Patent Application
20060264090
The present invention relates to an electrical connector assembly. More particularly, the present invention relates to an electrical connector assembly including an insulation displacement connector block (“connector block”) comprising a plurality of housing assemblies, where the housing assemblies are stacked in a generally vertical orientation. The present invention also relates to a method of forming an electrical connector assembly that includes housing assemblies stacked in a generally vertical orientation.
In a telecommunications context, electrical connector blocks are connected to cables that feed subscribers while other electrical connector blocks are connected to cables that are connected to the service provider. To make the electrical connection between the subscriber block and the service provider block, an electrical conductor (e.g., a jumper wire) may be inserted in the electrical connector blocks to complete the electrical circuit. This process of connecting two connector blocks is generally known as “cross-connecting”. Typically the electrical conductor can be connected, disconnected, and reconnected several times as the consumer's needs change.
The basic components of a typical connector block typically include a housing, an IDC element disposed within the housing, and a conductor-receiving opening for introducing an electrical conductor (which is typically insulated) into the housing. The IDC element is used to make an electrical connection with the conductor so that the electrical circuit between the subscriber block and service provider block is completed. The IDC element displaces the insulation from a portion of the conductor when the conductor is inserted into a slot within the IDC element. An electrical contact is then made between the conductive surface of the IDC element and the conductive core of the electrical conductor. The IDC element thereby forms a portion of a circuit path by making an electrical connection with the conductor.
When a connector block is used in the telecommunications context, the connector block is typically mounted in a central location, such as a telecommunications closet, along with a plurality of other connector blocks. It is desirable for each connector block to be mounted in a position that allows a telecommunications worker to access to the openings in connector block in order to feed a conductor into the housing, and to the IDC elements, in order to make the necessary electrical connections.
In a first aspect, the present invention is an electrical connector assembly comprising a connector block. The connector block includes a plurality of housing assemblies aligned in a generally vertically stacked orientation. Each housing assembly comprises a housing, an insulation displacement connector element disposed within the housing, an access cover connected to the housing, a generally vertical surface, and a conductor-receiving opening along the generally vertical surface of the housing assembly. The insulation displacement connector element is adapted to electrically connect with a conductor partially disposed within the housing. The access cover is moveable between a closed position and an open position, where in the open position, the insulation displacement connector is accessible,
In a second aspect, the present invention is an assembly for connecting at least two electrical conductors. The assembly comprises a frame, a first insulation displacement connector block including a first elongated edge, and a second insulation displacement connector block including a second elongated edge. The first insulation displacement connector block is attached to the frame such that the first elongated edge extends in a generally vertical direction. The second insulation displacement connector block is attached to the frame such that the second elongated edge extends in the generally vertical direction. The first elongated edge of the first connector block is generally parallel to the second elongated edge of the second connector block.
In a third aspect, the present invention is a method of forming an electrical connector assembly. The method comprises providing a first connector block, providing a frame for receiving the first connector block, and attaching the first connector block to the frame. The first connector block includes a first generally vertical surface, a conductor-receiving opening along the first generally vertical surface of the housing, a plurality of housings aligned in a generally vertically stacked orientation, an insulation displacement connector element disposed within each housing, where the insulation displacement connector element is adapted to electrically connect with a conductor partially disposed within each respective housing, and an access cover on the housing which is moveable between a closed position and an open position, where in the open position, the insulation displacement connector is accessible.
The above summary is not intended to describe each disclosed embodiment or every implementation of the present invention. The figures and the detailed description which follow more particularly exemplify illustrative embodiments.
The present invention will be further explained with reference to the drawing figures listed below, where like structure is referenced by like numerals throughout the several views.
While the above-identified figures set forth an exemplary embodiment of the present invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention.
The present invention is an electrical connector assembly including a connector block, where the connector block includes a plurality of housing assemblies aligned in a generally vertically stacked orientation. A plurality of conductor-receiving openings (“openings”) are positioned along a generally vertical wall of the connector block. Each of the housing assemblies includes at least one corresponding opening, which provides a means of introducing a conductor into a housing of the housing assembly. The present invention also includes a method of forming an electrical connector assembly that includes housing assemblies stacked in a generally vertical orientation.
