Patent Application
20200295518
The present application relates generally to the field of electrical connectors, and more particularly to a connector including an electrical connector and a wire guide that facilitates positioning of an insulated wire relative to the electrical connector.
The following description is provided to assist the understanding of the reader. None of the information provided or references cited are admitted to be prior art.
Various types of connectors are used for forming connections between an insulated wire and any manner of electronic or electrical component. These connectors are typically available as sockets, plugs, and shrouded headers in a vast range of sizes, pitches, and plating options. Traditionally, for a user to mechanically and electrically connect one or more wires to another electrical component such as an insulation displacement contact (IDC) connector the user must handle the one or more wires simultaneously in order to ensure all of the wires are correctly positioned before terminating the one or more wires. This process can be tedious, inefficient, and undesirable. Moreover, a wire-to-component connection that may fall apart or short out unexpectedly due to incorrect placement during assembly could be hazardous or expensive, especially when connecting the wires to an expensive component (e.g., a printed circuit board (PCB)). Thus, a quick, efficient, and reliable means of positioning a variety of sizes of wires in a variety of applications is needed.
The systems, methods and devices of this disclosure each have several innovative aspects, no single one of which is solely responsible for the desirable attributes disclosed herein.
A wire guide is disclosed. The wire guide includes a latching portion and a body portion. The latching portion includes a first latching prong. In an embodiment, the latching portion also includes a second latching prong. The body portion includes at least one wire opening. The at least one wire opening extends entirely through the body portion from a rear surface to a front surface of the body portion. The at least one wire opening may include retention ribs that extend from the outer rim of the at least one wire opening toward a centerline axis of the at least one wire opening. Additionally, the retention ribs may extend from the front surface toward the rear surface. The at least one wire opening may be circularly shaped with a diameter that is consistent as it extends from the front surface to the rear surface. The at least one wire opening may also have a bevel that transitions the diameter of the at least one wire opening to the rear surface.
The body portion may be a solid piece of material that extends from the front surface to the rear surface, from a top surface to a bottom surface, and from a first surface to a second surface. The first latching prong may extend from the first surface toward and past the front surface to a first prong distal end. The second latching prong may extend from the second surface toward and past the front surface to a second prong distal end. In an embodiment, the at least one wire opening, the first latching prong, and the second latching prong extend along respective axes that are substantially parallel. Further, the top surface may be symmetrical to bottom surface. Similarly, the first side and first latching prong may be symmetrical to the second side and second latching prong. The first latching prong may also include a first-prong knob that extends from the first prong distal end toward the second latching prong. Similarly, the second latching prong may also include a second-prong knob that extends from the second-prong distal end toward the first latching prong. The front surface extends along a front plane and the rear surface extends along a rear plane, the front and rear planes may be parallel.
The wire guide may be used with an insulation displacement contact connecter that includes a housing cap and at least one electrical contact. The housing cap includes a wire alignment opening, an electrical contact opening, and a latch-receiving portion. The electrical contact includes an insulation displacement contact portion and a base portion. The wire alignment opening and the electrical contact opening perpendicularly intersect at an intersection within the housing cap. The latch-receiving portion may include a notch on a first side of the housing cap and a second notch on a second side of the housing cap. The first side is opposite of the second side on the housing cap.
In an operation, a first insulated wire is inserted into a first wire opening of the at least one wire openings and the first insulated wire is extended entirely through the body portion. The retention ribs center and mechanically secure the first wire within the insulated housing. In an embodiment, the operation may be repeated for however many insulated wires are being terminated in a given application. The front surface of the wire guide is then aligned with the housing cap. The front surface and protruding wires are then joined to the housing cap. That is, the first wire enters a first wire alignment opening of the housing cap and the latching portion mechanically secures to the latch-receiving portion. The electrical contact may then be compressed into electrical contact opening in order to mechanically and electrically connect the first insulated wire to the electrical contact.
The wire guide is not limited by its number of wire openings or other components. Particular embodiments of insulation displacement connectors are described in greater detail below by reference to the examples illustrated in the various drawings.
Reference will now be made to various embodiments, one or more examples of which are illustrated in the figures. The embodiments are provided by way of explanation of the invention, and are not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment may be used with another embodiment to yield still a further embodiment. It is intended that the present application encompass these and other modifications and variations as come within the scope and spirit of the invention.
