Note: Descriptions are shown in the official language in which they were submitted.
Field of the Invention
This invention relates to terminal blocks and adaptors
for connecting wires to binding posts, particularly for con-
necting telecommunications drop wires to telecommunications
cables or other equipment. In particular, a first embodi-
ment of this invention relates to modular terminal blocks
suitable for attaching telecommunication drop wires to
binding posts in terminals blocks which are in turn con-
nected to telecommunication cables or other equipment. In a
second embodiment, the invention relates to adaptors for use
on prior art terminal blocks which require striping of insu-
lation from wires before connection to binding posts where
they were secured with a washer and simple nut.
.
Backqround of the Invention
Various configurations of terminal blocks have been used
in the telecommunications industry which typically require
the stripping of the drop wires before attaching the drop
wires to the binding posts in the terminal block. An
example of such terminal blocks is the Western Electric 9A
which typically contains 5,10 or more pairs of binding
posts for attaching drop wires or service wires. In other
configurations such as the TII Model 325, the terminal block
may also contain circuit protection devices. These existing
terminal blocks in use in the telecommunications industry
require that the ends of the drop wires or service wires be
stripped of insulation before connection to the desired
binding post with conventional nuts and washers. In addi-
tion, the binding posts and the stripped portion of the drop
wire or service wire are left exposed to moisture, corro-
sion, insects and other environmental factors which inter-
fere with the reliability of the electrical connection
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intended between the drop wires or service wires and the
terminal block binding posts. Other types of terminal
blocks contain insulation-displacement type connections
which causes the wires to break or corrode.
This invention can provide an improved device such as a
modular terminal block or adaptor which allows the worker to
make a connection between a wire and binding post without
prestripping the insulation from the wire.
This invention can also provide an improved terminal
block or adaptor that prevents corrosion or other damage of
the wire connected to the binding post.
This invention can also provide an access port for
testing the connection made between the wire and the binding
post.
This invention can also provide a modular terminal block
having improved visibility and ease of use for the worker
connecting the wire to the binding post.
This invention also provides an adaptor that allows con-
nection to be made between an insulated wire and a binding
post with no risk of damage to the wire.
Summary of the Invention
The present invention provides a device for electrically
connecting an insulated wire to a binding post, which
comprises:
- (a) an insulative housing having an opening through
which a binding post may pass and having another opening
through which the insulated wire may pass such that the wire
extends into ~he first-mentioned opening; and
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(b) a cap having a conductive inner portion that ma~ ~e
received by the binding post to bring the cap into the first
mentioned opening, the cap having bottom edge means that
engages a conductor of the wire by passing through insulation
of the wire when the cap is thus received by the binding
post; and
(c) means that limits the extent to which the cap can be
received by the binding post thereby preventing the conduc-
tor being broken or severed by the bottom edge means.
In a first preferred embodiment, this invention provides
a terminal block for connecting insulated wires to binding
posts comprising:
an insulative housing containing a plurality of spaced .
apart conductive binding posts;
conductive binding posts having opening means therein for
receiving the insulated wire; and
caps on the binding posts; wherein:
the insulative housing has first opening means therein
aligned with the opening means in the binding posts whereby
an insulated wire is received through the opening in the
housing and into the opening in the binding posts; and
the binding posts have thread means for engaging a
threaded cap and have first shoulder means positioned between
the thread means and the opening means for engaging opposing
shoulder means in the cap and have second shoulder means
positioned on the opposite side of the opening means which
second shoulder means is adapted for supporting the wire
when pressure i5 applied to the wire by the cap threaded
onto the binding posts; and
~1 288~93 r~
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the caps have a conductive inner portion and an insula-
tive outer portion wherein the conductive inner portion has
thread means adapted to engage the thread means on the
binding posts and has shoulder means at the end of said
thread means for engaging the first shoulder means of the
binding posts and has bottom edge means for engaging the
wire positioned in the opening means of the binding posts and
compressing the wire against the second shoulder means of the
binding posts as the cap is tightened on the binding posts
whereby the edge means contacts a conductor in the wire by
passing through the insulation on the wire;
wherein the distance between the shoulder means in the
cap and the edge means of the cap is such that ~hen the
shoulder means in the cap seats against the first shoulder
means of the binding posts the distance between the edge
means of the cap and the second shoulder means of the
binding post is a preselected distance which allows connection
of the edge means of the cap through the insulation of the
wire to a conductor in the wire without breaking or ser-
vering the wire; and
wherein the housing has second opening means positioned
substantially at right angles to said wire receiving ope-
nings through which second opening means the binding posts
extend and adapted for receiving the caps therethrough.
