Information
-
Patent Grant
-
6171119
-
Patent Number
6,171,119
-
Date Filed
Thursday, December 31, 199825 years ago
-
Date Issued
Tuesday, January 9, 200123 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Abrams; Neil
- Zarroli; Michael C.
Agents
- Blank Rome Comisky & McCauley, LLP
-
CPC
-
US Classifications
Field of Search
US
- 439 149
- 439 150
- 439 135
- 439 892
- 439 144
- 439 509
-
International Classifications
-
Abstract
A protection cap for an electrical connector with several terminals extending from a first end thereof. The cap includes a body having a cavity for releaseably receiving a second end of the connector which is opposite the first end, at least one arm extending from the body for wrapping partially around the connector, and a terminal retainer arranged on the free end of the arm for engaging at least some of the terminals.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to retainers for the terminals on an electrical connector, and, more particularly, to a cap for protecting the terminals on an electrical connector module during shipping, storage, and installation.
2. Description of Related Art
FIG. 1
illustrates a typical connector module
2
fitted with a conventional tie bar
4
on the ends of the terminals, or contact tails,
6
for protecting the terminals during shipping and storage, and for maintaining tail registration and co-planarity during installation of the connector
2
onto a circuit board. The tie bar
4
is preferably made from brass in order to allow it to be easily fitted to the terminals
6
and to minimize the effects of static electricity on the connector module
2
.
During manufacturing, the tie bar
4
is crimped onto the end of the terminals
6
with pliers or other crimping tools. During subsequent installation of the connector, the terminals
6
are soldered to a circuit board, or other device, with the tie bar
4
in place. The free ends of the terminals
6
between the solder connection and the tie bar
4
are then trimmed in order to remove the tie bar
4
and terminal stubs from the soldered connection.
SUMMARY OF THE INVENTION
Such conventional tie bars have several drawbacks. For example, they are not reusable. The narrow width of the tie bar
4
also prevents it from adequately covering the entire length of the terminals
6
while the crimping process can otherwise bend or stress the terminals. Furthermore, since the tie bar
4
is fixed to the ends of the terminals
6
, it can only be removed by pulling the terminals against the solder or trimming the ends of the terminals after the connector module
2
has been soldered onto the board. Often the connector module
2
must be installed in an inconvenient position relative to other components on the board. Consequently, removing the tie bar
4
after the connector
2
has been installed requires a significant amount of time and skill to complete without damaging the connector module
2
.
These and other drawbacks associated with the prior art are addressed by providing a protection cap for an electrical connector having a plurality of terminals extending from one side of one end. The cap includes a body having a cavity for releasably receiving a second end of the connector which is opposite from the first end. At least one arm extends from the body for wrapping partially around the connector. A terminal retainer is then arranged on the free end of the arm for engaging and at least some of the connector terminals.
The cap may be formed from a contiguous sheet of material having hinges or folds which rotatably separate the body, arm, and terminal retainers from each other. The terminal retainer may include a plurality of wells, slots, holes, or terminal receiving cavities which each receive and protect one, or more, of the terminals. These slots may also extend all the way through the walls of the terminal retainer for providing access to the terminals through a wall in the retainer.
In another embodiment, the cap may further include means for releasably securing the terminal retainer to the connector. For example, the securing means may include a fastener arranged on the side or top of the terminal retainer for attaching to the side or top of the connector. The fastener may include a tab, latch, snap-clamp, adhesives, or other easily-releaseable devices. Alternatively, the terminal retainer may be secured to the connector without a fastener by the frictional force created between the terminals and the walls of the slots inside the terminal retainer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention will now be described with respect to the following drawings wherein the numerals have been used to identify the similar features in each of the figures, and wherein
FIG. 1
is an isometric view of a connector module with a conventional tie bar;
FIG. 2
is an exploded isometric view of a connector module and protection cap assembly with the protection cap open;
FIG. 3
is an isometric view of a connector module and protection cap assembly with the protection cap closed; and
FIGS. 4 through 15
are isometric views of alternative embodiments for a protection cap.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 2 and 3
illustrate an assembly including a connector module
7
and a protection cap
8
. Although a variety of other connector modules could be used with the protection cap, the connector module
7
shown in FIGS.