In an exemplary embodiment of the present invention, each housing assembly includes a housing and an access cover. An IDC element is disposed within the housing. The IDC element is adapted to electrically connect with a conductor that is at least partially disposed within the housing. The access cover is connected to the housing and moveable between a closed position and an open position. In the open position, an IDC element that is disposed within the connected housing is accessible.
Each housing assembly also includes a generally vertical surface and a conductor-receiving opening positioned along the generally vertical surface. A conductor may be introduced into the housing of the housing assembly through the conductor-receiving opening. Because the housing assemblies of the connector block are aligned in a generally vertically stacked orientation, the plurality of conductor-receiving openings of the connector block are aligned along the vertical surface of the connector block.
In the exemplary embodiment described herein (“first embodiment”), each housing of the plurality of housing assemblies has a generally vertical surface. In that embodiment, the generally vertical housing surfaces are aligned in a generally vertical direction to form the generally vertical surface of the connector block. In the first embodiment, which is described herein, a conductor-receiving opening of each housing assembly is on a generally vertical surface of a housing.
In an alternate embodiment (“second embodiment”), each access cover of the plurality of housing assemblies has a generally vertical surface, and the generally vertical surface of the connector block may be formed by a plurality of generally vertical access cover surfaces aligned in a generally vertical direction. In the second embodiment, the conductor-receiving opening of each housing assembly is on a generally vertical surface of the access cover of the housing assembly. In yet another alternate embodiment, a generally vertical surface of the connector block is mutually independent of the generally vertical surface of a housing assembly mounted in the connector block.
The modifier, “generally”, is meant to convey that “generally vertical” includes more than a strictly vertical direction (i.e., a z-coordinate direction, where orthogonal x-y-z coordinates are shown in
Throughout the detailed description of the present invention, “top”, “bottom”, and “side” are defined according to conventional meaning. A “top” of a connector block is the surface of the connector block having the greatest z-coordinate when the connector block is mounted in a central location (e.g., a telecommunications closet), a “bottom” of the connector block is the surface of the connector block having the smallest z-coordinate when the connector block is mounted in the central location, and a “side” is a surface of the connector block running vertically between the top and bottom.
The number of housing assemblies a connector block includes varies depending on many factors, including the dimensional parameters of the central location in which the connector block is to be mounted. In the telecommunications industry, the connector blocks are typically referred to by the number of pairs of conductors the connector block is capable of connecting (e.g., the number of circuit paths the connector block is capable of forming). A common connector block in the telecommunications industry is a ten-pair block, which is capable of being connected to up to ten pairs of conductors (e.g., telecommunication conductors that are electrically connected to a service provider or to ten pairs of telecommunication conductors that are electrically connected to a subscribers). Jumper wires can be used to complete the connection between these blocks. While ten pair blocks are illustrated in
A plurality of connector blocks are typically mounted in a central location, such as a telecommunications closet. The number of connector blocks in the central location depends upon the needs of the telecommunications network. The central location is typically located in an area where a telecommunications worker is able to access it in order to connect and disconnect service provider and customer circuits as needed.
Within each central location, each connector block must be mounted in a position that allows the telecommunications worker to access to the openings and IDC elements so that the worker may make the necessary electrical connections. In one of the present methods of mounting a connector block, the connector block is mounted so that a conductor-receiving opening of a housing assembly is positioned at the top of the housing, along a horizontal wall of the housing. This type of positioning is illustrated in
Connector block 10 includes housings 14, openings 16, horizontal wall 18, and access covers 20. Each housing assembly of connector block 10 is defined by a housing of the plurality of housings 14 and a respective access cover of the plurality of access cover 20. “Housings 14” generally refers to the plurality of housings in connector block 10 and “openings 16” generally refers to the plurality of openings in connector block 10. Housings 14 include housing 14A and housing 14B, whose access covers 20 are each in an open position 20A so that two IDC elements 15 disposed in each housing 14A and 14B are exposed. Although housings 14A and 14B house two IDC elements 15 each, housings 14A and 14B, as well as the other housings 14, may each have any suitable number of IDC elements. Only two access covers 20 are shown in an open position 20A and as a result, only the interiors of two housings 14A and 14B are visible.