In a second preferred embodiment, the invention provides
a terminal bloc~ adaptor for connecting an insulated wire to
a conductive binding post of a terminal block comprising in
combination an insulative collar and a threaded cap wherein:
the collar comprises (a~ a first opening means
therethrough which is smaller in one portion for
receiving the binding post from one side of the collar
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and is larger in another portion for receiving the cap
from the opposing side of the collar thereby forming a
shoulder in the first opening means proximate to the
bottom of the cap when installed whereby the threads
in the cap can engage the threads on the binding post and
(b) a second opening means in a lateral side thereof,
communicating with the first opening means and being
positioned laterally opposite from the position of the-
binding post received in the first opening means, for
receiving an insulated wire whereby the wire is
positioned by the second opening means at least in part
adjacent the binding post and underneath the cap and is
engaged by the cap when the cap is threaded on the
binding post; and
the cap comprises a conductive inner portion and an
insulative outer portion wherein the conductive inner
portion has thread means adapted to engage the thread
means on the binding post and has bottom edge means for
engaging the wire positioned in the second opening means
of the collar and adjacent the binding post and for
compressing the wire against the shoulder means in the
first opening means as the cap is tightended on the
binding post whereby the edge means contacts a conductor
in the wire by passing through the insulation on the
wire; and
wherein the collar and cap contain cooperative stop
means for stopping the advance of the cap on the binding
post at a preselected distance between the edge means of
the cap and at least the portion of the shoulder means
against which the wire is compressed, thereby allowing
connection of the edge means of the cap through the insu-
lation of the wire to a conductor in the wire without
breaking or severing the wire.
_escription of First Preferred Embodiment
The terminal block preferably has edge means of the cap
positioned at an appropriate distance form the shoulder
means in the cap and has an appropriate configuration whereby~
when the shoulder in the cap engages the first shoulder means
of the terminal posts the edge means of the cap makes con-
tact through the insulation to the conductor in a wire of a
minimum predetermined size and whereby the edge portion of
the cap can engage a conductor in a larger wire through the
insulation thereof by compressing the wires against the
second shoulder means of the binding posts without servering
the wire and without the shoulder means in the cap engaging
the first shoulder means of the binding posts when the
larger wire is present.
openings in the housing of the terminal block preferably
contain a sealant material (preferably a gel) which is
placed under compressive force when the wire is inserted
into the opening means in the housing and binding posts and
the cap means is advanced against the wire to make connection
with a conductor in the wire.
The cap of the term~nal block preferably has conductive
means connected with the inner conductive portion which con-
ductive means is accessible through an opening in the outer
insulative portion of the cap to provide access for test
probe for testing the connection made by the cap.
The housing of the terminal block preferably has a base
adapted for mounting on a substrate and wherein the binding
posts and associated openings in the housing are positioned
at an angle of at least 2~ from normal to the base to
thereby facilitate visibility by the worker when inserting
the wires into the opening means.
~ ~3B~
Descrietion of Second Preferred Embodiment
The terminal block adapter preferably has cooperative
stop means comprising a shoulder on the cap which engages an
outside surface of the collar.
The terminal block adapter preferably has cooperative
stop means comprising a portion of the shoulder means in the
first opening means which engages the edge means of the cap
thereby leaving the desired preselected distance between the
edge means of the cap and another portion of the shoulder
means where the wire is positioned between the cap and the
shoulder means.