2
and three is particularly well-suited.
In
FIG. 2
, the protection cap
8
is in an open configuration where the arms
10
A and
10
B on each side of a body
12
are fully extended from the sides of the body. The arms
10
form a living, flexible hinge which may be creased or scored to help control its movement. Other hinging devices may also be used.
Each arm
10
is provided with a terminal retainer
14
on its free end. The terminal retainer
14
A on arm
10
A has a securing means or fastener
16
on each end of the terminal retainer
14
A. Although each of the fasteners
16
are illustrated in the drawings as tabs or latch-type fasteners having a barb
18
which engages a corresponding post
20
on the opposite terminal retainer
14
B, a variety of other releaseable fasteners may also be used, such as hook and loop fasteners, snaps, buckles, and/or adhesives. In a preferred embodiment, the post
20
includes an inclined surface
22
for urging the barb
18
over the top of the post
20
and allowing the fastener
16
to snap into place when the terminal retainers
14
A and
14
B are secured together in a closed configuration as described in more detail below and shown in FIG.
3
.
As noted above,
FIG. 2
also illustrates one embodiment of a connector module
7
which is particularly well suited for use with the protection cap
8
. However, a variety of other connectors with terminals may also be used. The connector module
7
includes a housing
24
which is preferably sized to fit snugly inside the cavity
26
in the protection cap
8
. In a preferred embodiment, the top and bottom surfaces of the housing
24
are provided with a ridge and trough pattern
28
which corresponds to a similar pattern in the side walls of the cavity
26
for use in aligning the housing
24
inside the cavity
26
. A variety of other surface patterns and/or alignment devices may also be used.
The connector module
7
also preferably includes two T-shaped shoulders
30
arranged on each end of the housing
24
and extending over the terminals
6
. As illustrated in
FIG. 3
showing the connector module
7
assembled inside of the protection cap
8
, the tab
16
on each end of the terminal retainer
14
A slides over the top of the shoulders
30
on the connector module
7
and latches against the post
20
on the end of the terminal retainer
14
B. In the closed configuration shown in
FIG. 3
, the terminals
6
are hidden from view and protected inside the cap
8
where they are pressed between the terminal retainers
14
A and
14
B.
In a preferred embodiment, the terminal retainers
14
A and
14
B are provided with a plurality of slots, wells, or contact tail cavities
32
which each receive one terminal from the connector module
2
. Each slot
32
may also receive more than one terminal
6
, or no terminals at all, depending upon the number of slots
32
and terminals
6
. As is alternatively shown in
FIG. 3
, the slots
32
may also be in the form of holes
32
A and/or
32
B which extend through the top walls
34
and side walls
36
of the terminal retainers
14
A and/or
14
B for providing access to the terminals
6
through the walls. In addition, a window
33
may be provided in the walls
34
and/or
36
. Although the openings
32
A,
32
B, and
33
are shown on only one portion of the walls
34
and
36
in terminal
14
A, they may also be arranged along the entire portion of one or both walls
34
,
36
, and/or along any portion of the corresponding outer walls in the other terminal retainer
14
B. Such holes and/or windows provide a visual inspection path which is useful for inspecting the terminals
6
while the assembly is in a closed configuration in order to ensure that each slot
32
receives the proper terminal and that terminals are not missing from the connector module
7
.
In a preferred embodiment, the protection cap
8
is molded out of plastic, such as an amorphous thermoplastic polyethermide (PEI) resin like Ultem 1000™ brand unreinforced, available from GE Plastics, or an equivalent thereof. Other materials and different plastics may also be used. However, the material is preferably chosen so that the arms
10
form living hinges which may plastically, and/or elastically, deform when the protection cap is closed, but do not fracture or otherwise catastrophically fail during closure, or when the protection cap is reopened and the connector module
7
is removed. Although the protection cap
8
is illustrated as being formed from a single material, different materials, or composite materials, may also be used for different parts of the cap.
