Crimping tool

Abstract

A crimping tool, for attaching at least one wire to a connector, includes a housing, a first handle coupled to the housing, and a second handle coupled to the housing and movable relative to the first handle. The crimping tool also includes a working head coupled to the housing opposite the first and second handles. The working head includes an upper wall, an end wall, and a gap defined between the upper wall and the end wall. The crimping tool also includes a punch assembly slidable along the working head toward the end wall in response to movement of the second handle toward the first handle. The punch assembly is visible through the gap as the punch assembly slides toward the end wall.

Claims

1. A crimping tool comprising: a housing; a working head coupled to the housing and comprising a center channel; a drive assembly disposed within the housing and comprising a drive pin that extends through the center channel of the working head; a first handle coupled to the housing; a second handle coupled to the housing, wherein movement of the second handle moves the drive assembly; and a punch assembly comprising a first punch and a second punch coupled to the drive pin of the drive assembly on either side of the center channel, wherein movement of the drive pin from a first position to a second position causes the first punch and the second punch of the punch assembly to move parallel to the center channel from an open position to an actuated position.

2. The crimping tool of claim 1, wherein the first punch is configured to crimp wires into a first connector type and the second punch is configured to crimp wires into a second connector type, wherein the first connector type is different from the second connector type.

3. The crimping tool of claim 1, wherein the first punch and the second punch each comprise an axial central bore on either side of the center channel, the central bore stabilizing the first punch and the second punch on either side of the central bore as the punch assembly moves between the open position and the actuated position.

4. The crimping tool of claim 1, further comprising a projection on the housing that rotatably couples the housing to the working head, wherein one of the working head or the projection comprises a detent and the other of the working head or the projection comprises a recess, wherein engagement between the detent and the recess resists rotation of the working head about the center channel.

5. The crimping tool of claim 1, further comprising a biasing member in an over-center arrangement that biases the punch assembly in the open position until the drive assembly reaches an equilibrium point, wherein the biasing member biases the punch assembly in the actuated position.

6. The crimping tool of claim 1, wherein the drive assembly comprises a rack and pinion configured to drive the punch assembly toward an end wall of the working head in the actuated position.

7. The crimping tool of claim 6, wherein the rack is separable from the drive pin and the rack bears against the drive pin to impart axial movement of the drive pin.

8. A crimping tool comprising: a housing defining a longitudinal axis through a center of the housing; a drive assembly extending along the longitudinal axis and through the housing; a first handle coupled to the housing; a second handle coupled to the drive assembly; a working head coupled to the housing, the working head including an end wall and a central channel; and a punch assembly coupled to the drive assembly extending through the central channel of the working head, the punch assembly comprising a first punch and a second punch; wherein movement of the second handle moves the drive assembly through the housing and the central channel and drives the punch assembly from an open position to an actuated position relative to the end wall of the working head.

9. The crimping tool of claim 8, further comprising a gap between the first punch and the second punch of the punch assembly and the end wall of the working head, wherein the gap between the first punch and the end wall is equal to the gap between the second punch and the end wall in the actuated position, and wherein the gap in the actuated position is less than the gap in the open position.

10. The crimping tool of claim 8, wherein the punch assembly and the working head are rotatable about the longitudinal axis between a first orientation and a second orientation.

11. The crimping tool of claim 10, wherein the first punch is configured to crimp wires into a first connector type and the second punch is configured to crimp wires into a second connector type, wherein the first connector type is different from the second connector type, and wherein the first punch and the second punch rotate 180 degrees about the longitudinal axis between the first orientation and the second orientation.

12. A crimping tool comprising: a housing; a working head coupled to the housing and comprising a center channel; a drive assembly disposed within the housing and comprising a drive pin that extends through the center channel of the working head; and a punch assembly comprising a first punch and a second punch coupled to the drive pin of the drive assembly on either side of the center channel, wherein movement of the drive pin from a first position to a second position causes the first punch and the second punch of the punch assembly to move parallel to the center channel from an open position to an actuated position; wherein the first punch and the second punch each comprise an axial central bore on either side of the center channel, the central bore stabilizing the first punch and the second punch on either side of the central bore as the punch assembly moves between the open position and the actuated position.