Housings 14, and therefore the housing assemblies, are aligned in the horizontal direction (i.e., in
In electrical connector assembly 8 shown in
A telecommunications worker may need to have access to openings 16 because when the worker is making the necessary electrical connections using connector block 10, the worker may need to manually feed a conductor through an opening in plurality of openings 16 in order to access an IDC element disposed within the respective housing of the opening, which makes the electrical connection with the conductor. In the central location, connector block 10 may be located at or near the bottom of a row of connector blocks, near the ground or the bottom surface of the central location; if openings 16 are located along the bottom of connector block 10, the telecommunications worker may find it difficult to access and view openings 16 if they are close to the ground (or the bottom surface of the central location) because the worker may need to lie on the ground (or be in a position close to the ground) in order to view and/or access openings 16. There may even be potential visibility problems with the mounting of connector block 10 in
Conductor 24 is received in opening 16A and connected to IDC element 15A, which is disposed in housing 14B, and conductor 28 is received in opening 16B and connected to an IDC element 15B, which is also disposed in housing 14B. Conductors 24 and 28 are only partially disposed in housing 14B because only an end portion of each conductor 24 and 28 is disposed in housing 14B and connected to IDC elements 15A and 15B, respectively, and a portion of each conductor 24 and 28 extends from housing 14B. Conductors 24 and 28 extend from housing 14B in a vertical and upward direction (see area 32 in
Access covers 20 are pivotally connected to their respective housing 14, and access covers 20 pivot along a common horizontal axis. The pivotal connection may be a hinge. Each of the plurality of access covers 20 has an open position 20A and closed position 20B. In order to move between closed position 20B and open position 20A, each of the access covers 20 pivots in a downward direction. When each of the plurality of access covers 20 is in an open position, IDC elements 15, which are disposed within each housing 14 may be accessible by the telecommunications worker.
The present invention recognizes that when electrical connector assembly 8 is mounted in a central location that is not climate or humidity controlled, there is a potential for moisture to accumulate in area 32, where conductors 24 and 28 enter (or exit) openings 16A and 16B, respectively, and extend from housing 14B. The present invention further recognizes that conductors 24 and 28 may provide a path for moisture to enter housing 14B through openings 16A and 16B, respectively, when conductors 24 and 28 extend from housing 14B in the vertical and upward direction. In this way, conductors 24 and 28 may each act as a “wick”. For example, moisture that has accumulated around area 32 may run down conductors 24 and 28 (as a result of gravity) and directly into openings 16A and 16B, respectively, thereby introducing water into housing 14B. Openings 16A and 16B (as well as openings 16 in general) may be larger than necessary to receive conductors 24 and 28, and so, there may be space for moisture to penetrate through openings 16A and 16B, even with conductors 24 and 28 moving through openings 16A and 16B. In this way, openings 16A and 16B (and openings 16 in general) are a housing entry point for moisture. Moisture may also be introduced into housing 14B directly through openings 16A and 16B without the assistance of “wicking” conductors 24 and 28. It is typically preferred that as little moisture enter each housing 14 as possible, whether or not there is an electrical connection in each housing 14, due to the deleterious effects of water on electrical connection points and conductors.
If connector block 10 of electrical connector assembly 8 were rotated 180 degrees such that openings 16 were aligned along the bottom of connector assembly 8, conductors 24 and 28 would extend from housing 14B in a downward direction. While this positioning of connector block 10 may help address the potential for moisture to be introduced into housing 14B because of the “wicking” affect, it may introduce another problem. When openings 16 are aligned along a bottom of connector block 10, a telecommunications worker may have difficulty accessing and viewing openings 16.