FIGS. 4 through 15
illustrate other embodiments for a protection cap
8
which were considered while completing the preferred embodiments illustrated in
FIGS. 2 and 3
. In
FIG. 4
, the protection cap
8
is formed from a solid block and has a plurality of holes
38
in one side for receiving the ends of the terminals
6
in the connector module
7
. This embodiment is preferably used with connector modules having terminals which are substantially straight so as to more easily fit inside the holes
38
. Nonetheless, in this embodiment, the terminals
6
(not shown) can be difficult to align with the holes
38
.
In another embodiment (not shown), the tips of the terminals
6
may be covered with a disposable coating material such as an epoxy or a plastic resin (including thermoplastic injection molded resins), putty, or sealant so as to mold a box, plate, or other shape, over the ends of the terminals. The terminals may also be covered with a tape. With such embodiments, the terminals
6
do not have to be aligned with any openings in the protection cap
8
as shown in FIG.
4
. Prior to installation of the connector module
2
, the coating or tape could be mechanically, thermally, an/or chemically removed from the terminals, or the protected terminals could be soldered to the board and then trimmed in order to remove the coated portions from the ends of the terminals.
FIG. 5
shows a protection cap
8
which is similar to the protection cap shown in
FIG. 4
except that it has a hinge
40
arranged at one end and a latch
42
at the other for securing the two halves together. In
FIG. 5
, the holes
38
extend through the protection cap
8
. This configuration allows the terminals
6
to be more easily positioned inside the holes
38
before each half of the device is latched together. The hinge
40
is preferably a live hinge consisting of a thin piece of material joining the two halves.
FIGS. 6 and 7
illustrate an embodiment for a protection cap
8
which is similar to the embodiment shown in
FIG. 5
except that the holes
38
have been replaced with slots
52
in FIG.
6
and teeth
54
in FIG.
7
. In addition, the embodiments shown in
FIGS. 6 and 7
have been provided with openings
56
on each end for securing to the shoulders
30
on each end of the connector module
7
(not shown in FIGS.
4
-
15
).
FIG. 8
illustrates another embodiment where dividers
58
extend between the terminals
6
. A groove
60
is arranged on one side of each divider
58
near the top of the divider and a tab
62
is arranged on the other side of each divider near the bottom for support the outside edges of two adjacent terminals
6
. The grooves
60
and tabs
62
may also be arranged on the same sides of the dividers
58
.
FIG. 9
illustrates another embodiment for a protection cap
8
in the form of a flexible clip including two handles
44
for opening the clip to receive the terminals
6
on the module connector
7
. The front side
46
and back side
48
the clip-type protection cap shown in
FIG. 9
are preferably formed to match the contours of the terminals
6
.
FIG. 10
illustrates an alternative embodiment for a clip in which the back face
48
may be formed in a different shape, such as substantially planar, while the front face
46
maintains substantially the same contour as the terminals
6
. Other curve shapes may also be used. The front face
46
of the clip-type protection cap shown in
FIG. 10
is divided by a plurality of slits
50
for increasing the flexibility of the front face
46
. The slits
50
eliminate the need for any handles, such as handles
44
in
FIG. 6
, in order to open the clip. However, handles may also be provided for each section which is separated by the slits
50
.
FIGS. 11 through 15
illustrate various embodiments for a protection cap
8
which is formed from a contiguous sheet of material having hinged, folded edges. In
FIG. 11
, the left and rear walls of the sheet form body walls or surfaces
12
which are separated from, and hinged to, the arm wall or surface
10
by a fold. A second fold separates and hinges the arm wall
10
from the terminal retainer wall or surface
14
. Other types of hinge mechanisms may also be used.
