ELECTRICAL CONNECTOR WITH EXTERNAL LOAD BAR, AND METHOD OF ITS USE

Abstract

An electrical connector, having an elongated plastic housing which is open at its rearward end and has an essentially continuous forward end wall with a flat upper portion, a lower portion of the forward end wall being integrally thickened to project forward beyond its upper portion.

Claims

1.-3. (canceled)

4. An electrical connector plastic exterior housing comprising: a) an open rearward end; and b) an integral forward end wall with holes in the forward end wall of the housing for insertion of wires therethrough, wherein adjacent holes in the forward end wall of the housing merge into each other such that adjacent holes blend together, wherein the forward end wall has a flat upper face and wherein an integrally formed thin layer of plastic material extends out beyond the flat upper face underneath a row of the holes adjacent to an anvil and resting upon the anvil.

5. The electrical connector plastic exterior housing of claim 1 further comprising contact blade grooves in the forward end wall comprising contact blades therein.

6. The electrical connector plastic exterior housing of claim 5, wherein the holes comprise an upper row of holes and a lower row of holes so as to provide at least two rows in the front end wall, with adjacent holes of the upper row of holes and the lower row of holes overlapping and merging into each other.

7. The electrical connector plastic exterior housing of claim 6, wherein the integrally formed thin plastic material layer extends beyond the flat upper surface such that the integrally formed thin plastic material layer is sheared when the wires through the lower row of holes are sheared.

8. The electrical connector plastic exterior housing of claim 4, wherein the integrally formed thin plastic material layer rests upon the anvil and extends beyond the flat upper surface such that the integrally formed thin plastic material layer is sheared when the wires through the row of holes are sheared.

9. An electrical connector plastic exterior housing comprising: a) an open rearward end; and b) an integral forward end wall having a plurality of wiring holes therethrough arranged in at least two parallel rows, wherein adjacent holes of the plurality of wiring holes overlap and merge into each other such that adjacent holes blend together, wherein the forward end wall has a flat upper face and wherein the front end wall comprises an integrally formed thin layer of plastic material extending beyond the flat upper face beneath a lowest of the at least two parallel rows and resting upon an anvil.

10. The electrical connector plastic exterior housing of claim 9 further comprising contact blade grooves in the forward end wall.

11. The electrical connector plastic exterior housing of claim 10 wherein the integrally formed thin plastic material layer extends beyond the flat upper surface such that the integrally formed thin plastic material layer is sheared when the wires through the lower row of holes are sheared.

12. The electrical connector plastic exterior housing of claim 9 wherein the integrally formed thin plastic material layer extends beyond the flat upper surface such that the integrally formed thin plastic material layer is sheared when the wires through the lower row of holes are sheared.

13. A method for forming a connector from an electrical connector plastic exterior housing, the method comprising: a) inserting wires though an open rearward end of the housing; b) inserting the wires through holes in an integral forward end wall of the housing, wherein adjacent holes in the forward end wall of the housing merge into each other such that adjacent holes blend together, and wherein the forward end wall has a flat upper face, and wherein the front end wall comprises an integrally formed thin plastic material layer extending beyond the flat upper face underneath a lowest row of the holes and resting upon an anvil; and c) shearing the wires and the integrally formed thin plastic material layer thereunder.

14. The method of claim 13 further comprising sliding contact blades into conductive engagement with respective ones of the wires.

Description

DRAWING SUMMARY

[0032] FIGS. 1 through 4 are provided as exact copies of certain figures in my prior patents, which is necessary in order to provide a proper basis for describing my present invention.

[0033] FIG. 5 is a front end elevation view of my modified connector housing and External Load Bar, showing the empty connector not loaded with wires;

[0034] FIG. 6 is an elevational cross-section taken on Line 6-6 of FIG. 5 showing the empty connector housing with the External Load Bar on its forward end wall;

[0035] FIG. 7 is a side elevational view of the connector housing loaded with wires;

[0036] FIG. 8 is a view like FIG. 7, but additionally with schematic indications showing how the crimping and shearing operation, and the separation of the External Load Bar with its encased wires, will be done;

[0037] FIG. 9 is a side elevational view showing the External Load Bar after it has been separated from the connector housing, and still retains its accompanying load of the insulated wires which still remain encased in it and protrude from it; and

[0038] FIG. 10 is a front end elevation of the loaded connector housing after the External Load Bar has been shorn off, exposing the bare ends of the insulated wires.

DETAILED DESCRIPTION

[0039] As shown in FIGS. 5 and 6, the modified connector housing 122 has a thickened Stiffener 100 (otherwise known as the External Load Bar) formed as an integral lower part of its front end wall 128. A horizontal row of four upper holes 145 and a horizontal row of four lower holes 144 are formed through the solid material of the Stiffener. As best seen in FIG. 5, the holes of the rows are staggered, and tend to blend or merge together. Stiffener 100 has a flat bottom surface identified by numeral 104. During the shearing operation, stiffener 100 will be supported from that bottom surface 104, which will in turn rest upon an anvil. There is a thin layer of plastic material underneath the lower holes 144, which forms the bottom surface 104.

