Abstract:
A splicing enclosure is comprised of a base portion and a lid portion, with a grounding contact positioned in both halves. The grounding contacts include a plurality of grounding contact portions to receive shielded cable in a transverse relation thereto. The enclosure is provided with a removable ferrule, which can be slidably received between the shielding and inner sheath of a shielded cable to enhance the strain relief on the cable between the cable and the grounding contact. The grounding contact is designed so as to accommodate a plurality of shielded cable configurations. The enclosure is also provided with a progressive latch, which cooperates upon rotation of the lid relative to its base portion to take off the load from the integrated hinge to prevent breakage of the hinge.

Description:
FIELD OF THE INVENTION 
     The present invention relates to the field of electrical connections and more particularly to enclosures for spliced cable connections such as telephone wires. 
     BACKGROUND OF THE INVENTION 
     It is common in the telephone industry, where cable splices need to be made along the path of distribution, that splices be made which will include some type of an electrical connection to splice the individual wires of the cable and environmentally seal them in a connection enclosure to prevent degradation to the connection. This type of splice could be either a so-called drop wire splice or could be a buried splice in the case of underground cable. It is also common to have either two or six pairs of twisted wire, which comprise the telephone cable. 
     As in almost any enclosure, it is requisite that the enclosure be latched together in a fixed relation. This is required for several reasons. First the contact system between the commoning of the ground may be degraded if the enclosure is not fully closed. Secondly, the strain relief system, if based upon the full closure, may also be degraded if not properly closed. And finally, most systems are sealed with a gel or grease which must be contained within the enclosure. 
     One such device is shown in the Tyco Electronics (AMP Division) commercial product known as the CERTI-SEAL Wire Splice Enclosure (for 2- to 6-pair buried drop wire splice) where the housing is formed as a shell of two similar halves, where the enclosure is defined by two housing halves integrally joined at a hinged seam. The edges of the halves also include snap latches which snap together when the two housing halves are fully closed. Splice connection blocks known as TEL-SPLICE (also a commercial of Tyco Electronics) then interconnect the individual wires to one another for making the individual wire splices. One of the shortcomings of this system is that the only retention between the housing halves is through the hinges, which by necessity is somewhat weak, due to its inherent need to be flexible. If this hinge were to break, then the alignment of the two housing halves is difficult to replicate, as there is now no connection between the housing halves. The gel or grease within the enclosure causes the two halves to float relative to each other, making it difficult to latch. 
     SUMMARY OF THE INVENTION 
     The objects of the invention have been accomplished by providing an electrical connector of the type for interconnecting at least two wires, comprising an enclosure having at least two housing parts hinged together along one edge thereof. The hinged side edge further comprises a latch assembly comprised of a projection and a complementary receiving opening, whereupon the projection rotates into the opening upon closure of the housing parts, retaining the two housing parts together. 
     In the preferred embodiment of the invention, the projection is profiled as an arcuately shaped wall, which rotates into the opening. The arcuately shaped wall has an inner surface facing the hinged side edge, and the opening is elongate and has a surface contoured to receive the inner surface. The arcuately shaped wall also has a rigidifying rib extending from one of the housing parts, interconnecting the inner surface with the one housing part. Preferably, the elongate opening is T-shaped to include a portion of the opening to receive the rigidifying rib. Also preferably, the one conductive contact member is positioned in at least one housing part to make electrical contact with a conductor of a cable upon closure, the arcuately shaped wall being profiled to engage the inner surface and remove load from the hinge, prior to the conductive contact making contact with the cable. 
     In another aspect of the invention, an electrical connector enclosure has two housing parts, which rotate relative to each other along a first side edge thereof. The housing parts having a latch assembly comprised of an arcuate latching member positioned on a first housing part which cooperates with a complementary surface on the second housing part, upon relative rotation therebetween, and progressively transfers load from the first side edge to the latch assembly upon closure thereof. 
     In the preferred embodiment, the two housing parts are integrally connected along the first side edge, and the arcuate latching member is defined by an arcuately shaped projection, which is slidably received under, and engages against, the complementary surface. Preferably, the complementary surface is positioned on an opening, which cooperates with the projection. Also preferably, the arcuately shaped projection is an elongate wall that curves towards the first side edge. The arcuate shaped projection has a rigidifying rib, which extends between the arcuately shaped projection and the housing part. The opening is T-shaped to include an elongate opening portion to receive the arcuately shaped projection and a transverse portion, which receives the rib. The latch assembly is positioned proximate the first side edge, and the connector includes a second snap latch latching assembly on a second side edge opposite the first side. 
