS. 6B and 7, a connector  10  is shown with a connector seal  80 , which is described more fully herein. Connector  10  includes a top section  12 , a hinge  13 , a bottom section pivotably mounted to top section  12  about hinge  13 , and a clasp  19 , which is selectively movable between an engaged position for engaging top section  12  to bottom section  14  (as shown in FIGS. 6B and 7) and a disengaged position (not shown). Connector  10  has two entrance apertures  22  that lead to wire insertion holes  20 . Wire insertion holes  20  are constructed so as to accept electrical conductors in a manner known in the art (not shown). Connector  10  is preferably formed of a molded synthetic resinous material with good insulating properties and mechanical strength, e.g. a plastic. The specific materials utilized in constructing connector  10  are an application-specific matter of design choice within the knowledge of the person of skill familiar with wiring connectors and terminal blocks utilized in telephony. 
     Connector  10  also includes a pair of terminal strips  30 ,  30 ′ (FIG. 9) and a housing  25  constructed to accept the pair of terminal strips  30  when the top section  12  is in the closed position as shown in FIGS. 6B and 7. Terminal strip  30  may be formed of any commonly known electrically conductive metal or electrical conductor known in the art and suitable for use in such terminals, such as, for example, platinum-washed phosphor bronze, or beryllium-copper alloy or any other material, metal or alloy combining good electrical conductivity with sufficient mechanical strength and resilience. Moreover, the means of affixing terminal strip  30  within connector housing  25  may be by snap fitting or by any one of the numerous methods of affixation known in the art, such as by way of non-limiting example, adhesives, friction fitting, integral molding, screws, and the like, depending on whether ready removal and re-insertion of the terminal is required, as a matter of application-specific design choice. 
     Referring to FIGS. 6A and 6B, an upper portion of top section  12  of connector  10  includes a plinth  21  and a cap  15  having a base  16  that extends from plinth  21 . Cap  15  includes a flange  17 , which extends outward from the top of base  16  and forming a lip thereon, thereby giving cap  15  a substantially t-shaped profile when seen from the side elevational view. 
     To facilitate testing of connections made through connector  10 , test channels  70 ,  70 ′ (FIG. 7) are formed within housing  25 , top section  12  and bottom section  14  to permit test leads or probe tips (not shown) to contact terminal strips  30 . Cap  15  includes a membrane  18  (FIG. 1) that closes one end of test channels  70 ,  70 ′. Membrane  18  may be formed of any molded synthetic resinous material, or it may be a plastic adhesive-backed material, such as for example tape, and should be of a thickness that prevents particles from entering test channel  70 . Membrane  18  is preferably integrally formed with and of the same material as cap  15 , but it may also be a separate member that is fastened to cap  15  by any known affixation means in the art, such as, by way of non-limiting example, adhesives, friction fitting, integral molding, screws, and the like, as a matter of application-specific design choice. 
     Referring now to FIGS. 1-5, a hand held, grippable test access tool  40  for creating a test aperture in a connector having a cap, is provided. As is shown particularly at FIG. 1, test access tool  40  includes a first plier member  41  that has a first jaw  43  and a first grip  42  pivotably mounted to first jaw  43  at a pivot  46 . First jaw  43  includes a first latch  47  for engaging cap  15  of connector  10 . A first spring  45  is mounted at a mounting point  44  formed on first grip  42  and a mounting point  48  formed on first jaw  43 . First spring  45  is fastened to mounting points  44 ,  48  by fasteners  49   a  and  49   b , which may be any fasteners known to those skilled in the art. First spring  45  biases first grip  41  to first jaw  43  at a first position and a second position, shown in FIGS. 1 and 2, respectively. At a third position, shown in FIG. 3, first grip  41  is pivotable relative to first jaw  43  at pivot  46 . As used herein, the term spring is intended to mean any biasing device known in the art, such as, for example, elastic bands, tension rods, leaf springs, and the like. 
     Test access tool  40  also includes a second plier member  51  that has a second jaw  53  and a second grip  52  pivotably mounted to second jaw  53  at a pivot  56 . Second plier member  51  is pivotably mounted to first plier member  41  and is pivotable relative to first plier member  41  at the first and second positions. A second spring  55  is mounted at a mounting point  54  formed on second grip  52  and a mounting point  58  formed on second jaw  53 . Second jaw  53  includes a second latch  57  for acting with first latch  47  to engage cap  15  of connector  10 . Second spring  55  is fastened to mounting points  54 ,  58  by fasteners  59   a  and  59   b , which may be any fasteners known to those skilled in the art. Second spring  55  biases second grip  51  to second jaw  53  at the first and second positions, shown in FIGS. 1 and 2, respectively. At a third position, shown in FIG. 3, second grip  51  is pivotable relative to second jaw  53  at pivot  56 . 