The terminal block adapter preferably has a sealing
material (preferably a gel) in at least one of the opening
means for environmentally sealing the wire, binding post, or
cap.
The terminal block adapter preferably has a test port for
communicating with the conductive inner portion thereof for
testing of electrical continuity of the cap and posts with
the wire.
Brief Description of the Drawings
Figure 1 is an illustration of the prior art 91A ter-
minal block.
Figure 2 shows a perspective partially cut away exploded
view of the terminal block of the first preferred embodiment
of the present invention.
Figures 3a, and 3b show side views of the binding post
and cap of the terminal block of the first preferred embodi-
ment of the present invention with a wire assembled therein.
~ ~8~
Figure 4 shows a perspective view of a preferred con-
figuration of the terminal block of the first preferred embo-
diment of the present invention.
Figure 5 shows a cross-section end view of a preferred
configuration of the housing of the terminal block of the
first preferred embodiment of the present invention.
Figure 6 is an exploded view of the collar and cap of
the adaptor of the second preferred embodiment of the pre-
sent invention to be assembed on a binding post of a ter-
minal block.
Figure 7 is a cross-section view of the adapter of the
second preferred embodiment of the present invention as
assembled on the terminal block binding post.
Figure 8 is a perspective view of an adapter of the
second preferred embodiment of the invention on a terminal
block, the adaptor being suitable for use over two binding
posts.
Figures 9a and 9b are cross-sections through the collar
illustrated in Figure 8.
Figure 10 is a cross section of a collar and cap of the
second preferred embodiment of the invention on a binding
post.
Figure 11 shows a further application of an adaptor of
the second preferred embodiment of the invention.
Figure 1 shows a conventional terminal block 1 which
contains pairs of threaded binding posts 2. In conventional
use wires 3 are striped of insulation at the end and the
wire wrapped around binding posts 2 and held in place by
washers 4 and threaded nut 5.
1~88~9~
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Description of the Drawinqs of the First Preferred Embodiment
of the Invention
Figure 2 shows one configuration of a five pair terminal
block having two banks of binding posts configured for three ~
pairs in the bottom tier and two pairs in the upper tier.
Terminal block 11 comprises a housing 12, binding posts 13
and caps 14. Openings 15 in the binding posts are aligned
with openings 16 in housing 12 whereby the wire intended to
be connected to the binding posts can be inserted through
opening 16 and received into opening 15 in the binding posts~
It is preferred that the opening lS extend all the way
through the binding posts so that the wire may be inserted
completely through binding posts 13 until it abuts against
the wall of cavity 17 in housing 12. Binding post 13 has
threaded portion 18 and shoulder means 19 positioned between
threaded portion 18 and opening 15. Binding post 13 has
second shoulder means 110 for supporting the wire when
compressed by the cap. The bottom portion 111 of binding
post 13 can be of any conventional or desired configration
for interconnection with the desired component. For
example, portion 111 may be connected to a wire tail which
is in turn spliced to a cable. Alternatively, portion 111
may be an opening for interconnecting with other electronic
or electric components such as circuit protection devices or
disconnect devices.
The cap 14 contains an inner conductive portion 112
which is threaded for engagement with the threaded portion
18 of binding post 13. The inner conductive portion of the
cap has shoulder means 113 adapted for engaging shoulder
means 19 on binding post 13. The inner conductive portion
112 of cap 14 has edge portion 114 adapted for engaging the
wire and compressing the wire against second shoulder means
~ 2~3~349~
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110 of binding post 13. The inner conductive portion 112
of cap 14 is covered by outer insulative portion 115. The
outer portion 115 of cap 14 may be solid for full enclosure or
ma~ contain preferred access port 116 for test probe access
to either the conductive inner portion 112 of cap 14 or the
top of binding post 13. A preferred configuration is where
conductive portion 112 of cap 14 is completely enclosed
across the top and opening 116 in cap 14 provides test probe
access to the top of conductive portion 112 of cap 14.