     In yet another embodiment of the invention, an electrical connector housing comprises two housing parts which rotate relative to each other along a hinged side edge, the two housing parts each having an upper face which, when closed, abut each other. One of the housing parts includes an arcuately shaped projection positioned on the upper face proximate to, and extending substantially parallel to, the hinged side edge. The arcuately shaped projection curves towards the hinged side edge and extends along a radius of curvature defined by a radius equal to the radial distance of the arcuately shaped projection to the hinged side edge. The housing also includes an opening profiled to receive the arcuately shaped projection. 
     In the preferred embodiment, the projection is profiled as an arcuately shaped wall, which rotates into the opening. The arcuately shaped wall has an inner surface facing the hinged side edge, and the opening is elongate and has a surface contoured to receive the inner surface. The arcuately shaped wall has a rigidifying rib extending from one of the housing parts, interconnecting the inner surface with the one housing part. The elongate opening is T-shaped to include a portion of the opening to receive the rigidifying rib. The connector has at least one conductive contact member positioned in at least one housing part to make electrical contact with a conductor of a cable upon closure, and the other housing part has a cable receiving section for receiving said cable. The arcuately shaped wall is profiled to engage the inner surface and begins to transfer load from the hinge, prior to the conductive contact making contact with the cable. 
     The preferred embodiment of the invention will now be described by way of reference to the following drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an isometric view of the subject enclosure in the open state; 
     FIG. 2 is an isometric view similar to that of FIG. 1 taken from a different perspective; 
     FIG. 3 is an upper plan view of the enclosure housing of FIG. 1 or  2  with the grounding contacts removed; 
     FIG. 4 is a side plan view of the grounding contact shown in FIG. 1 or  2 ; 
     FIG. 5 is an isometric view of the grounding contact of FIG. 4; 
     FIG. 6A is an upper plan view of the strain relief ferrule utilized in the subject invention; 
     FIG. 6B is a side plan view of the strain relief ferrule of FIG. 6A; 
     FIG. 6C is an end view of the strain relief ferrule of either of FIG. 6A or  6 B; 
     FIG. 7 is an upper plan view similar to that of FIG. 3 showing the grounding contacts in position; 
     FIG. 8 is a perspective view of the enclosure illustrating two 12-pair cables spliced together, poised for receipt in the enclosure; 
     FIG. 9 shows the configuration of two 12-pair cables in a butt splice configuration; 
     FIG. 10 shows two 12-pair cables in an in-line configuration; 
     FIG. 11 shows the incorporation of the strain relief ferrule with a 6-pair cable; 
     FIG. 12 shows a perspective view of the enclosure for use with the 6-pair cable; and 
     FIGS. 13A-13D show various positions of the progressive latch, as cross-sections through lines  13 — 13  of FIG.  3 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With respect first to FIGS. 1 and 2, the invention will be described in greater detail. As shown, a splicing enclosure is shown generally as reference  2 , which incorporates a housing comprised of a first housing portion, or base portion  4 , and a second housing portion or lid  6 . The enclosure  2  further comprises grounding contact members shown at  8 , which common the shielding of spliced shielded cables as will be described in further detail. Finally, the enclosure  2  includes removable strain relief ferrules  10 , which as shown in FIGS. 1 and 2, are shown in a stored position. With reference now to FIGS. 1 through 3, the housing member comprised of first and second housing portions  4  and  6  will be described in greater detail. 
     With respect first to FIG. 3, the base portion  4  is comprised of a base wall  12  provided with a plurality of strengthening ribs shown at  14 . The base wall  12  includes an outer peripheral wall  16 , which forms the concavity of the enclosure and further includes two spaced-apart and opposing walls at  18 . The base portion  4  further includes a receiving nest  20  to receive the associated grounding contact  8  as shown in FIGS. 1 and 2. As shown best in FIG. 3, the nest  20  is comprised of a first wall  22 , intermediate walls  24 , and an outer wall  26 . The nest  20  is bounded on its inner end by an upstanding wall at  28  as best shown in FIG. 2 or  3 . As also best viewed in FIG. 3, locking ribs  30  and  32  project upwardly to form locking surfaces for the grounding contact as will be described in greater detail. Locking rib  30  extends integrally upwardly from both the base wall  12  and the wall  28 . Locking rib  32  extends upwardly from the base member  12  and integrally from an inner surface  34  of the peripheral wall  16 . 