Another potential problem that may arise if connector block 10 of electrical connector assembly 8 were rotated 180 degrees is that the connection point between each one of housings 14 and its respective access cover 20 would be positioned at the top of connector block 10. Moisture that accumulates along the top surface of connector block 10 may penetrate through the connection point between each one of housings 14 and its respective access cover 20 to thereby enter the respective housing. In this way, the connection point between each one of housings 14 and its respective access cover 20 may also act as a housing entry point.
A gel or other sealant material may be added to each one of housings 14 prior to the closure of its respective access cover 20 to create a moisture seal within the housing when the access cover closed. While a sealant material helps minimize the amount of moisture that contacts the IDC element 15 disposed within each one of the housings 14 after the moisture enters the housing 14, the present invention helps to further minimize the amount of moisture that enters the housing.
Because moisture is likely to accumulate along the top surface of a connector block when it is mounted in a central location, there is a need for a connector block assembly that has fewer housing entry points (as compared to connector block 10 of electrical connector assembly 8) along the top surface of the connector block. Fewer openings along the top surface will help to minimize the amount of moisture that may enter each one of housings 14 due to moisture penetrating through a housing entry point. A housing entry point may be any conductor-receiving opening, connection point between an access cover and housing, or any other channel that leads into each housing.
While electrical connector assembly 8 makes tremendous improvements in the art of electrical connector assemblies and may be designed such that it does not introduce enough water into housing 14 to be problematic, the present invention provides a further improvement. The present invention helps to further minimize the possibility that excess moisture may enter a housing of a connector block, through a “wicking” conductor or otherwise.
In part, the present invention minimizes the amount of moisture that may potentially be introduced into a housing of the connector block by way of openings and/or a path created by a conductor. In the present invention, it is preferred that a conductor, which is received in the opening of the housing, extends from its respective housing in a horizontal and downward direction. The horizontal and downward extension of the conductor from the housing helps to minimize the possibility that moisture that condenses around the conductor will be introduced into the housing. Compared to conductors 24 and 28 of electrical connector assembly 8 (shown in
The present invention also minimizes the amount of moisture that may potentially be introduced into a housing of the connector block by minimizing the number of housing entry points positioned along the top surface of the connector block (where moisture may accumulate) when it is mounted in a central location. In the exemplary embodiment, the top surface of the connector block does not have any entry points for the moisture (conductor-receiving openings or otherwise) to enter the housing, and the top surface is preferably monolithic. Furthermore, in the exemplary embodiment, the top surface of the connector block has a smaller area than in the top surface of connector block 10, thus further decreasing the amount of moisture that may accumulate on the top surface.
In the present invention, the housing assemblies of a connector block are aligned in a vertically stacked orientation, rather than aligned in a horizontal direction as in electrical connector assembly 8. When the housing assemblies are aligned in a vertically stacked orientation, the conductor-receiving opening(s) of the housing assemblies are aligned along a vertical surface of the housing assembly. An opening which is positioned along a vertical surface of the housing assembly minimizes the potential for water to enter its respective housing because gravity may cause moisture to flow downwards, and when the opening is on a side of the connector block, the possibility of moisture entering the opening because of gravity is reduced. That is, moisture that originates from above the connector block may move downward because of gravity and when the opening is positioned on the side of the connector block, it is unlikely that the moisture will flow directly into the opening.
If electrical connector assembly 8 is rotated 180 degrees so that access cover opens in the opposite direction as that shown in
The present invention may also increase visibility of the openings of each housing assembly, as compared to electrical connector assembly 8 of
In the embodiment shown in
As a result of the vertically stacked orientation of housings 44, openings 46 are aligned along vertical surface 48 of connector block 40 (or otherwise stated, openings 46 are aligned along a vertical surface of each of the housing assemblies, which include housings 44 and access covers 50). Openings 46 are positioned at a side of connector block 40, rather than the top, as with openings 16 of connector block 10 in electrical connector assembly 8 of
A telecommunications worker may access openings 46 in order to be able to introduce a conductor into each of openings 46 to access one or more IDC elements 45 located within each of the respective housings 44. Because openings 46 are aligned along vertical surface 48, a conductor which is received in each of the openings 46 extends from its respective housing 44 in a horizontal (i.e., in the x and/or y-coordinate directions) and downward (i.e., in the z-coordinate direction) direction, thereby minimizing the potential for moisture which may accumulate around the conductor (e.g., area 62) to wick into the respective housing 44 by way of the conductor. Similarly, because openings 46 are positioned on vertical surface 48 (or a side of connector block 40), the possibility of moisture directly entering opening 46 because of gravity (i.e., moisture that enters housing 44B from the above connector block 40) is minimized.
