Patent Document

BACKGROUND OF INVENTION  
         [0001]    Surge protectors protect voltage sensitive equipment connected to electrical lines by discharging high voltage signals or current surges to ground before the high voltage signal can damage the equipment. Telecommunications systems employ very large numbers of surge protectors to connect voltage sensitive switching equipment and other equipment to outside telephone lines. Telephone lines, which normally carry relatively low voltage message signals, are subject to current surges caused by lightning and other extrinsic phenomena associated with the location of the telephone lines.  
           [0002]    Each telephone line includes a pair of wires, referred to as the “tip” line and the “ring” line, that carry the message signal. Each tip and ring line is connected through an industry standard surge protector device having five pins: one for an incoming wire and one for an outgoing wire for each tip line; one for an incoming wire and one outgoing wire for each ring line; and one to connect to ground. The surge protector device passes low-voltage signals traveling between the incoming and outgoing wires for a given line, but discharges current surges on the line to the ground pin, which in turn is connected to a ground line.  
           [0003]    Surge protectors include a surge protector base. The base serves to provide a rigid structural platform for supporting a plurality of surge protector devices for coupling to multi-line telecommunications cables. Generally, the base can handle ten, twenty-five, fifty and one hundred surge protector devices for coupling to an equal number of communication lines.  
           [0004]    The base is fabricated as a single slab of plastic insulating material with a plurality of holes formed in the slab. Into each hole is inserted a metal socket that faces toward a rear side of the base. There are a plurality of connector pins and ground pins that are inserted through the metal sockets. Each pin of a surge protector device fits into one of these metal sockets and forms with the socket as a compression fit to establish a good electrical connection. Extending from each hole on a front side of the protector base are both connector pins and ground pins. After each ground pins are inserted into the metal sockets, a rail is laid across each ground pin and then soldered to each ground pin. The rail is then connected to a ground line. Inserting each ground pin into each metal socket and soldering each ground pin to the rail is a time consuming and inefficient process.  
         SUMMARY OF INVENTION  
         [0005]    The above discussed and other drawbacks and deficiencies of the prior art are overcome or alleviated by a carrier assembly for a surge protection assembly. In an exemplary embodiment of the invention, a carrier assembly for a surge protection assembly includes: a connector strip; a plurality of pins extending from the connector strip; and wherein the connector strip and the plurality of pins are formed from a single piece of conductive material. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0006]    Referring to the exemplary drawings wherein like elements are numbered alike in the several Figures:  
         [0007]    [0007]FIG. 1 is an exploded view of a surge protector assembly;  
         [0008]    [0008]FIG. 2 is a plan view of a base of the surge protector assembly of FIG. 1;  
         [0009]    [0009]FIG. 3 is a front view of a carrier assembly for the surge protector assembly of FIG. 1;  
         [0010]    [0010]FIG. 4 is a ground pin of the carrier assembly of FIG. 3;  
         [0011]    [0011]FIG. 5 is a top view of a progressive die manufacturing process for a carrier assembly;  
         [0012]    [0012]FIG. 6 is a side view of the progressive die manufacturing process of FIG. 5;  
         [0013]    [0013]FIG. 7 is a cross-section of the base of FIG. 2;  
         [0014]    [0014]FIG. 8 is a cross-section of the base with the carrier assembly of FIG. 2;  
         [0015]    [0015]FIG. 9 is a cross-section of the base with the carrier assembly of FIG. 2;  
         [0016]    [0016]FIG. 10 is a front view of an alternative embodiment of the carrier assembly of FIG. 3;  
         [0017]    [0017]FIG. 11 is a ground pin of the carrier assembly of FIG. 10;  
         [0018]    [0018]FIG. 12 is a front view of an alternative embodiment of the carrier assembly of FIG. 3; and  
         [0019]    [0019]FIG. 13 is a ground pin of the carrier assembly of FIG. 12. 
     
    
     DETAILED DESCRIPTION  
       [0020]    Referring to FIG. 1, a surge protector assembly  10  is illustrated. Surge protector assembly  10  includes a base  12  with a first end  14 , a second end  16 , a third end  15 , a fourth end  17 , a front surface  18 , and a rear surface  20 . First end  14  and second end  16  are generally straight and parallel with each other. Third end  15  and fourth end  17  are generally straight and parallel with each other. Together, first end  14 , second end  16 , third end  15 , and fourth end  17  for a square. Base  12  is formed using a rigid slab of plastic or other electrically insulating material.  
         [0021]    Base  12  contains a plurality of holes  22 , which passes from front surface  18  through to rear surface  20 . At rear surface  20 , a metal socket (not shown) is inserted into each hole. Surge protection devices  30  (only one shown) are mounted at rear surface  20  of base  12 . Each surge protection device  30  includes a base member  32  having a plurality of connector pins  34  extending therefrom. When surge protection device  30  is mounted to base  12 , connector pins  34  extend from rear surface through holes  22  to front surface  18 . Each connector pin  34  and metal socket (not shown) form a compression fit to establish a good electrical connection. A multi-layer printed circuit board  40  is mounted to front surface  18  of base  12 .  