Disclosed herein is a wire guide that facilitates the alignment and positioning of wires with respect to a corresponding electrical connector. The wire guide can be used with a variety of electrical connectors. In an example embodiment, the wire guide is used with an insulation displacement contact connecter. The wire guide includes a body portion that receives one or more wires and a latching portion that mechanically secures the wire guide to the corresponding electrical connector. The body portion includes at least one wire opening that extends entirely through the body portion. In an example embodiment, the body portion includes multiple wire openings. Such a wire guide may be used to efficiently and reliably mechanically and electrically couple one or more wires to an electrical contact in a corresponding electrical connector. Specifically, the wire guide allows for discrete wires to be placed and held securely in position prior to inserting the wires into a corresponding electrical component (e.g., an insulation displacement contact). The wire guide assists in positioning and termination of such wires with an electrical contact. The unique design of the wire guide disclosed herein ensures that one or more wires can be efficiently, safely, and reliably staged before each of the wires are electrically connected to a sensitive or live electrical component. Specifically, the unique design of the wire guide is particularly useful with small wires in small products including the termination of a plurality of wires to a printed circuit board. Traditionally, a user must manually handle each wire and position each wire so that each wire can be terminated to the correct component. This method has proved to be cumbersome and inefficient. However, the design of this wire guide facilitates a more efficient and reliable manner of connecting such wires.
Various embodiments of a wire guide and corresponding electrical connectors are illustrated throughout
The body portion 150 includes a first wire opening 101, a second wire opening, 102, a third wire opening 103, and a fourth wire opening 104. In other embodiments, the body portion 150 may have fewer or more wire openings than depicted in
The latching portion 190 includes a first latching prong 110 and a second latching prong 120. The first latching prong 110 extends from the first surface 180 of the body portion 150 to a first-prong distal end 114. The second latching prong 120 extends from the second surface 181 of the body portion 150 to a second-prong distal end 124. The first and second latching prongs 110 and 120 extend toward and past the front surface 170. The first latching prong 110 includes a first-prong knob 111 that extends from the first-prong distal end 114 toward the second latching prong 120 and toward a centerline axis 199 of the wire guide 100. The second latching prong 120 includes a second-prong knob 121 that extends from the second-prong distal end 124 toward the first latching prong 110 and toward the centerline axis 199 of the wire guide 100. In alternative embodiments, other manners of mechanical latching may be used. For example, in other embodiments, the latching portion 190 may only include one latching prong. In another embodiment, the latching portion 190 may include two, three, four, or more latching prongs. In yet other embodiments, the latching portion 190 may include any other structure that can be used to mechanically secure the wire guide to a corresponding electrical connector.
The housing cap 201 includes a first wire-alignment opening 230 that corresponds to the first electrical contact 240, a second wire-alignment opening 231 that corresponds to the second electrical contact 250, a third wire-alignment opening 232 that corresponds to the third electrical contact 260, and a fourth wire-alignment opening 233 that corresponds to the fourth electrical contact 270. The housing cap 201 also includes an electrical contact opening (not depicted) for each wire-alignment opening 230, 231, 232, or 233. In alternative embodiments, the insulation displacement contact connector 200 may have fewer or more wire-alignment openings and electrical contact openings than depicted in
The first electrical contact 240 includes an insulation displacement contact portion 242 and a base portion 241. The second electrical contact 250 includes an insulation displacement contact portion 252 and a base portion 251. The third electrical contact 260 includes an insulation displacement contact portion 262 and a base portion 261. The fourth electrical contact 270 includes an insulation displacement contact portion 272 and a base portion 271. That is, each electrical contact 240, 250, 260, and 270 has a corresponding insulation displacement contact portion 242, 252, 262, and 272 and a base portion 241, 251, 261, and 271. Each base portion 241, 251, 261, and 271 and may be mechanically and electrically attached to a corresponding electrical component (e.g., contact pads on a printed circuit board). Each insulation displacement contact portion 242, 252, 262, and 272 has at least two blades designed to displace insulation from a corresponding insulated wire and electrically and mechanically attach to a conductive core of the corresponding insulated wire. For example, the first electrical contact 240 includes a first blade 243 and a second blade 244 that extend in parallel to each other in a perpendicular direction from the base portion 241. In alternative embodiments, other designs of electrical contacts 240, 250, 260, and 270 may be used.
The housing cap 201 also includes one or more latch-receiving portions 290. In an embodiment, the latch-receiving portion 290 includes a first end notch 210 located on a first surface 211 of the housing cap 201 and a second end notch 220 located on a second surface 221 of the housing cap 201. The first surface 211 is opposite from the second surface 221. In this way, a corresponding wire guide can mechanically secure to the housing cap 201. For example, latching prongs of a corresponding wire guide can mechanically secure to the notches 210 and 220 and create a frictional force that mechanically secures the corresponding wire guide to the housing cap 201. In alternative embodiments, the latch-receiving portion may be any structure that mechanically secures the housing device to a corresponding wire guide.