13. A crimping tool comprising: a housing; a working head coupled to the housing and comprising a center channel; a drive assembly disposed within the housing and comprising a drive pin that extends through the center channel of the working head; a punch assembly comprising a first punch and a second punch coupled to the drive pin of the drive assembly on either side of the center channel, wherein movement of the drive pin from a first position to a second position causes the first punch and the second punch of the punch assembly to move parallel to the center channel from an open position to an actuated position; and a projection on the housing that rotatably couples the housing to the working head, wherein one of the working head or the projection comprises a detent and the other of the working head or the projection comprises a recess, wherein engagement between the detent and the recess resists rotation of the working head about the center channel.

14. A crimping tool comprising: a housing; a working head coupled to the housing and comprising a center channel; a drive assembly disposed within the housing and comprising a drive pin that extends through the center channel of the working head; a punch assembly comprising a first punch and a second punch coupled to the drive pin of the drive assembly on either side of the center channel, wherein movement of the drive pin from a first position to a second position causes the first punch and the second punch of the punch assembly to move parallel to the center channel from an open position to an actuated position; and a biasing member in an over-center arrangement that biases the punch assembly in the open position until the drive assembly reaches an equilibrium point, wherein the biasing member biases the punch assembly in the actuated position.

15. A crimping tool comprising: a housing; a working head coupled to the housing and comprising a center channel; a drive assembly disposed within the housing and comprising a drive pin that extends through the center channel of the working head; and a punch assembly comprising a first punch and a second punch coupled to the drive pin of the drive assembly on either side of the center channel, wherein movement of the drive pin from a first position to a second position causes the first punch and the second punch of the punch assembly to move parallel to the center channel from an open position to an actuated position; wherein the drive assembly comprises a rack and pinion configured to drive the punch assembly toward an end wall of the working head in the actuated position.

16. The crimping tool of claim 15, wherein the rack is separable from the drive pin and the rack bears against the drive pin to impart axial movement of the drive pin.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a crimping tool according to one embodiment.

(2) FIG. 2 is an exploded view of the crimping tool of FIG. 1.

(3) FIG. 3 is a cross-sectional view of the crimping tool of FIG. 1, taken along line 3-3 in FIG. 1.

(4) FIG. 4 is a cross-sectional view of the crimping tool of FIG. 3, illustrated in an actuated configuration.

(5) FIG. 5 is a cross-sectional view of the crimping tool of FIG. 1, taken along line 5-5 in FIG. 1.

(6) FIG. 6 is a perspective view of a crimping tool according to another embodiment.

(7) FIG. 7 is a cross-sectional view of the crimping tool of FIG. 6, taken along line 7-7 in FIG. 6

(8) FIG. 8 is a cross-sectional view of the crimping tool of FIG. 7, illustrated in an actuated configuration.

(9) FIG. 9 is a cross-sectional view of a portion of the crimping tool of FIG. 6, taken along line 9-9 in FIG. 6.

(10) Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

(11) FIG. 1 illustrates a hand tool 10, which is a crimping tool in the illustrated embodiment. The crimping tool 10 includes a housing 14, a first handle 18, a second handle 22, and a working head 26. In the illustrated embodiment, the first handle 18 is a fixed handle (i.e. the first handle 18 is fixed relative to the housing 14), and the second handle 22 is movable relative to the first handle 18. In other embodiments, both handles 14, 18 may be movable relative to the housing 14 such that the crimping tool 10 may be actuated in a scissors-like manner.

