Note: Descriptions are shown in the official language in which they were submitted.
~'f~35762
ELECTRICAL CONNECTOR KIT
The invention reiates to a connector for connecting
individual conductors of a first planar array of conductors to
preselected alternative individual conductors of a second,
S parallel, planar array, at least some of the individual conductors
of the second array being laterally spaced from individual
conductors of the first array. In particular, the invention
relates to a kit for making such connector.
As a result of the increasing demand for complex electrical
10 wiring, there is frequently a requirement to interconnect
individual conductors of planar arrays of conductors, for
example, of two flat cables, which conductors are in parallel
planes but displaced laterally from each other. In the interests
of minimizing inventories and capital expenditure, it is also
15 desirable to avoid a requirement for a different connector for
each different combination of interconnections. At the same
time, the connector should desirably be designed to facilitate
fabrication by mass production techniques and relatively simple
to assemble and use in the field, minimizing applied costs. In
20 addition, the connector should be of relatively small size
consistent with a requirement for compact and unobtrusive
equipment, particularly in undercarpet cable applications where a
low profile is important.
According to the invention, there is provided a kit for
25 making a connector for connecting individual conductors of a
first planar array of conductors to preselected alternative
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individual conductors of a second, parallel, planar array, at
ieast some of the individual conductors of the second array being
laterally spaced from individual conductors of the first array,
the kit comprising a plate-like Ensulating body formed with
S contact locating means to locate a plurality of first and second
contact parts respectively on first and second opposite faces of
the body for alignment with respective conductors of the first
and second array, predetermined of the contact locating means
including through sockets extending between the faces, first and
10 second contact parts for location in respective locating means,
the first and second contact parts for location by the
predetermined locating means being integrally joined together by
body portions receivable in the through sockets, bus receiving
channels extending laterally across the body between locating
15 means for the second contact parts and the predetermined
locating means, a bus portion adapted for location in preselected
alternative channels electrically to connect preselected second
contact parts with laterally spaced first contact parts associated
with the through sockets whereby on interposing the connector
20 erected from the kit between the first and second array of
conductors preselected individual conductors of the second array
can be connected to laterally spaced conductors of the first
array .
Thus, a single kit is suitable for establishing alternative
25 interconnections.
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The connector may constitute an adaptor for use, for
example, with a connector of the kind disclosed in our European
Patent No. 0,090,494 published on December 4, 1985 in which con-
ductor engaging contact elements are located on a cable engaging
face of an insulating housing body at the same pitch as the con-
ductors of a flat cable so that clamping the face against the
cable effects connection between the aligned contact elements and
the cable conductors. In use, the adaptor is inserted between the
cable engaging face and the cable with the first and second con-
tact parts aligned with the contact elements and cable conductors,respectively and one or more bus portions located in preselected
channels to interconnect individual connecting elements of the
flat cable connector with chosen conductors of the cable.
The contact elements of the flat cable connector com-
prise tabs having surfaces formed with outstanding knife edges
adapted to penetrate conductor insulation of the cable and estab-
lish electrical connection with the core. The first contact parts
may be tabs with recesses complementary to the knife edges and the
second contact parts may comprise tabs having insulation penetrat-
ing knife edges.
In a convenient more specific form, a contact part isintegrally formed with means to grip a bus portion which is
integrally joined to the contact part by a body portion receivable
in a through socket with the bus gripping portion in a bus
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receiving channel on one face and the contact part on the
opposite face,
This facilitates the provision of a compact and stable
structure that can readily be assembled in various combinations.
The kit may be designed particularly to enable the contact
elements of a connector constructed for a single phase wiring
array to be connected to preselected, alternative conductors of a
three phase wiring array. In such case, there are three
laterally spaced first and second aligned contact part locating
means each including common through sockets and two further
second contact part locating means respectively laterally spaced
to opposite sides of the second contact part locating means, the
further second contact part locating means including through
sockets common to locating means for bus gripping portions on
the first face, the bus receiving channels respectively extending
between the bus gripping portion locating means and distal and
adjacent first contact part locating means, third bus receiving
channels also extending between a bus gripping portion locating
means and the central first contact part locating means.
In the interests of simplicity of structure and body
strength, the third channel includes a portion common with an
adjacent channel.
Desirably, a first contact part is integrally formed with a
bus strip of sufficient length to provide the precursor of any of
the bus portions, and the bus gripping portion includes a tab
formed to extend transversely of the body portion and provided
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at a free end with spaced bus gripping fingers returned for
receipt in the bus receiving channel.
