GB1558811A

GB1558811A - Electrical connentors

Info

Publication number: GB1558811A
Application number: GB4072876A
Authority: GB
Original assignee: Western Electric Co Inc
Current assignee: AT&T Corp
Priority date: 1975-10-06
Filing date: 1976-09-30
Publication date: 1980-01-09
Also published as: IT1074272B; DE2644936C2; DE2644936A1; FR2327654A2; JPS5246489A; CA1022253A; SE426628B; JPS552068B2; BE846783R; SE7610674L; FR2327654B2

Description

(54) IMPROVEMENTS IN OR RELATING TO ELECTRICAL CONNECTORS (71) We, WESTERN ELECTRIC COMPANY, INCORPORATED, of 222 (formerly of 195) Broadway, New York City, New York State, United States of America, a Corporation organised and existing under the laws of the State of New York, United States of America, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates to electrical connectors, and is an improvement in or a modification of the invention (hereinafter termed the parent invention) contained in Patent No. 1, 445, 270.

In the telephone industry, increasing use is being made of modular plug-type connectors on retractile handset and on straight line cords which are used between the telephone base and a wall terminal block. In a presently used plug, a terminal is applied to each of a plurality of insulated conductors contained within ajacketed length of a retractile cordage. These terminals are mounted within a dielectric structure which is attached securely to the associated cordage.

The dielectric portions of the plugs, which are mounted on both ends of a length of a cordage, cooperate with receptacles in the wall terminal block and in the telephone base to properly align the terminals of the plug with associated terminals within the wall block and the telephone.

In a plug disclosed in U.S. Patent 3, 699, 498 conductors are confined in conductor-receiving troughs formed in a dielectric base by a cover bonded to the base with flat terminals inserted into individual grooves in the base in a side-byside arrangement with contact portions thereof extending into engagement with the conductors (see also U.S. Patent 3, 761, 869).

It would be desirable both from the ease and the cost of manufacturing to construct a onepiece plug, into which telephone cord end may be inserted and secured and subsequently engaged by terminals moved into terminalreceiving openings in the plug.

Accordingto theparent invention an electrical connector for terminating a cord haying a plurality of insulated conductors includes a unipartite dielectric housing having a cavity that opens to at least one end of the housing for receiving and for substantially enclosing an end portion of a said cord, the housing having a plurality of terminal-receiving openings communicating with the cavity and the exterior of the connector, and one or more portions of the housing being moveable at least partially into the cavity, whereby the housing prevents return movement of the or each portion thereof, for securing said cord within the housing.

According to this invention an electrical connector for terminating a cord having a plurality of insulated conductors includes a unipartite dielectric housing having a cavity that opens to at least one end of the housing for receiving and for substantially enclosing an end portion of a said cord, the housing having a portion adjacent the cavity and connected to the remainder of the housing toward the other end thereof, the connected portion being moveable from an initial position in a well in the housing at least partially into the cavity whereby first and second portions of the moveable portion engage an inwardly facing surface of the cavity toward said one end of the housing and a wall of the well adjacent the inwardly facing surface, respectively, to lock the moveable portion in a position for securing a said cord in the housing, the latter being adapted to receive a plurality of electrically conductive terminals for permitting electrical contact thereto external to the housing and for effecting electrical contact in the cavity with the conductors of a said cord.

The housing may include a plurality of terminal-receiving openings communicating with the cavity and the exterior of the connector.

The moveable portion may be connected through a connecting portion at one end thereof and through a frangible portion at the other end thereof to the housing toward the other and the one end thereof, respectively, whereby application of force to the moveable portion causes its other end to separate from the housing. Preferably the frangible portion is such that after separation thereof from the housing it provides a curvable extension to the moveable portion, whereby, in use, a blunt curved portion of the extension contacts the cord.

The housing may include a conductorrestraining portion separated partially from the housing by first and second slots extending different depths towards the cavity and being such that, in use, application of force to the conductor-restraining portion causes it to fracture from the more extensive one of said slots to the cavity and to move generally along the fracture line and be reformed into engagement with the conductors in the cavity and into locking engagement with the housing.