         [0022]    Circuit board  40  includes a first end  42 , a second end  44 , a front surface  46 , and a rear surface  48 . Circuit board  40  also includes sockets  50 , which are formed by a hole plated with metal and extending from front surface  46  to rear surface  48  in circuit board  40 . Connector pins  34  are inserted into each socket  42  at circuit board  40 . Circuit board  40  is formed from multiple layers of dielectric material, such as fiberglass, bonded together. Each layer of circuit board  40  is fabricated with a predetermined pattern of metal traces or “runs” using a conventional subtractive process. Connector sockets  52  are mounted to front surface  46  of circuit board  40 , by passing pins  54  through rear surface  48  to front surface  46  and inserting pins  54  into connector sockets  52 . Pins  54  extend through connector socket  52 . An aluminum hood  60  is mounted to front surface  46  of circuit board  40  and is coupled to base  12 .  
         [0023]    Aluminum hood  60  includes a first end  62 , a second end  64 , a front surface  66 , and a rear surface  68 . Aluminum hood  60  includes rectangular holes  70  that extend from front surface  66  to rear surface  68 . Each hole  70  has dimensions slightly larger than connector socket  52  so that connector socket  52  can extend through hole  70 . In addition, connector sockets  72  are coupled with connector sockets  52  and are held together by connector pin  54 . Pins  54  are either soldered to connector socket  72  or are a compression fit pin. A line-in cable  74  is coupled with connector socket  72  and a line-out cable  76  is coupled with connector socket  72 . Both line-in cable  74  and line-out cable  76  include a plurality of communication lines  77 .  
         [0024]    Referring to FIG. 2, base  12  is shown in more detail. Base  12  includes a first transverse rail  80  extending along first end  14  and a second transverse rail  82  extending along at second end  16 . First transverse rail  80  is an elongated strip of conductive material coupled to a ground line  83 . Base  12  also includes a carrier assembly  90  located between rows of connector pins  34  and extending generally parallel to third and fourth ends  15  and  17 . Carrier assembly  90  includes a connector strip  91  and a plurality of ground pins  92  electrically connected to connector strip  91 . Connector strip  91  is an elongated strip of conductive material including a first end  102  coupled to first transverse rail  80  and a second end  104  coupled to second transverse rail  82 . Connector strip  91  may be coupled to first and second transverse rails  80  and  82  by soldering.  
         [0025]    Extending through base  12  from front surface  18  through to rear surface  20  (not shown) are holes  94 . Holes  94  are generally formed in a line and are parallel to sides  15  and  17 . Ground pins  92  extend through every other hole  94  and are flush at rear surface  20 . Each hole  94  has a centerline  96 , and the spacing from centerline  96  of one hole  94  to centerline  96  of another hole  94  is a predetermined distance  98 . A grouping  93  of four connector pins  34  and one ground pin  92  completes one surge protection device  30 .  
         [0026]    Referring to FIGS. 3 and 4, carrier assembly  90  is depicted in greater detail. Connector strip  91  includes first side  110 , a second side  112 , a third side  114 , and a fourth side  116 . First side  110  and third side  114  are generally straight and parallel to each other. Second side  112  and fourth side  116  are generally straight and parallel to each other. Carrier assembly  90  also includes a connector piece  118  that connects connector strip  91  to ground pin  92 . Ground pin  92  includes a body portion  93  shaped generally as a cylindrical shell. Extending from a side  95  of body portion  93  is a lance  120 , which is located near an end  97  of body portion  93  proximate connector strip  91 . A slot  124  is formed in the outside diameter of body portion  93 , and extends from end  97  of body portion  93  to an end  99 . Two additional slots  122  are also formed in body portion  93 . Those additional slots  122  are evenly spaced around the periphery of body portion  93  and extend from end  99  to a point generally midway between ends  97  and  99 .  
         [0027]    Referring to FIG. 5, an embodiment of a progressive die manufacturing process  200  for carrier assembly  90  is illustrated. Carrier assembly  90  is manufactured from a strip  202  of conductive material, such as metal or the like. Progressive die manufacturing process  200  includes strip  202  proceeding through a plurality of stations  204 , which are numbered one to ten. At each station  204 , a specific function, such as gutting, lancing, rolling, or the like, is performed on strip  202  to form strip  202  eventually into carrier assembly  90 . Each station  204  has a centerline  206 . Each centerline  206  of each station  204  is separated by the same predetermined distance  98  as each centerline  96  (shown on FIG. 2) of each hole  94  (shown on FIG. 2) in base  12  (shown on FIG. 2).  
         [0028]    Referring to FIGS. 5 and 6, progressive die manufacturing process  200  occurs as follows. Strip  202  is inserted into progressive die machine (not shown) at a first end  208  of strip  202 . At station  1 , pilot holes  210  are punched into strip  202 . Pilot holes  210  are located adjacent second side  112  and a third end  214  of strip  202 . Pilot holes  210  are small round holes that are used to guide strip  202  through progressive die machine. At station  2 , two slots  122  are gutted out of strip  202 . Slots  122  are generally rectangular in shape with a first side  218 , a second side  220 , a third side  222 , and a fourth side  224 . First side  218  and third side are generally straight and parallel to first end  208  of strip  202 . Second side  220  and fourth side  224  are generally straight and parallel to second side  112  and third end  214  of strip  102 . Slots  122  are also located near third end  214 . At station  3 , there is no activity. This open station allows for additional functions to be added at a later date, if needed.  