Excess lengths of the bus portions may quickly be removed
in the field and the bus portion bent to the desired
configuration. Each contact part and the bus gripping parts
may be stamped and formed from blanks of identical size
minimizing capital equipment costs, the small structural
differences readily being made by substituting alternative die
i nserts .
An example of a kit according to the invention will now be
described with reference to the accompanying drawings in which:
FIGURE 1 is an exploded perspective view of a flat cable
connector assembly incorporating a connector adaptor erected
from the kit;
FIGURE 2 is an exploded perspective showing, in
particular, the adaptor body and base plate;
FIGURES 3A and 3B are perspective views of the connector
body partly in cross-section before and after assembly with
contacts;
FIGURES 4A to 4F are perspective views of the individual
contacts; and
FIGURES 5A to 5E are perspective views of alternative
connector and contact combinations to provide alternative
interconnections between conductors located for single and
three-phase suppliers.
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Referring to Figure 1, the kit comprises a plate-like
insulating body 11 formed with laterally spaced contact locating
means 1 2a-3 and a series of contacts 1 3a-f ( Figures 4A to 4F~
partly formed for assembly with the body by location in
preselected of the locating means.
The body 11 is molded in one piece of suitable plastic
material and the contact locating means 1 2a-3 comprise first and
second pairs of recesses 1 4a-e and 1 5a-e respectively on first
and second opposite faces 16 and 17 of the body respectively the
rec~sses of respective pairs intercommunicating by through
sockets 1 9a-e respectively extending between the faces. The
three central recesses 1 4b, c and d on the first face 16 and
each of the recesses 1 5a-e on the second face 17 have flat base
walls for reception of contact parts, but the two outer recesses
1 4a and e communicate at ends remote from the through sockets
with bus receiving channels 22 and 24 which extend laterally
across the first face 16 and communicate with contact receiving
recesses 14d and 14c respectively. A third bus receiving
channel 25 extends between recess 1 4d and the approximate
mid-point of channel 24. Locating posts 26a and 26b upstancl
from diagonally opposite corners of the second face 17 and a
series of sockets 28 for the receipt of self-tappiny clamping
screws 29 (Figure 1 ) extend in symmetrically spaced relation
across the centerline of the body. Locating sockets 30 are
formed in the first, upper face 16 adjacent opposite edges of the
body on respective opposite sides of the centerline. Two
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further sockets 31 for the receipt of clamping screws 32 extend
through the body on opposite sides of the centerline. Cavities
20, 20' are formed adjacent opposite edges of the body in the
interests of economy of material.
S As shown more particularly in Figures 4A to 4F, the kit
includes six different stamped and formed contacts 13a-f. The
contact 13a comprises first contact part or tab 33a and second
contact part or tab 34a joined by a neck 35a from respective
opposite sides of which extend locating flanges 36a. The tabs
1 Q 33a and 34a each constitute conductor engaging contact parts, a
pair of locating recesses 37a being stamped in $ab 33a on each
side of a screw receiving aperture 38a. Insulation penetrating
teeth 39a are pushed out of the tab 34a. For the convenience of
the user to facilitate assembly with the body, the tab 33a may be
bent to extencl transversely of the neck 35a and tab 34a and the
flange 36a bent out of the plane of the neck as shown.
Referring to Figures 3A and 3B, the contact 13a is
assembled with the body 11 by insertion from the first face 16 of
the body 11, second tab 34a leading into the central through
socket 19c so that the first tab 33a is received in a recess 14c
on the first face of the body and the neck 35a is received as an
interference in the through socket 19c. The second tab 34a is
then bent to extend transversely of the neck under the first tab
so that its inherent resiliency causes it to remain spaced from
the body defining an obtuse angle with the neck 35a as shown in
Figure 3B. Subsequent engagement with a cable will enable
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sufficient resilient flexure of the tab towards the body with the
teeth 39a remaining proud of the surface 17 to provide a
permanent connection to the cable conductor.
The contact 13d shown in Figure 4D is similar to the
5 contact 13a of Figure 4A except that the aperture 38a is omitted,
locating recesses 37d are more closely spaced, and the flanges
36d are bent to extend under the tab 33d. Assembly of contact
13d is similar to that of contact 13a except that tab 34d is bent
to extend away from the tab 33d . Contact 13d is intended for
10 location by either contact locating means 12b or 12d (Figure 2).