In another preferred configuration, cavity 17 is filled
with a sealing material to provide a barrier to moisture
entry and to prevent corrosion of the binding post and the
wire. The sealing material is preferably a gel material
having a cone penetration in the range of about 10-0 to about 350
(lo-lmm) and an ultimate elongation of at least 200%. Such
preferred sealing materials are disclosed in U.S. Patents
4,600,261 and 4,634,207 to Debbaut.
Figures 3A and 3B show the installation of a binding
post and terminal cap of this invention on a minimum prede-
termined size of wire and on a larger wire. In Figure 3A cap
14 is screwed down on terminal post 13 whereby the small
wire 121 extending through opening means 15 is deformed by
edge means 114 of cap 14 whereby edge means 114 makes con-
tact with conductor 122 of wire 121 through the insulation
of wire 121. Figure 3~ also illustrates how shoulder means
113 in cap 14 engages shoulder means 19 of binding post 13
to thereby stop the advance of cap 14 on binding post 13
before the conductor 122 in wire 121 is severed. As will be
apparent to one skilled in the art, the selection of dimen-
sions of the distance between edge means 114 of the cap and
shoulder means 113 as well as the dimension between the
bottom of opening means 15 and shoulder means 19 of binding
post 13 as well as the distance between the bottom of
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opening means 15 and shoulder 110 of binding posts 13 will
all be preselécted depending upon the size of wire 121 and
the size of conductor 122 in wire 121. These dimensions may
also be affected by the lateral distance provided between
the s~irk of cap 14 and the outer surface of binding posts
13 between shoulder means 19 and shoulder means 110. -The
wider the gap between the skirt and consequently edge means
114 and the surface of that portion of binding post 13 will
provide easier conformability of wire 121 when it is
compressed against shoulder 110. The smaller the gap between
the skirt and edge means 114 and binding post 13 will pro-
vide more likelihood that shear forces may cut or break wire
121 or conductor 122 before shoulder 113 of cap 14 is seated
on shoulder 19 of binding post 13. Likewise the con-
figuration of edge means 114 will be determined by the
characteristics of the preselected wire 121 and conductor
122. If the insulation on wire 121 is hard or tough the
edge means 114 may need to be sharp in order to cut through
the insulation to make contact with conductor 122. In
contrast, if the insulation on wire 121 is soft, edge means
114 may desirably be rounded so that it will pierce through
the insulation on wire 121 and make contact with conductor
122 without cutting conductor 122.
Figure 3B illustrates the assembly of a larger wire 123
with larger conductor 124 assembled in a binding post 13 and
cap 14. As can be seen in this illustration, edge means 114
has engaged conductor 124 of wire 123 but shoulder means 113
has not contacted or seated on shoulder means 19. In this
use with the larger wire, it can be seen that the con-
figuration of edge means 114, the distance between the skirt
of the cap and edge means 114 from the binding post 13
should be designed such that the edge means 114 will not cut
or break conductor 124 when the usual torque is applied by
~,~88~f;3~,
the worker in installing cap 14 on binding post 13.
Although not shown in Figure 3B, it is generally preferred
that the skirt diameter and edge means 114 diameter compared
to the binding posts diameter as well as the shape of edge
means 114 are such that conductor 123 will be deformed by the
downward pressure of cap 14 against shoulder 110 of binding
post 13 for the best holding power to prevent wire 123
from being pulled out of the binding post and cap assembly.
The binding post and cap configuration of the present
invention provides a number of advantages among which are
the following. Edge means 114 of the cap may be configured
in a very round shape rather than a cutting edge shape
because when edge means 114 contacts the wire 121 or 123 and
deforms the wire against shoulder 110 placing the wire under
cGmpression a rounded edge means can easily pass through even
tough insulation because of the rotational movement of cap 14
in order to make contact with wire 122 or wire 124 while the
rounded edge will not be likely to cut or break the conduc-
tor 122 or 124 in the wires. Such a rounded configuration of
edge 114 is less likely to cause a nick or notch in the con-
ductor of the wire which would weaken it structurally and
increase the likelihood that the wire would break at that
point. Therefore improved surface life of wires is one
advantage of the terminal block in the present invention.