     Test access tool  40  further includes a piercing device, such as an awl  60  having a first rod  61  pivotably mounted to first grip  42  at a pivot  65  and a second rod  62  pivotably mounted to first rod  61  at a pivot  67  and second grip  52  at a pivot  66 . Awl  60  includes a punch  63  having a slot  68  slidably mounted to first jaw  43  and second jaw  53  at a pin  69  for sliding relative to first jaw  43  and second jaw  53 . Punch  63  includes a lancet  64  formed at the free end of punch  63  for piercing an access hole in connector  10 . Slot  68  includes a lower edge  68   a  and an upper edge  68   b  as is shown in FIG.  2 . First jaw  43  has a throughhole  43   a  and second jaw  53  has a throughhole  53   a  for communicating with slot  68  of punch  63 . Pin  69  extends through first jaw throughhole  43   a , slot  68  and second jaw throughhole  53   a  and forms a pivot joint, such that first jaw  43  is pivotable with respect to second jaw  53  and punch  63  is slidable with respect to first and second jaws  43 ,  53  around pin  69 . 
     Pivots  46 ,  56 ,  65 ,  66 ,  67  and  69  may consist of a screw and nut fastening arrangement, or a bolt and retention member that are snap fit together, or a bolt and cotter pin, or a flanged pin or axle, or any other fastening configuration or hinge that permits the members to pivot with respect to one another. 
     Test access tool  40  preferably includes a strut  50  connected to an inside surface  43   b  of first jaw  43 . When first plier member  41  is in the second position, depicted in FIG. 2, strut  50  prevents first jaw  43  from moving with respect to second jaw  53  in a gripping direction shown as arrows F and F′ by contacting an inside surface  53   b  of second jaw  53 . In this manner, strut  50  prevents cap  15  of connector  10  from being crushed by preventing the overpivoting of first jaw  43  and second jaw  53  when the craftsperson secures test access tool  40  to connector  10 . 
     Referring to FIG. 1, to use access tool  40 , the craftsperson pivots first and second grips  42 ,  52  in directions respectively shown as arrows A and A′, thereby pivoting first rod  61  in the direction shown as arrow B about pivot  65  and second rod  62  in the direction shown as arrow B′ about pivot  66 , and first jaw  43  and second jaw  53  in directions respectively shown as arrows C and C′ about pin  69 . In the fully open position depicted in FIG. 1, pin  69  travels within slot  68  to lower edge  68   a  thereby fully releasing punch  63  and preventing any further pivoting of first and second grips  42 ,  52  in the direction shown as arrows A, A′. In this first position, the craftsperson may position test access tool  40  over flange  17  of cap  15  as the distance between first latch  47  and second latch  57  is greater than the diameter of flange  17 . This first position is the preferred position for the tool at rest, and the tool is preferably biased to return to this position when not in use. 
     Referring to FIG. 2, to secure test access tool  40  to connector  10 , the craftsperson pivots first and second grips  42  and  52  in the direction indicated by arrows D and D′, thereby pivoting first rod  61  in the direction shown as arrow E about pivot  65  and second rod  62  in the direction shown as arrow E′ about pivot  66 , and first jaw  43  and second jaw  53  in directions respectively shown as arrows F and F′ about pin  69 . As first rod  61  and second rod  62  pivot about pivots  66  and  67 , punch  63  slides within slot  68  in a direction indicated by arrow G to a position intermediate upper edge  68   b  and lower edge  68   a  of slot  68 . At this location, strut  50  contacts inner surface  53   b  of second jaw  53  to prevent further motion of first jaw  43  with respect to second jaw  53 , first and second latches  47 ,  57  secure test access tool  40  to cap  15  of connector  10 , and lancet  64  is positioned above membrane  18  of cap  15 . In this position, cap  15  is retained by tool  40  and ready for the aperture to be formed. 
     Referring to FIGS. 3 and 4, to pierce a test access hole in connector  10 , the craftsperson further pivots first and second grips  42  and  52  in the direction indicated by arrows H and H′. Because strut  50  contacts inner surface  53   b  of second jaw  53 , first jaw  43  and second jaw  53  are prevented from moving in the gripping direction. As such, the force imparted by the craftsperson on first and second grips  42 ,  52 , causes the biasing force of first and second springs  45 ,  55  to be overcome and first grip  42  rotates relative to first jaw  43  in the direction indicated by arrow J and second grip  52  rotates relative to second jaw  53  in the direction indicated by arrow J′, thereby pivoting first rod  61  in the direction shown as arrow I about pivot  65  and second rod  62  in the direction shown as arrow I′ about pivot  66 . As first rod  61  and second rod  62  pivot about pivots  66  and  67 , punch  63  slides within slot  68  in a direction indicated by arrow K to a third position where lancet  64  pierces an access hole  70   a  in membrane  18  (FIG.  6 A). Lower edge  68   a  is positioned and slot  68  is sized to permit lancet  64  to travel through a predetermined distance to pierce membrane  18 . 