(12) With reference to the orientation of the crimping tool 10 illustrated in FIG. 2, the housing 14 includes a front end 30, a back end 34, opposite first and second side walls 38, 42, and an upper wall 46. The housing 14 is disposed between the handles 18, 22 and the working head 26 and defines a longitudinal axis 50 extending between the front and back ends 30, 34. The housing 14 further includes a projection 54 extending from the front end 30. The working head 26 receives the projection 54 to couple the working head 26 to the housing 14.

(13) With reference to FIGS. 2 and 3, the first handle 18 and the second handle 22 are coupled to the housing 14, proximate the back end 34, by a first pin 58. The first handle 18 includes a grip portion 62, an upper bracket 66, and a pair of spaced walls 70 that collectively define a lower bracket 74. The upper bracket 66 engages the upper wall 46 of the housing 14, and the lower bracket 74 engages an interior shelf 78 located within the housing 14 (FIG. 3). The first pin 58 and the engagement between the brackets 66, 74 and the housing 14 inhibit movement of the first handle 18 relative to the housing 14. In the illustrated embodiment, the second handle 22 is received between the two walls 70 of the first handle 18 and is pivotable relative to the first handle 18 about the first pin 58. Each of the illustrated handles 18, 22 includes an arcuate relief 82 to provide space between the handles 18, 22 (e.g., to accommodate a user's fingers) when the crimping tool 10 is in an actuated configuration (FIG. 4).

(14) The illustrated crimping tool 10 further includes a drive assembly 86, a link 90 extending between the drive assembly 86 and the second handle 22, and a punch assembly 94 engaged with the drive assembly 86 (FIG. 2). The link 90 is pivotally coupled to the second handle 22 at one end by a second pin 98, and the link 90 is pivotally coupled to the drive assembly 86 at its opposite end by a third pin 102. The drive assembly 86 has a clevis 106 that receives the third pin 102 and a drive pin 110 that extends from the clevis 106. In the illustrated embodiment, the drive pin 110 extends along the longitudinal axis 50. The third pin 102 extends through slots 114 formed in the side walls 38, 42 of the housing 14. The engagement of the third pin 102 with the slots 114 generally restricts movement of drive assembly 86 to sliding movement along the longitudinal axis 50.

(15) With continued reference to FIG. 2, the punch assembly 94 includes a first punch 118, a second punch 122, and a connecting portion 126 disposed between the first punch 118 and the second punch 122. In the illustrated embodiment, each of the punches 118, 122 includes a first chamfered guide surface 130 and a second chamfered guide surface 134. The guide surfaces 130, 134 are engageable with a connector to facilitate guiding the connector into a proper position during a crimping operation. In other embodiments, only one of the first and second punches 118, 122 may include guide surfaces 130, 134, or the guide surfaces 130, 134 may be omitted.

(16) The crimping tool 10 is operable to crimp or terminate wires, such as data/communications wires, with a desired connector. In the illustrated embodiment, the first punch 118 is configured to crimp wires into a first type of connector, and the second punch 122 is configured to crimp wires into a second type of connector that is different from the first type of connector. For example, the punches 118, 122 may be differently sized, may be able to crimp a different number or gauge of wires, may include one or more cutting blades, etc. In some embodiments, the first punch 118 may be configured to crimp wires into an RJ45 type connector, and the second punch 122 may be configured to crimp wires into an RJ11 type connector.

(17) Referring to FIGS. 3 and 4, the punch assembly 94 is slidably received within the working head 26. The drive pin 110 is engageable with the connecting portion 126 to move the punch assembly 94 from an open position (FIG. 3) to an actuated position (FIG. 4) in response to movement of the second handle 22 toward the first handle 18. In the illustrated embodiment, each of the punches 118, 122 includes an axial bore 138 that receives a corresponding post 142 on the working head 26. The posts 142 guide and stabilize the punch assembly 94 as it slides between the open and actuated positions. A biasing member 146, which is a coil spring in the illustrated embodiment, is disposed within the working head 26 and engages the connecting portion 126 to bias the punch assembly 94 toward the open position.