     As shown in FIG. 3, walls  24  and  26  are disposed in a parallel relation to each other and define a gap  36  therebetween. It should also be appreciated that the walls  24  and  26  are profiled to receive cables transversely thereof, see particularly FIG. 1 with contoured surfaces  40 ,  42 ;  44 ,  46 ; and  48 ,  50 . It should also be appreciated that the opposing wall  18  and peripheral wall  16  are also profiled to receive a cable transversely therethrough, as shown in FIG. 2, the opposing wall  18  and peripheral wall  16  include openings  52 ,  54 ;  56 ,  58 ; and  60 ,  62 , as shown in FIG.  2 . It should be appreciated that in comparing FIGS. 1 and 2, the pair of openings  52 ,  54  are aligned with the openings  40 ,  42 ; the openings  56 ,  58  are aligned with the openings  44 ,  46 , and that the openings  60 ,  62  are aligned with the respective openings  48 ,  50 . It should also be appreciated that the openings  52 ,  54 ;  40 ,  42 ; and  60 ,  62 ;  48 ,  50  are profiled to receive the same sized cable, and in the preferred embodiment of the invention are sized to receive a 12-pair shielded cable. As shown in FIG. 1, wall  22  also includes contoured surfaces to allow for a cable entrance, and includes surfaces  64 ,  66 , and  68 . With reference now to FIG. 2, contoured surfaces  70 - 80  are provided in walls  16  and  18  which are aligned with the surfaces  64 ,  66 , and  68 , that is, surfaces  70  and  72  are aligned with surface  64 ; surfaces  74 ,  76  are aligned with surface  66 ; and surfaces  78 ,  80  are aligned with surface  68 . As shown best in FIG. 3, a support for the contact  8  is formed by a plurality of transversely extending ribs  84  extending intermediate the walls  22 ,  24 . Finally, support walls  88  provide structural rigidity to the contact nest  28  and include a transverse wall portion  90  and a plurality of upstanding posts at  92 . As shown in FIG. 3, a ferrule storage area is shown at  94  having an upstanding wall at  96  and upstanding posts at  98 . The opposing walls  18  further comprise gel relief ports at  100 , as shown in FIG.  1 . 
     With respect to FIG. 3, the lid  6  includes a base wall  102  having structural ribs at  104 . The lid  6  further includes a peripheral wall at  106  and opposing walls at  108 . Upstanding walls  112  and  114 , together with end wall  116 , provide a secondary contact-receiving nest  110 . In a like manner as the contact receiving nest  20 , contact receiving nest  110  further includes retaining ribs  120  and  122  (FIG.  3 ); contoured surfaces  124 ,  126 ,  128 , and  130  (FIGS.  1  and  2 ); and transversely extending ribs  132 . As also shown in FIGS. 1 and 2, the outer peripheral wall  106  and the opposing wall  108  further include cable-receiving openings similar to items  52 - 62 , and  70 - 80 . As shown in FIG. 2, openings  140 ,  142  cooperate with openings  52 ,  54 ; openings  144 ,  146  cooperate with openings  56 ,  58 ; and openings  148  and  150  cooperate with openings  60 ,  62 , to complete the cable receiving openings. Similarly, openings  152 ,  154  cooperate with openings  70 ,  72 ; openings  156 ,  158  cooperate with openings  74 ,  76 ; and openings  160 ,  162  cooperate with openings  78 ,  80 . The opposing walls  108  further comprise gel relief ports at  168 , as shown in FIG.  1 ). 
     With respect again to FIGS. 1 through 3, the housing portions  4  and  6  are shown as integrally molded about their edges, that is, about a hinge  170  formed between support walls  172  and  174 . An edge latching system is comprised of projections  176  and complementary openings  180 , as best shown in FIG.  2 . Each of the projections  176  includes a curved wall portion  182  (FIG. 2) and an upstanding support rib  184  (FIG.  1 ). Each of the openings  180  is comprised of a Tshaped slot including an elongate portion  186  and a transverse portion at  188  (FIG.  3 ). It should be appreciated that each of the projections  176  is receivable in sliding engagement with a corresponding opening  180  as will be further described herein. 
     With respect now to FIGS. 4 and 5, the grounding contact  8  will be described in greater detail. The contact  8  is comprised of a base portion  200  having generally upstanding wall sections at  202  and  204 . The wall sections  202  and  204  define a plurality of grounding contact portions at  206 ,  208 , and  210 . Each of the contact portions  206 - 210  is comprised of side edges  212 ,  214 , and  216 , respectively, having serrated edges at  220 ,  222 , and  224 . Also with respect to FIG. 4, due to the cut-out sections  230 , the base portion  200  of the contacts  8  are bendable at  232 , at both ends as will be described in greater detail herein. Finally, as shown in FIGS. 4 and 5, the contact member  8  includes a locking lance  236  which has been struck from the base portion  200  to lock the contact in place in the housing as will also be described in greater detail herein. 
     With respect now to FIGS. 6A and 6C, the ferrule  10  is disclosed as including a substantially cylindrical barrel portion  252  formed from rolling to include top edges at  254 . The ferrule  10  further includes a front leading edge at  256  and a rear edge at  258 . A gripping tab  260  extends integrally from the rear edge  258  as will be described in further detail. 