The terminal retainer wall
14
in the embodiment shown in
FIG. 11
includes flexible teeth
54
formed by slots
52
in the front edge of the wall. The teeth
54
may also be rigid. The body walls
12
, arm wall
10
, and terminal retainer wall
14
wrap around a cavity space
26
for receiving and supporting a connector module
7
inside the cavity with the terminals
6
(not shown) extending through the slots
52
between the teeth
54
in the terminal wall
14
.
In the contiguous sheet embodiment shown in
FIGS. 12 and 14
, the arm wall
10
and terminal retainer wall
14
are separated by additional wall
15
and an additional fold or hinge for providing greater flexibility in arranging the terminals
6
(not shown) inside the slots
52
. The slots
52
may be lengthened so that they extend to the edge of the retaining wall
14
so as to form rigid or flexible teeth (not shown) for separating the terminals
6
. In the embodiments shown in
FIGS. 13 and 15
, the terminal retaining walls
14
are folded in the opposite direction for allowing the protection cap
8
to accommodate wider connectors in the cavity
26
. In
FIGS. 14 and 15
, the body wall
12
has been replaced with a finger or tab fastener
62
for securing the connector module
7
against the arm wall
10
and accommodating thicker connectors. The tab
62
may be an adhesive tab and/or may extend farther underneath the arm wall
10
.
Although described with respect to preferred embodiments of the invention, it should be readily understood that various changes and/or modifications may be made without departing from the spirit of the invention. In general, the invention is only intended to be limited by the scope of the following claims.
Claims
- 1. A protection cap for an electrical connector with a plurality of terminals extending from a first side thereof, said cap comprising:a body having a cavity for releaseably receiving a second side of the connector which is opposite the first side; at least one arm extending from the body to wrap around at least a portion of the connector; the arm comprising a terminal retainer arranged on a free end of the arm to engage at least one of the terminals.
- 2. The cap recited in claim 1, wherein said arm is hinged to the body and said terminal retainer is hinged to the arm.
- 3. The cap recited in claim 2, wherein said body, arm, and terminal retainer are formed from a contiguous sheet.
- 4. The cap recited in claim 3, wherein said body, arm, and terminal retainer are hinged by a fold in said sheet.
- 5. The cap recited in claim 1, wherein said terminal retainer includes a plurality of slots, each slot for receiving a receiving a terminal.
- 6. The cap recited in claim 5, wherein each of said slots includes an opening extending through said terminal retainer for providing access to the terminals through a wall of the terminal retainer.
- 7. The cap recited in claim 1, further comprising means for securing the terminal retainer to the connector.
- 8. The cap recited in claim 7, wherein said securing means includes a releaseable fastener.
- 9. The cap recited in claim 8, wherein said fastener includes a latch arranged on an end wall of said terminal retainer.
- 10. A protection cap for an electrical connector with a plurality of terminals extending from a first side thereof, said cap comprising:a body having a cavity for releaseably receiving a second side of the connector which is opposite the first side; at least one arm extending from, and hinged to, the body to wrap around at least a portion of the connector; a terminal retainer hinged to the free end of the arm to engage at least one of the terminals, said terminal retainer including a plurality of slots, each slot for receiving a receiving a terminal; and a device for securing the terminal retainer to the connector.
- 11. The cap recited in claim 10, wherein said body, arm, and terminal retainer are formed from a contiguous sheet.
- 12. The cap recited in claim 11, wherein said body, arm, and terminal retainer are hinged by a fold in said sheet.
- 13. The cap recited in claim 10, wherein each of said slots includes an opening extending through said terminal retainer for providing access to the terminals through a wall of the terminal retainer.
- 14. The cap recited in claim 10, wherein said securing device includes a releaseable fastener.
- 15. The cap recited in claim 14, wherein said fastener includes a latch arranged on an end of said terminal retainer.
US Referenced Citations (15)