(18) With reference to FIG. 2, the working head 26 includes a front end 150, a back end 154, a first wall 158, and a second wall 162. The working head 26 further includes a center channel 166 extending along the longitudinal axis 50 and first and second stop surfaces 170, 174 extending radially outwardly from the center channel 166, proximate the front end 150. A first gap or opening 178 is defined between the first wall 158 and the first stop surface 170, and a second gap or opening 182 is defined between the second wall 162 and the second stop surface 174. The first punch 118 is visible through the first gap 178 from the exterior of the crimping tool 10, and the second punch 122 is visible through the second gap 182 from the exterior of the crimping tool 10 (FIG. 1). With reference to FIG. 2, in the illustrated embodiment, the working head 26 and the punch assembly 94 are rotatable about the longitudinal axis 50 between a first orientation in which the first wall 158 of the working head 26 is generally adjacent the upper wall 46 of the housing 14 and a second orientation (not shown) in which the second wall 162 of the working head 26 is general adjacent the upper wall 46 of the housing 14. As such, the first orientation and the second orientation are rotationally offset by about 180 degrees.

(19) The illustrated working head 26 further includes a detent 200 (FIG. 5) that is engageable with a first recess 204 on the projection 54 when the working head 26 is in the first orientation and that is engageable with a second recess 208 on the projection 54 when the working head 26 is in the second orientation. The engagement between the detent 200 and the first recess 204 resists rotation of the working head 26 out of the first orientation, and the engagement between the detent 200 and the second recess 208 resists rotation of the working head 26 out of the second orientation. In other embodiments, the working head 26 may include the recesses 204, 208, and the projection 54 may include the detent 200. In some embodiments, one or more additional detents and/or recesses may be provided.

(20) In operation, a user inserts a connector of a first type (not shown) into the working head 26 between the first punch 118 and the first stop surface 170. The user aligns the wires to be crimped (not shown) with the appropriate terminals of the connector. Next, the user squeezes the handles 18, 22 together to pivot the second handle 22 toward the first handle 18. As the second handle 22 pivots, it drives the drive assembly 86 in the direction of arrow A (FIG. 3). The drive pin 110 bears against the connecting portion 126 to move the punch assembly 94 toward the actuated position (FIG. 4), compressing the biasing member 146. During this process, the user can observe the connector and the wires from the top side of the crimping tool 10 by looking through the first gap 178. If the user notices that the wires are not properly aligned with the connector before the crimp is completed, the user may release pressure on the handles 18, 22. The biasing member forces 146 the punch assembly 94 to return to the open position (FIG. 3), which in turn causes the second handle 22 to pivot away from the first handle 18.

(21) If the user continues the crimping operation, a line 212 extending through the centers of the second and third pins 98, 102 passes over the center point of the first pin 58 (FIG. 4). Accordingly, the biasing force of biasing member 146, which previously acted through the punch assembly 94, drive assembly 86, and link 90 to bias the second handle 22 away from the first handle 18, now biases the second handle 22 toward the first handle 18. This over-center arrangement may indicate to the user that the crimping operation is completed. The user then applies an opening force to the handles 18, 22 until the line passes 212 back over the center point of the first pin 58 (i.e. the equilibrium point). The biasing member 146 then returns the punch assembly 94 and the second handle 22 to the open position. Because the equilibrium point occurs near the end of travel of the punch assembly 94, the user may abort the crimping operation with relative ease throughout the majority of the crimping operation.

(22) If the user desires to perform a crimping operation on a differently sized connector, the user may grasp the working head 26 and rotate it to the second orientation by overcoming the engagement force of the detent 200 and first recess 204. Once the working head 26 is in the second orientation, the user inserts a connector of a second type (not shown) into the working head 26 between the second punch 122 and the second stop surface 174. The user may then commence a crimping operation as described above. During this process, the user can observe the connector and the wires from the top side of the crimping tool 10 by looking through the second gap 182.