Contacts 4b, c and e (Figures 4B, C and D) have tabs 33b, c
and e constituting conductor engaging contact parts joined by
short necks 41 b, c and e to bus bars 42b, c and e, which are
bent, as necessary, to enable receipt in channels 25 and 24
15 (Figure 5C), channel 24 ((Figure 5D), channel 22 (Figure 5B),
or channels 22 and 24 (Figure 5E). It is envisaged that only
contacts with straight busses need be supplied, the busses being
cut to length and severed in the field.
As shown in Figures 4F, 3A and 3B, tab 33f is bent to
20 extend transversely of neck 41 f and bifurcated at a free end to
form bus gripping spring fingers 43 returned towards the tab
34f. Assembly of the contact with the base 11 and a bus bar is
by inserting the contact 13f in locating means 12a (or 12e), tab
34f leading, with bus 42e preloaded in channel 22 so that the
25 fingers 43 grip the bus 42e between them. The tab 34f is then
bent towards the base 11 to the position shown in Figure 3B.
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As shown particularly in Figures 1 and 2, a stamped and
formed base olate 45 particularly adapted for use with the
connector adaptor includes flanges 46 bent up from opposite
sides to define a central cable receiving portion 47 having
5 downturned entry and exit surfaces 48 for the cable 67. A
raised land 49 is pushed out along a centerline in alignment with
the connecting parts and formed with clamping screw receiving
apertures 50. A recessed portion 51 is formed in the center
land for receipt of a grounding contact 52 having locating tangs
10 53 struck from diametrically opposite corners for receipt in
apertures 55 in the recess. Four further raised lands 57 are
pushed out at symmetrical locations on the cable receiving
portion, two of which are provided with apertures 58 for
clamping screws. Two further apertures 59 are formed between
15 the flanges 46 for the receipt of clamping screws 60 for a cover
61 (Figure 1).
As stated above, the adaptor kit is designed to enable
various combinations of connection between cable engaging
contacts 63c, d and e of a known single phase duplex outlet 64
20 connector described in European Patent Application No.
83300934.3, and the individual conductors 66ape of a triple phase
flat cable 67. The conductors 66a-e correspond respectively to
the secondary, neutral, ground, primary and tertiary lines.
When the three phase supply is not connected to the cable, the
25 conductor 66e may be used as an alternative ground.
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Referring again to Figure 1, to assemble the cable 67 with
the base plate 45, an upper metal shield 71 of the cable is
turned back and secured by U-form clips 72 to the flanges 46 so
that an exposed insulated cable portion extends across the cable
receiving portion of the base plate. The base 11 assembled with
a chosen combination of contacts is covered with fish paper 18
on surface 16 and surface 17 is clamped against the cable 67
which overlies a layer of fish paper 73 by screws 29 so that the
contacts establish connection to the individual conductors as
required. The duplex outlet 64 is then clamped by screws 32
against the body so that conductors 63c, d and e engage tabs of
contacts 1 2b, c and d O The cover is then clamped to the base
plate by screws 60.
The combinations of interconnections that can be obtained
using the kit are illustrated in Figures 5A to 5E.
In Figure 5A, a standard ground primary phase connection
is obtained by using contacts 1 3d in locating means 1 2a and 1 2d
and contacts 1 3a in 1 2c .
In Figure 5B, a standard ground secondary phase
connection is obtained by the use o~ contacts 1 3a in locating
means 1 2c as above, contacts 1 3d in 1 2b, spring contact 1 3f in
1 2a, and contact 1 3e in 1 2d .
In Figure 5C, a standard ground tertiary connection is
obtained by locating contacts 1 3a and 1 3d as above, spring
contact 1 3f in 1 2e, and bus contact 1 3b in locating means 1 2d .
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In Figure 5D, an isolated ground primary phase connection
is obtained by locating contacts 1 3d in locating means 1 2b and
1 2d, bus contact 1 3c in 1 2c, and spring contact 1 3f in 1 2e.
In Figure 5E, an isolated ground secondary phase
5 connection is obtained by locating contact 1 3d in locating means
1 2b, respective bus contacts 1 3c and 1 3e in 1 2c and 1 2d, and
spring contacts 1 3f in 1 2a and 1 2e.
The isolated ground requirement is necessary to prevent a
surge (spike) possibility when the usual ground is connected to
10 other equipment and is particularly sought in data applications.
It should be noted that in some other applicaticns, only
three different contacts may be required to obtain all of the
above combinations of interconnection, namely contacts 1 3b, d
and e, the apertures 38a, c for grounding screws not being
15 required. Each tab may be of the same size minimizing die
alterations when a series of different contacts are to be stamped
and enabling the same press to be used.