[0040] On the front wall of housing 122 as best seen in FIG. 5, there is an upper vertical area 132, above the Stiffener 100, where the slots or grooves 130 for contact blades 36 are located. There are eight of these slots to accommodate the eight contact plates 36. The cross-section view of FIG. 6 shows one contact blade 36 occupying the corresponding slot or groove 130.

[0041] As shown in FIG. 6, the bottom wall of connector housing 122 is designated 124 and its bottom surface as 126. When the connector is loaded with wires, they will be in suitable guideways extending the length of the hollow connector housing, and will also extend through the holes 144, 145, and protrude outward from the front side of the Stiffener 100.

[0042] Since FIG. 6 is a cross-section view, it shows one of the contact blades 36 occupying a corresponding one of the slots 130.

[0043] As also indicated in FIG. 6, the plastic material of Stiffener 100 is formed integral with front end wall 128 of housing 122. That is extremely important, because when the Stiffener 100 and the encased wires it contains are sheared off, the Stiffener continues to mechanically support the front end wall 128 until the shearing is fully complete.

[0044] As shown in FIG. 6, the upper surface of Stiffener 100 has a small groove 102 that is immediately adjacent the flat upper face 132 of the connector housing. The purpose of that groove is to guide the action of cutting blade 60 when the stiffener and wire ends are to be sheared off.

[0045] Reference is now made to FIG. 7 which shows the connector housing when loaded with insulated wires. Wires 16 are unsheathed from an incoming cable with a length sufficient to protrude at least several inches of gripping length from the front side of Stiffener 100. This allows the technician to pull the wires tight before doing the crimping and shearing operation. Tightness of the wires inside the connector housing improves the electrical performance of the connector.

[0046] FIG. 8 reproduces the loaded housing of FIG. 7 on a smaller scale, to provide space to schematically illustrate how the crimping and shearing will be done. A hand tool 300 above the housing drives arrows 301, 302, and 303 downward. Arrow 301 represents the crimping of the plastic housing, in the manner shown in my prior patents. Arrow 302 represents the blade driver, that drives all of the blades 36 into electrical engagement with the corresponding contact blades. And arrow 303 represents the cutting blade 60 that will shear off both the Stiffener 100 and its encased wires. A block 42 shown in the lower left corner of the drawing represents an anvil that supports the bottom surface 104 of the Stiffener 100, and that the blade 60 will engage at the end of its cutting stroke.

[0047] As shown in FIG. 9, the Stiffener 100 after separation from front wall 128 of the housing still retains its load of insulated wires 16 protruding from its front side. It is then no longer needed, and may be disposed of.

[0048] As shown in FIG. 10, removal of the Stiffener 100 has left the bare front wall 128 in which the bared ends of the insulated wires are clearly visible. The wire ends do not and must not protrude, or there would be a risk of electrical engagement with the female connector. To accomplish the appropriate electrical function of the connector, that must not be tolerated. Removal of the Stiffener brings the size and shape of the housing 122 back to the industry and FCC standard, so as to correctly mate with a female RJ45 connector.

Method of Operation

[0049] As described above, the modified connector housing of the present invention is made with the Stiffener or External Load Bar as an integrally formed part of it. Four pairs of insulated wires are inserted into and through the housing 122, and through the upper and lower holes 144, 145, in the Stiffener. The manner of guiding the wire pairs is such that one wire of each pair protrudes through an upper hole 145, and the other wire of each pair protrudes through the adjacent lower hole 144.

[0050] Before shearing the Stiffener and encased wire ends the technician will check the color coding of the wires to verify their correct locations. He then preferably stretches each of the wire pairs by pulling its protruding ends. The purpose of that is to bring each wire pair, inside the connector, as close as possible to the respectively associated contact blades. This is essential to maximize the electrical performance of the connector.

[0051] I have modified my crimping and shearing tool 50, 70, to provide two small posts that extend the ends of anvil 42, so that all eight of the wires will be cut in a single pass of the cutting blade 60. The Stiffener sits directly on the anvil, with no space between its bottom surface and the anvil. There is a measurable thickness of plastic material below the bottom row of holes. When the shearing takes place, the blade 60 first cuts all of the wires in the upper row 145, and then all wires in the lower row 144.

[0052] After the shearing is done the Stiffener—which is now detached from the front wall 128—may be disposed of. Connector housing 122 is then moved into mating engagement with an associated female receptacle, bringing the contact prongs of the female receptacle into engagement with the contact blades 36. Performance tests, if necessary or desired, may then be conducted.

[0053] Although I have described my invention in detail in order to comply with requirements of the patent laws, it will be understood that the scope of my protection is to be adjudged only in accordance with the appended claims.