(23) FIGS. 6-9 illustrate a hand tool 1010, which is a crimping tool in the illustrated embodiment. The crimping tool 1010 includes features similar to the crimping tool 10 described above with reference to FIGS. 1-5, and like components have been given like reference numbers plus 1000. The following description focuses primarily on the differences between the crimping tool 10 of FIGS. 1-5 and the crimping tool 1010 of FIGS. 6-9.

(24) With reference to FIGS. 7 and 8, the illustrated crimping tool 1010 has a drive assembly 1087 including a rack member 1089 and a pinion 1091 in meshed engagement with the rack member 1089. The rack member 1089 is coupled to the drive pin 1110 such that the rack member 1089 and the drive pin 1110 are movable together along the longitudinal axis 1050. The pinion 1091 is fixed to the second handle 1022 for rotation therewith about the pivot axis of the second handle 1022. In some embodiments, the rack member 1089 and the drive pin 1110 are integrally formed together as a single piece. In other embodiments, the drive pin 1110 may be fixed to the rack member 1089. In yet other embodiments, the rack member 1089 may be separable from the drive pin 1110 and may bear against the drive pin 1110 to impart axial movement to the drive pin 1110.

(25) With continued reference to FIGS. 7 and 8, the crimping tool 1010 further includes a handle lock assembly 1300. A first member 1304 of the handle lock assembly 1300 extends from the first handle 1018 in a direction generally toward the second handle 1022. A second member 1308 of the handle lock assembly 1300 extends from the second handle 1022 in a direction generally toward the first handle 1018. The second member 1308 includes a plurality of teeth 1312 and a release recess 1316 adjacent the teeth 1312. The first member 1304 supports a pawl 1320 that is engageable with the teeth 1312. A spring 1324 extends from the pawl 1320 to an anchor point 1328 on the first handle 1018.

(26) Referring to FIG. 9, the working head 1026 of the crimping tool 1010 includes a first detent 1200A that is engageable with a first recess 1204 on the projection 1054 and a second detent 1200B that is engageable with a second recess 1208 on the projection 1054 when the working head 1026 is in the first orientation. When the working head 1026 is rotated 180 degrees to the second orientation, the first detent 1200A is engageable with the second recess 1208, and the second detent 1200B is engageable with the first recess 1204. The engagement between the detents 1200A, 1200B and the recesses 1204, 1208 resists rotation of the working head 1026 out of the first orientation and the second orientation, respectively. In other embodiments, the working head 1026 may include the recesses 1204, 1208, and the projection 1054 may include the detents 1200A, 1200B. In some embodiments, one or more additional detents and/or recesses may be provided, or other means may be provided for retaining the working head 1026 in the respective first and second orientations.

(27) In operation, a user inserts a connector of a first type (not shown) into the working head 1026 between the first punch 1118 and the first stop surface 1170 (FIGS. 6 and 7). The user then squeezes the handles 1018, 1022 together to pivot the second handle 1022 toward the first handle 1018. As the second handle 1022 pivots, the pinion 1091 rotates, causing the rack member 1089 and the drive pin 1110 to advance in the direction of arrow A. This drives the punch assembly 1094 to perform a crimping operation (FIG. 8). During this process, the user can observe the connector and the wires from the top side of the crimping tool 1010 by looking through the first gap 1178 (FIG. 6).

(28) In addition, as the second handle 1022 pivots toward the first handle 1018, the pawl 1320 incrementally engages with the teeth 1312. This inhibits the second handle 1022 backing away from the first handle 1018 before the crimping operation is complete, even if the user releases pressure on the handles 1018, 1022. Once the crimping operation is complete, the pawl 1320 enters the release recess 1316 and pivots under the influence of the spring 1324 to release the handles 1018, 1022. The biasing member forces 1146 the punch assembly 1094 to return to the open position (FIG. 7), which in turn causes the second handle 1022 to pivot away from the first handle 1018.

(29) Various features of the disclosure are set forth in the following claims.