     With the components described with respect to FIGS. 1 through 6, the assembly of the apparatus will be described with greater detail. With reference to both FIGS. 3 and 7, the grounding contacts  8  are positioned between respective walls  22  and  24 ; and  112 ,  114 . The contacts  8  are inserted into their respective positions such that the base portions  200  of the grounding contacts  8  contact the transverse wall portions  84  and  132  of the respective receiving nests. This places the locking lances  236  in locking engagement with the respective ribs  30 ,  32 ;  120 ,  122 . It should also be noted that a grease or gel  270  can also be placed in and around the base and lid as shown at  270 , and can be placed in the unit prior to the termination of the various cables, or could be injected afterwards. 
     With respect now to FIG. 8, the application of the enclosure  2  as a splicing member will be described. As shown in FIG. 8, the enclosure can be used to splice two cables  300 ,  302  where each of the cables includes an inner shielding  304 ,  306 , which shields individual twisted pair conductors  308 ,  310 . As shown, the cables  300  and  302  have been terminated by a plurality of electrical splicing connectors such as  312 , which could be the TEL-SPLICE connectors as described above. As shown in FIG. 8, cables  300  and  302  are shown as 12-pair cables, and as such, will be positioned in grounding contact portions  206  and  210  (FIGS. 4 &amp; 5) as will be further described herein. As shown in FIG. 9, the layout of the grounding contact allows for the splicing of the cable to be in a butt splice arrangement, as well as an in-line configuration as shown in FIG.  10 . With respect now to FIGS. 11 and 12, in the event that a smaller cable, for example, a 6-pair shielded cable is to be spliced, such as a cable shown at  320 , the cable is prepared by stripping the insulation back a sufficient portion to expose a length of the shielding sheath  322  for a length similar in length to the strain relief ferrule  10 . As shown in FIG. 11, this is accomplished by exposing a portion of the inner shielding  328 , with the individual twisted pair of conductors  326  extending therefrom. The seam  324  of the shield can be opened to receive the ferrule  10  therein. As the ferrule has a leading edge portion, the ferrule can be grasped by the tab  260 , for example, by a pair of pliers, and can be slidably received so as to be positioned between the shield  322  and the inner sheath  328 . The ferrule  10  rigidifies the cable diameter and can now be received in a transverse relation, similar to that shown in FIGS. 9 and 10, but can be received in the center grounding contact portion  208  of the grounding contact  8 , or in either of the contact portions  206 ,  210 . Thus, the 6-pair cable  320  would be positioned either in openings  56 ,  58 , or  74 ,  76  (FIG.  2 ). 
     With respect now to FIGS. 13A-13D, the progressive nature of the hinging latch will be described in greater detail. With respect to FIG. 13A, the lid portion  6  is rotated clockwise, as viewed in the orientation of either FIG. 1 or  2 , such that the lid  6  is rotated about the hinge  170 . FIG. 13A shows the position of the lid relative to the base prior to the projection  176  entering the opening  180 . At this position, the contact  8  in the lid  6  would not have begun to make contact with the cable shielding. Given the location of the cross sectional view, the portion  188  (FIG. 3) of the T-slot opening  180 , cannot be viewed, but rather, is behind the support wall portion  174  as shown in FIGS. 13A and 13B. As viewed in FIG. 13B, the lid  6  is shown in the position where the curved wall portion  182  has first made entry into the elongate portion  186  of the T-slot where the support rib  184  will be positioned in the transverse portion  188  of the T-slot. FIG. 13C shows further rotation of the lid  6  relative to the base  4 , where the upstanding wall portion  198  begins entry into its corresponding slot  196 . Finally, FIG. 13D shows the closed position of lid  6  relative to base  4 . In this position, the corresponding latch members  190 ,  192  (FIGS. 1) would also be latched together retaining the entire assembly in a closed position. 
     This progressive hinging structure, as described in FIGS. 13A through 13D prevents any of the shortcomings of prior art connectors. As discussed earlier, without the progressive latching configuration, due to the forces required to properly engage the cables with the corresponding grounding contacts, together with the force required to displace the grease or gel within the enclosure, it is not uncommon that a hinge portion can break, leaving the entire enclosure, both unsealed, as well as not fully connected vis-a-vis the grounding clip. 
     In the embodiment described herein, the latching projection  176  with this corresponding opening  180  begins to engage while in a position corresponding to FIG.  13 B. In particular, this engagement takes place between surface  183  of wall  182 , surface  183  being an arcuate surface facing the hinge  170 ; and surface  187  of opening  186 . This engagement takes load off of the hinge (a load such as force F depicted in FIG. 13D, which would tend to separate the housing halves  4 ,  6  and/or break the hinges  170 ) preventing the hinge  170  from breaking. This enhanced configuration provides for an easier assembly, as well as preventing the breaking of the hinge and possible misalignment of the base and lid portions  4 ,  6 .