The one end of the housing may have a curved flared entrance portion, and the moveable portion may be such that, when in its cordsecuring position, a portion thereof is aligned with a tangent to the flared entrance.

The cavity may terminate at a wall toward the other end of the housing, or it may open toward the other end of the housing.

The housing may include conductor-receiving troughs in the cavity. These may be between a plurality ofparallel partitions in a portion of the cavity. The partitions may extend completely or partially between opposed surfaces of the cavity.

Unipartite or one piece as used to describe the housing is intended to define the housing as not divided or divisible into parts. The housing may be such that no securing, including bonding, is necessary to form the initial configuration of the housing.

The invention will now be described by way of example with reference to the accompanying drawings, in which: FIGURE 1 is a perspective view of plugs embodying the invention inserted into a handset and a base portion of a telephone set and into a wall terminal block; FIGURE 2 is a perspective view of a plug prior to assembly of a cord and terminals therewith; FIGURE 3 is a perspective view of the plug of FIGURE 2 with terminals and the cord end inserted therein and with the jacket strain relief member moved into engagement with the cord; FIGURE 4 is a view of a housing of the plug partially in section prior to the assembly of the cord and terminals therewith; FIGURE 5 is an elevational view partially in section showing the jacket strain relief member of the plug after engagement with the jacket of the cord to provide strain relief for the cord, a portion of the housing reformed into a strain-relief member in engagement with the conductors, and the terminals inserted; FIGURE 6 is an end view in section taken along line 6-6 of FIGURE 4 and showing a preferred form of the conductor-receiving troughs; FIGURES 7 and 8 are end views in section taken along lines 7-7 and 8-8, respectively, of FIGURE 4 and showing other forms of the conductor-receiving troughs; FIGURE 9 is a front end view of the plug housing shown in FIGURE 4 with a portion of an end wall broken away to show another form of the conductor-receiving troughs; FIGURE 10 is an elevational view of another form of the plug housing; FIGURES 11 and 12 are enlarged detail views in section showing jacket and conductorstrain-relief portions prior to and subsequent to the operation thereof; FIGURE 13 is an elevational view in section showing the plug inserted into a jack in a telephone set; and FIGURE 14 is an enlarged detail view of a portion of a latching member in engagement with surfaces of a jack in the telephone set.

Referring now to FIGURE 1, a telephone 20 includes a base portion 21 and a handset portion 22. A retractile cord 23 interconnects the base portion 21 and the handset portion 22.

Each end of the retractile cord 23 is provided with a plug 24 designed to be inserted into a jack 26. One of the plugs 24 is inserted into one of the jacks 26 assembled to handset portion 22 and the other plug of the retractile cord 23 is inserted into a jack in the base 21 of the telephone 20. The plug 24 has means for establishing electrical connections between the cord 23 and internal contacting components 27 of the telephone 20 (see FIGURE 13). Ones of the plugs 24 are also assembled to each end of a line cord 28 for connecting the line cord to jacks 26 in the telephone base 21 and in a wall terminal block 29.

Referring now to FIGURE 5, the retractile cord 23 includes a jacket 31 which covers a plurality of insulated conductors 32 and which has a ridge 34 formed longitudinally thereof.

A free end portion of each of the conductors 32 is designed to be connected to an associated one of a plurality of terminals 33. Each of the conductors 32 is constructed of a nylon core 35 having a tinsel ribbon 36 wrapped helically thereabout. The tinsel ribbon 36 has an insulation covering 37 extruded thereon (see U.S.

Patent 3, 553, 042). The outside nominal diameter of the individual insulated conductors 32 is approximately 0.040 inch.

unipartite housing 40 is designed to be easily moulded by using conventional injection mould ing techniques. The housing 40 may be constructed of materials such as, for example, polycarbonate, polyamide, polystyrene, polyterephthalate, or polyester elastomers or related polymers such as ABS resin or glass-filled mixtures thereof. The rigid, dielectric housing 40 has a free end 41, a cord-input end 42, and a terminal-receiving side 43 (see also FIGURE 3).