     Once access hole  70   a  has been created by test access tool  40 , the craftsperson may disengage test access tool  40  from connector  10  by once again pivoting first and second grips  42 ,  52  in directions respectively shown by arrows A and A′, thereby pivoting first rod  61  in the direction shown as arrow B about pivot  65  and second rod  62  in the direction shown as arrow B′ about pivot  66 , and first jaw  43  and second jaw  53  in directions respectively shown as arrows C and C′ about pin  69 . The craftsperson pivots first and second grips  42 ,  52  until punch  63  is fully disengaged from cap  15  and first and second jaws  47 ,  57  disengage from flange  17  of cap  15 . 
     Once test access tool  40  is disengaged, the craftsperson may create a second access hole  70 ′ a  in membrane  18 ′ (or in a second location of membrane  18 ) to permit testing in test channel  70 ′ by positioning test access tool  40  over membrane  18 ′ of cap  15 , which seals test channel  70 ′ from outside contaminants, and gripping first and second grips  42 ,  52  until lancet  64  pierces membrane  18 ′ in the same fashion as described above. Alternatively, the tool may be designed such that punch  63  comprises two lancets  64  for forming access apertures in membranes  18  and  18 ′ over both terminal strips  30 ,  30 ′ (see FIG. 9) at approximately the same time. 
     Once test access tool  40  is disengaged a second time, the craftsperson may test the wire connection at connector  10  by inserting the test leads of a bridge clip or test probe (not shown) into test channels  70  and  70 ′ until the test leads contact terminal strips  30 ,  30 ′. 
     After testing the connection, the craftsperson preferably closes test apertures  70   a  and  70 ′ a . Referring to FIGS. 6A,  6 B and  7 , seal  80  is depicted. Seal  80  is preferably spring-loaded; i.e., seal  80  is normally biased to its closed position. Seal  80  includes a body  81 , having a mating surface  88 , and a latch  82 , having a first beam  83  formed with a first hook  84  and a second beam  85  formed with a second hook  86 . Preferably, beams  83 ,  85  and hooks  84 ,  86  are integrally formed with body  81 , however, hooks  84 ,  86  may be connected to beams  83 ,  85  in any fashion known to those skilled in the art. First hook  84  and second hook  86  are constructed to matingly engage with flange  17  of cap  15 . A portion  88   a  of a mating surface  88  may be formed to engage and partially enter access hole  70   a  formed by punch tip  64  of test access tool  40 , as a matter of design choice. 
     As shown in FIG. 6A, to engage seal  80  to connector  10 , the craftsperson compresses beams  83 ,  85  in the directions shown as arrows Y, Y′ to rotate hooks  84 ,  86  outward in the directions shown by arrows Z, Z′. Once hooks  84 ,  86  rotate a distance sufficient to clear flange  19 , the craftsperson may cease compressing beams  83 ,  85 , thereby permitting hooks  84 ,  86  to rotate to the closed position and engage flange  19  of cap  15  of connector  10 . Thus, latch  82  is in its open position as shown in FIG. 6A, when beams  83 ,  85  are deflected inwardly by forces Y, Y′. Conversely, as shown in FIG. 6B, latch  82  is in its closed position when first hook  84  and second hook  86  engage flange  17  of cap  15 . In the closed position, seal  80  seals test channels  70 ,  70 ′ to prevent particles from entering the channels. 
     Referring to FIGS. 8 and 9, a second embodiment of a seal  180 ,  180 ′ is depicted, wherein elements common to the first seal embodiment depicted in FIGS. 6A,  6 B and  7  are designated with similar numerals. Seal  180  includes an inner diameter  181  and an outer diameter  182 , which is shorter in length compared to inner diameter  181 . Seal  180  is preferably formed in the shape of a trapezoid in cross section, but may be formed in any cross-sectional shape having an inner diameter  181  and a longer, outer diameter  182 . Seal  180 ,  180 ′ is preferably a malleable plug of, for example, a rubber or rubber-like material, so as to frictionally fit into access holes  170   a ,  170 ′ a  and against an inner surface  16   a  of cylinder  16  to seal test channels  170 ,  170 ′, although the specific material and slope of the seal is a matter of design choice . In this manner, after testing connectors  10 , the craftsperson may seal the access hole created in the connector to permit testing by employing a seal sized to plug the access hole. 
     Thus, while there have been shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the disclosed invention may be made by those skilled in the art without departing from the spirit of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.