The latching portion 390 includes a first latching prong 310 and a second latching prong 320. In alternative embodiments, the latching portion 390 may be of any design that allows the wire guide 300 to be secured to a corresponding device (e.g., an insulation displacement contact connector). The first latching prong 310 extends from the first surface 380 toward and past the front surface 370 along a first-prong axis 341 to a first-prong distal end 315. The second latching prong 320 extends from the second surface 381 toward and past the front surface 370 along a second-prong axis 342 to a second-prong distal end 325. The first wire opening 301 extends from the front surface 370 entirely through to the rear surface 371 along a centerline wire-axis 343. In an embodiment, the first-prong axis 341, the second-prong 342, and the centerline wire-axis 343 extend in generally the same direction.
The first, second, third, and fourth wires 551, 552, 553, and 554 were inserted into a respective first, second, third, and fourth wire opening 501, 502, 503, and 504 before the mechanical connection of the wire guide 544 and the insulation displacement contact connector 592 occurred. The wires 551, 552, 553, and 554 were held in position via a frictional force created between the wire openings 501, 502, 503, and 504 and the respective wires (e.g., using retention ribs or other structures designed to create an interference fit) as the wire guide 544 was positioned adjacent to the insulation displacement contact connector 592. The wires 551, 552, 553, and 554 were then guided through respective first, second, third, and fourth wire alignment openings 530, 531, 532, and 533 in the insulation displacement contact connector 592. In this way, the wires 551, 552, 553, and 554 are all in position to be connected to respective first, second, third, and fourth electrical contacts 540, 541, 542, and 543. It is to be appreciated that four wires in this example is only an example and that other embodiments may include one, two, three, four, five, six or more wires, electrical contacts, wire openings, and/or wire-alignment openings.
The latching portion 590 includes a first latching prong 510 and a second latching prong 520. The first latching prong 510 has been positioned such that a first-prong knob 511 of the first latching prong is positioned within a first notch 513 of a housing cap 594 of the insulation displacement contact connector 592. Similarly, the second latching prong 520 has been positioned such that a second-prong knob 521 of the second latching prong 520 is positioned within a second notch 523 of the housing cap 594. This positioning of the first latching prong 510 and the second latching prong 520 mechanically secure the wire guide 544 to the insulation displacement contact connector 592. In this way, the wires 551, 552, 553, and 554 are mechanically secured via a frictional force with their respective wire openings 501, 502, 503, and 504 and the wire guide 544 is mechanically secured to the insulation displacement contact connector 592 via the latching prongs 510 and 520 and respective notches 513 and 523.
In an operation 602, the wire guide is positioned and aligned adjacent to a housing of an insulation displacement contact connector (or other electrical connector to which the wires are to be connected). The alignment of the wire guide ensures that the first (and other) insulated wires are aligned with a first (or other corresponding) wire alignment opening of the housing cap. In this way, all of the insulated wires that were inserted into the wire guide are easily manipulated into correct positions via movement of the wire guide.
In an operation 603, the wire guide is joined with the housing (or other portion of a corresponding electrical connector) such that a latching portion of the wire guide joins and mechanically secures to a latch-receiving portion of the housing. In an embodiment, a first knob of a first latching prong of the latching portion is positioned within a first notch on a first side of the housing and a second knob of a second latching prong of the latching portion is positioned within a second notch on a second side of the housing. The first side of the housing is opposite the second side of the housing. In alternative embodiments, other structures or known methods of mechanically securing devices can be used in order to mechanically secure the wire guide to the housing cap. The joining of the wire guide with the housing ensures that each insulated wire that was inserted into the housing is now aligned within the wire alignment openings with an insulation displacement contact portion of a corresponding electrical contact. The electrical contacts can then be inserted into the housing and cause the electrical contacts to displace insulation from corresponding insulated wires and create a mechanical and electrical contact with the conductive cores of the insulated wires. In an embodiment, a base portion of each electrical contact may already be mechanically and electrically affixed to a contact pad of a printed circuit board. In this way, the insulated wires are electrically connected and mechanically secured to the printed circuit board. In alternative embodiments, the wire guide may be used with other types of electrical connectors (e.g., a poke-home electrical connector). That is, in alternative embodiments, an insulated wire may already have insulation stripped from one of its ends before the insulated wire is inserted and retained by the wire guide. In still other embodiments, some or all of the wires may not have any insulation at all and a corresponding wire opening may be positioned and sized accordingly (e.g., ground wires).
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
The foregoing description of illustrative embodiments has been presented for purposes of illustration and of description. It is not intended to be exhaustive or limiting with respect to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the disclosed embodiments. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.
This application claims priority to U.S. Provisional Patent Application No. 62/816,312, filed Mar. 11, 2019, the entire disclosure of which is incorporated herein by reference in its entirety, for any and all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 62816312 | Mar 2019 | US |