Other features include the fact that cap 14 can be backed off
to open or disconnect the circuit and provide testing capa-
bility to isolate sources of problems in the circuit without
moving the wire. After testing, the connection can be
restored by rotating the cap back into position so that edge
means 114 is in contact with the conductor in the wire.
Figure 4 shows a preferred configuration of the terminal
block of the present invention wherein housing 132 contains
, ~
~ ~8849~
a single tier of terminal posts and caps. Illustrated in
Figure 4 is a five pair terminal block having openings 136
in housing 132 for receiving the wires which are desired to
be connected with the terminal posts inside housing 132,
Caps 134 contain openings 116 for test access to either the
conductive inner portion of caps 134 or to the binding posts
on which caps 134 are mounted. Base 131 of housing 132 is
adapted for attachment to either horizontal or vertical
substrates or can be adapted to be plugged into other
components. The angle at which the face 133 is positioned
provides easier visual access for the worker to install the
desired wires in openings 136. The angle at which caps 134
are positioned (essentially perpendicular to face 133~ provi-
des easy access for the worker to turn the caps with conven-
tional tools.
Figure 5 is a cross-section end view of the preferred
embodiment shown in Figure 4 and illustrates that the longi-
tudinal axis 141 of binding posts 143 may be positioned at
any desired angle, A, preferably between about 20 and 60
from the vertical. In general, it is preferred that the
axis 142 of the openings in the housing and the binding
posts in general be perpendicular to axis 141 but these may
be positioned at different angles as desired for different
applications.
Description of the Drawin~s of the Second Preferred Embodiment
of the Invention
Figure 6 illustrates the basic elements of the terminal
block adapter of the present invention which comprises
collar 221 and cap 222 which are for use on conventional
terminal block 21 and threaded binding post 22. It will be
noted that in actual use the conventional washers 224 and
nuts 222 will preferably be removed from the binding posts
and discarded and wire 23 will preferably be cut at the end
to provide a straight section of wire with the insulation on
the wire for insertion into the collar of the terminal bloc~
adapter of the present invention. In use the terminal bloc~
adapter of the present invention involves placing collar 221
on binding post 22 inserting wire 23 into the opening 223 in
collar 221 then placing cap 222 into collar 221 and engaging
threads in cap 222 on the threads of binding post 22 and
tightening cap 222 down on binding post 22 until the bottom
edge 224 of cap 222 engages the insulation and cuts through
the insulation of wire 23. Cap 222 thus makes the connec-
tion through insulation of wire 23 to the conductor in wire
23 through the conductive portion of the cap 222 at edge 224
to binding post 22.
In Figure 7 the details of the terminal block adapter of
the present invention can be more clearly understood. Collar
221 has a first opening means 231a which is small in one
portion for the binding posts to pass therethrough and is
larger in portion 231b for receiving the bottom of the cap
222. Collar 221 contains a second opening 232 extending
from the lateral side of the collar into the larger portion
231b of the first opening whereby opening 232 is adapted to
receive the insulated wire from the lateral side of the
collar 221~ Cap 222 comprises an inner conductive portion
233 which has lower edge 224 adapted for engaging the wire
and cutting through the insulation of the wire to engage the
conductor 23a in wire 23, and outer insulative portion 235.
The conductive inner portion 233 of cap 222 is threaded to
engage the binding post 22 and thereby make the electrical
connection from the conductor 23a of wire 23 to binding
post 22. Collar 221 contains a shoulder area 23~ which is
the bottom of the wider part of the first opening 231b in
collar 221. Shoulder area 234 in collar 221 provides the
~ ~38~1
-16-
base against which wire 23 is compressed by the bottom edge
224 of cap 222. Collar 221 and cap 222 contain coopera~i~Je
stop means which stops the advance of bottom edge 224 so
that edge 224 of the cap 222 does not sever or cut too
deeply into wire 23 and conductor 23a. Such cooperative
stop means can be of various configurations and is
illustrated in Figure 7 by shoulder area 236 on cap 222 which
engages the top surf~ce of collar 221 whereby the distances
from the top surface of collar 221 and shoulder 236 to the
bottom edge 224 of cap 222 provides a predetermined distance
between bottom edge 224 of cap 222 and shoulder means 234 in
collar 221 against which wire 23 is compressed by bottom
edge 224 of cap 222.