The “horizontal and downward” positioning of the conductors as they leave their respective housings 44 is illustrated with conductors 54 and 58. Conductor 54 is received in opening 46A and connected to an IDC element 45A disposed in housing 44B, and conductor 58 is received in opening 46B and connected to an IDC element 45B disposed in housing 44B. Conductors 54 and 58 are only partially disposed in housing 44B because only an end portion of each conductor 54 and 58 is disposed in housing 44B and connected to IDC elements 45A and 45B, respectively, and a portion of each conductor 54 and 58 also extends away from housing 44B.
Conductors 54 and 58 extend from housing 44B in the horizontal direction because openings 46A and 46B, respectively, are positioned on the side of connector block 40. Conductors 54 and 58 also extend from housing 44B in a downward direction because as understood by those skilled in the art, the typical practice of a telecommunications worker when making cross connections between a subscriber block and a service provider block in the central location is to route conductors 54 and 58 so that the low point (i.e., the smallest z-coordinate) on each conductor 54 and 58 is found somewhere in the middle of the conductor 54 and 58, not at either end connected to a connector block. For example, conductors 54 and 58 may be routed from connector block 40 to the bottom of the central location before being routed to another block. This type of routing may be practiced for wire management purposes. This practice, when applied to the present invention, will permit each conductor 54 and 58 to extend from housing 44B, as well as the housing of the other connector block conductor 54 and 58 are connected to, in a downward direction, regardless of which end is located higher (i.e., has the greatest z-coordinate) in the central location.
While some moisture may still enter housing 44B, the present invention helps to minimize the amount of moisture that enters housing 44B due to gravity and/or the use of conductors 54 and 58 as a “wick” or a direct path into housing 44B. The positioning of conductors 54 and 58 no longer invites moisture to run along conductors 54 and 58 directly into housing 44B. Rather, at least some moisture will have a tendency to move generally down and away from housing 44B because of the downward slope of conductors 54 and 58 away from openings 46A and 46B, respectively, as they extend from housing 44B. Further, the positioning of openings 46A and 46B along the side of connector block 40 also helps to minimize the amount of moisture that enters housing 44B due to gravity.
Access covers 50 are pivotally connected to housings 44. Preferably, access covers 50 pivot with respect to their respective housings about a vertical axis (i.e., an axis along the z-coordinate direction). Even more preferably, access covers 50 pivot about a common vertical access. The pivotal connection may be a hinge. In an alternative embodiment, access covers 50 may be detachable from housings 44, rather than being pivotally connected. Each of the plurality of access covers 50 has an open position 50A and closed position 50B. In order to move between closed position 50B and open position 50A, each of the access covers 50 pivots sideways (e.g., in the x and y-coordinate directions for the embodiment shown in
A gel or other sealant material may also be added to each one of housings 44 prior to the closure of its respective access cover 50 to create a moisture seal within the housing when the respective access cover 50 closed. The sealant material will further help minimize the amount of moisture that will potentially enter each one of housings 44. The sealant materials include greases and gels, such as, but not limited to RTV® 6186 mixed in an A to B ratio of 1.00 to 0.95, available from GE Silicones of Waterford, N.Y.
Gels, which can be described as sealing material containing a three-dimensional network, have finite elongation properties, which allow them to maintain contact with the elements and volumes they are intended to protect. Gels, which are useful in this invention, may include formulations which contain one or more of the following: (1) plasticized thermoplastic elastomers such as oil-swollen Kraton triblock polymers; (2) crosslinked silicones including silicone oil-diluted polymers formed by crosslinking reactions such as vinyl silanes, and possibly other modified siloxane polymers such as silanes, or nitrogen, halogen, or sulfur derivatives; (3) oil-swollen crosslinked polyurethanes or ureas, typically made from isocyanates and alcohols or amines; (4) oil swollen polyesters, typically made from acid anhydrides and alcohols. Other gels are also possible. Other ingredients such as stabilizers, antioxidants, UV absorbers, colorants, etc. can be added to provide additional functionality if desired.