         [0029]    At station  4 , strip  202  has two larger apertures  230  gutted out of strip  202 . Apertures  230  are generally square in shape and have a first side  232 , a second side  234 , a third side  236 , and a fourth side  238 . First side  232  and third side  236  are generally straight and parallel to first end  208  of strip  202 . Second side  234  and fourth side  238  are generally straight and parallel to second end  212  and fourth end  214  of strip  202 . Aperture  230  is located near second side  112 . At station  5 , two slits  240  are cut into strip  202 . Slits  240  extend from apertures  230  to near third end  214 .  
         [0030]    At station  6 , a first slit  242 , a second slit  244 , and a third slit  246  are cut into strip  202 . First slit  242  and third slit  246  are formed approximately midway between second side  112  and third end  214  of strip  202 . In addition first slit  242  and third slit  246  are approximately straight and perpendicular to each other. Second slit  244  is formed approximately perpendicular to first slit  242  and third slit  246 . Together, first slit  242 , second slit  244 , and third slit  246  form lance  120  on ground pin  92  (see FIG. 4).  
         [0031]    At stations  7  through  9 , a rolling operation occurs, which begins to form body portion  93  of ground pin  92 . Slits  240  have an edge  250 , which are rolled away from a front surface  252  of strip  202 , forming body portion  93 . In order to roll edges  250  to form body portion  93 , a rod (not shown) may be used to assist in forming a generally cylindrical shape. Edges  250  create slot  124 . In addition, at station  9 , a lower end  254  of strip  202  is cut away. Station  10  reflects the completed ground pin  92  and carrier assembly  90 . Once carrier assembly  90  is complete, strip  202  may be cut to the appropriate length needed so that it can be inserted into base  12 . It is recognized that ground pin  92  may be formed with more or less slots and that the above-described embodiment is just one embodiment of ground pin  92 .  
         [0032]    Referring to FIGS. 7 through 9, a cross-section of base  12  is illustrated. Holes  22  and  94  are disposed in base  12 , with rows of holes  22  located on either side of a row of holes  94 . Holes  22  have a notch  270 , which allow for connector pins (not shown) to have a compression fit with holes  22 . Hole  94  is generally cylindrical in shape with an inside diameter  272  larger than an outside diameter  274  of ground pin  92 . Extending inwardly from base  12  along a portion of the circumference of hole  94  is an angled d é tente  276 . Ground pin  92  is inserted in hole  94  from front surface  18  towards rear surface  20  as carrier assembly  90  is forced in the direction indicated by arrow  278 . Lance  120  of ground pin  92  is aligned with angled d é tente  276  formed in base  12 . As carrier assembly  90  is forced in the direction indicated by arrow  278 , lance  120  is forced against an angled surface  280  of angled d é tente  276 , causing lance  120  to flex inward towards body portion  93  of ground pin  92 . When ground pin  92  is fully inserted in hole  94 , as shown in FIG. 9, lance  120  is released from angled surface  280  and ground pin  92  is secured in hole  94  by interaction between lance  120  and angled d é tente  276 . In the fully inserted position, second side  112  of connector strip  91  is flush with front surface  18 , and end  99  of body portion  93  is flush with rear surface  20 .  
         [0033]    Referring to FIGS. 10 and 11, a second embodiment of carrier assembly  90  is illustrated. Carrier assembly  90  is manufactured as described in FIGS. 5 and 6. An additional step is then added in which connector strip  91  is folded over to produce a u-shape connector strip  301 . It is desirable to fold connector strip  91  because it is means to increase surface area and current carrying capability. In addition, by folding connector strip  91 , a stronger connector strip is obtained, which makes for a more durable manufacturing component that is less likely to become damaged during handling process.  
         [0034]    Referring to FIGS. 12 and 13, a third embodiment of carrier assembly is illustrated. Carrier assembly  90  is manufactured as described in FIGS. 5 and 6. However, ground pin  92  also includes an additional aperture  401 , which is gutted out during the progressive die manufacturing process. The end result of aperture  401  is that it is generally circular in shape. In addition, there is an additional opening  403  at a top end  405  of ground pin  92 . Additional steps include separating ground pin  92  from connector strip  91  and then reattaching connector strip  91  to a round strip  407  that is formed from a conductive material. Opening  403  allows ground pin  92  to be secured onto strip  407 .  
         [0035]    In all three concepts, soldering of the ground pin to a conductive strip is no longer necessary because the ground pin is either already attached to strip through the progressive die manufacturing process or the ground pin is secured onto strip. The carrier assembly decreases the time to assemble the surge protector assembly because an entire strip is inserted simultaneously into the base, rather than one ground pin at a time and the additional step of soldering each ground pin to the connector strip is eliminated. Additionally, by eliminating the soldering step, efficiency and product quality is improved.  
         [0036]    While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

Technology Category: h