Additional optional but preferred aspects of the ter- : -
minal block adapted of this invention are illustrated in
Figure 7 wherein cavity 237 created by skirt 238 on collar
221 i5 filled with a sealing material which seals around the
base of the binding posts 22. Likewise, openings 231a, 231b
and 232 in collar 221 may be filled with a sealing material
to thereby seal all of the void spaces around the wire and
binding post. Figure 7 also illustrates opening 239 and cap
222 which provides a test port to binding post 22 for
testing electrical continuity from conductor 23a in wire 23
through the inner conductive portion 233 of cap 222 to binding
post 22. ~s with the other parts of the terminal block
adapter, port 239 may be filled with a sealing materal and
may contain any kind of protective cap or plug to environmen-
tally protect the top of binding post 22.
The sealing materials useful in the terminal block
adapter of the present invention may be any conventional
sealing material such as gels or greases. However, it is
preferred that the sealing material be a gel as disclosed in
U.S. Patents 4,600,261, 4,634,207, 4,595,635.
~ ~8~34~
-17-
Another configuration of t'ne cooperative stop means,
while not shown specifically in the drawings, can be
understood by reference to Figure 7. An alternative embodi-
ments of the cooperative stop means can be made where the
second opening 232 in collar 221 is recessed down in and
partially below shoulder 234 whereby bottom edge 224 of cap
222 would engage at least a portion of shoulder 234 oppositè
opening 232 containing wire 23 thus halting the advance of
cap 222 when edge 224 engages the higher portion of shoulder
234 which would occur after edge 224 of cap 222 had engaged
wire 23 and passed through the insulation to contact conductor
23a. Various other configurations of the cooperative stop
means will be apparent to those skilled in the art. Also with
reference,to Figure 7 it will be apparent that opening 232
can be extended into the opposite side of collar 221 whereby'
wire 3 could extend further into opening 232 thereby
allowing edge 224 to contact wire 23 on both sides of cap 222
rather than just one side.
As an alternative to the cooperative stop means
requiring cooperation between some element of cap 222 and
some element of collar 221, this invention may also utilize a ,
unilateral stop means in cap 222 which comprises a shoulder
similar to shoulder 236 which is a predetermined distance
from the edge 224 of cap 222 whereby the shoulder would
engage and rest on the flat surface of the insulation of wire
23 after edge 224 has cut through the insulation and engaged
conductor 23a. Other configurations within the scope of the
present invention will be apparent to one skilled in the art
following the present disclosure and illustrations in the
drawings.
Figure 8 (which uses the same reference numbers as above
where applicable) illustrates a collar 241 that may be simi-
:
~884~
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lar to that illustrated in Figure 7, but has two (and may
have more) openings in order that it can be over two (or
more) terminal posts, and thus provide means for connection of
two (or more) wires to said posts.
A section through line BB is shown in Figures 9a and 9b.
In Figure 9a the shoulder 234 is of uniform height, and the
opening 232 lies above it. Thus, a wire in the opening 232
(at the position illustated) would be cut through if a cap
were fully screwed into opening 231b. In Figure 9b a portion
of collar 234a (generally opposite hole 232a) is positioned
higher than the hole 232 so that a cap is prevented from
being screwed so far into the opening 231b that severing of
the wire would occur. Thus, the adapter can be designed to
cut away excess length of a wire, and make contact to the
length that remains in the adapter.
Figure 10 shows a cap partially screwed into an adapter.
In Figure 11 a terminal block of different design is
illustrated. Here a collar covers three binding posts, two of
which are provided with insulating-cutting caps.