Useful gels will have ball penetrometer readings of between 5 g and 40 g when taken with a 0.25 inch diameter steel ball and a speed of 2 mm/sec to a depth of 4 mm in a sample contained in a cup such as described in ASTM D217 (3 in diameter and 2.5 in tall cylinder filled to top). Further, they will have an elongation as measured by ASTM D412 and D638 of at least 100%, and more preferred at least 350%. Also, these materials will have a cohesive strength, which exceeds the adhesive strength of an exposed surface of the gel to itself or a similar gel. Representative formulations include gels made from 3-15 parts Kraton G1652 and 90 parts petroleum oil, optionally with antioxidants to slow decomposition during compounding and dispensing.
Connector block 64 includes a plurality of housing assemblies which are each defined by one of the plurality of housings 70 and a respective access cover 80. Connector block 64 is mounted on frame 42 in a similar position as connector block 40, where openings 66 are positioned along generally vertical surface 68 of connector block 64, and housings 70 (and therefore, the housing assemblies of connector block 64) are positioned in a vertically stacked orientation. Housing 70A includes IDC elements 71A and 71B. Conductors 72 and 76 are connected to IDC elements 71A and 71B, respectively, and extend from their respective openings 66A and 66B in a horizontal and downward direction, similar to conductors 54 and 58 (shown in
Electrical connector assembly 38 may further include any suitable number of additional connector blocks, which is defined by the needs of the user as well as the dimensional parameters of the central location electrical connector assembly 38 is mounted in. The additional connector blocks may also be mounted parallel to connector blocks 40 and 64 to form a row of connector blocks, and/or may also be mounted in an additional row which is mounted parallel to the row shown in
Similar to housings 44, a gel or other sealant material may also be added to each one of housings 70 prior to the closure of its respective access cover 80 to create a moisture seal within the housing when the access cover closed.
The present invention also includes a method of forming an electrical connector assembly in accordance with the present invention. The method includes providing a first connector block and a suitable frame for receiving the first connector block and attaching the connector block to the frame. The first connector block includes a plurality of housing assemblies and is preferably mounted so that the plurality of housing assemblies are aligned in a generally vertically stacked orientation. Additional connector blocks may also be mounted adjacent and generally parallel to the first connector block.
The present invention is described in reference to the first embodiment. However, the description of the first embodiment is partially applicable to the second embodiment. In the second embodiment, a conductor-receiving opening is positioned along a vertical surface of the access cover (e.g., opening 51 in
The depiction of the connector blocks and electrical connector assemblies in the figures are for clarity of illustration and are merely used as aids to describe the present invention. Details of the connector blocks have been left out of
Examples of suitable connector blocks that may be used in accordance with the present invention are described in U.S. patent application Ser. No. 10/941,506, entitled, “INSULATION-DISPLACEMENT SYSTEM FOR TWO ELECTRICAL CONNECTORS”, and filed on Sep. 15, 2004, U.S. patent application Ser. No. 10/941,441, entitled, “CONNECTOR ASSEMBLY FOR HOUSING INSULATION DISPLACEMENT ELEMENTS”, and filed on Sep. 15, 2004, U.S. Pat. No. 6,406,324, issued on Jun. 18, 2002 and entitled, “INSULATION DISPLACEMENT CONNECTOR TERMINAL BLOCK”, and U.S. Pat. No. 6,254,421, issued on Jul. 3, 2001 and entitled, “CONNECTOR ASSEMBLY HAVING PIVOTING WIRE CARRIER WITH POSITION DETENTS”.
Frame 42 (
Although the present invention is only described with respect to the telecommunications industry, other applications of a connector block or an electrical connector assembly in accordance with the present invention are contemplated. Likewise, although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