It may be observed from FIGURES 4 and 5 that the housing 40 is formed with a cord input aperture 44 which circumscribes substantially the portion of the jacket 31 of the cord 23 extending therethrough. As may be appreciated from the drawing, the housing 40 is constructed in one-piece with the cord input aperture 44 formed entirely therewithin. The aperture 44 has a flared entrance which prevents sharp bends in the cord 23 about an otherwise sharp edge during use of the telephone 20 by the subscriber. This increases the life of the cord 23 and also facilitates insertion of a leading end of the cord 23.

The cord input aperture 44 opens to a cavity 46 (see FIGURE 4) which terminates adjacent a ledge 47 at the free end 41 of the base of the housing 40. The walls of the cavity 46 substantially enclose the entire end section of the cord which is inserted into the aperture 44 and is completely formed as moulded. No further securing together of parts such as by bonding or moving hinged parts with subsequent bonding together is required to form the cavity 46.

The formation of a one-piece housing 40 with the surfaces defining the cavity 46 substantially enclosing the entire end portion of the cord 23 facilitates holding the cord while other operations are performed by automated equipment.

The housing 40 is preferably constructed to prevent a dielectric breakdown between adjacent conductors 32. Such a breakdown may occur, for example, because of the ingress of moisture of other corrosive contaminants and because of shortened dielectric paths between adjacent conductors 32. These provisions include moulding of the housing 40 such that the cavity 46 is closed off from the free end 41 of the housing 40 by a wall 45 (see FIGURE 4).

As can best be seen in FIGURES 2 and 6, the cavity 46 is formed with a plurality of longitudinally extending partitions 48 which are moulded with the dielectric housing 40 and extend the full height of cavity 46 to form a plurality of flat-bottom conductor-receiving troughs or ducts 49 therebetween. The conductor-receiving troughs 49 are designed to receive associated ones of the conductors 32.

The full-cavity height of the partions 48 maintains effectively the conductors 32 in separate compartments, each approximately 0.038 inch wide and 0.042 inch high. Although the outside diameter of each conductor 32 is about 0.040 inch, the conductor because of the insulation covering 37 and tinsel conductor 36 and air space therebetween may be reconfigured with ease to be received in the troughs 49. Each of troughs 49 is dimensioned so that the conductor 32 therein cannot move laterally. This is necessary to ensure that during the insertion of the terminals 33, the terminals remain aligned with the conductors 32 to make electrical engagement therewith.

The troughs 49 are constructed advantageously with the flat-bottom portions (see FIGURE 6) which provide a bearing surface against which the terminals 33 are driven and provide substantial support for the associated conductors 32 to avoid undue lateral displacement thereof during terminal insertion.

The partitions 48 may however take the configuration shown in FIGURE 7 on approximately 0.040 inch centres. The configuration shown in FIGURE 7 or that in FIGURE 8 increases the dielectric path between conductors over that shown in U.S. Patent 3, 860, 316 and reduces substantially the probability of breakdown.

In yet another form the partitions 48 are in the form of toothed ridges (see FIGURE 9) with the plurality of flat-bottom, conductorreceiving troughs 49 formed therebetween on 0.040 inch centres. Each of the flat-bottom portions of the troughs 49 is approximately 0.018 inch wide. The troughs 49 may extend into the wall 45 to receive the ends of the conductors 32 to avoid inadvertent crossover of the conductors over the partitions during insertion.

Alternatively, the housing 40 may be constructed as shown in FIGURE 10 with the cavity 46 and the ends of the troughs 49 shown in FIGURES 6, 7, 8 or 9 opening to the free end ledge 47.

In FIGURE 10, the bottoms of the troughs 49 are substantially coplanar with the top surface of the ledge 47 at the free end 41. This facilitates the use of the ledge 47 at the free end 41 as an anvil for conductor cut-off during assembly of the plug 24 to the cord 23. Since the construction of the housing 40 with the end wall 45 precludes use of the free end 41 as an anvil to cut off the conductors 32, the cord end must be stripped with some precision insofar as length of the jacket removed.

As can best be seen in FIGURE 2, the housing 40 is formed with a well 51 having a plurality of spaced parallel terminal-receiving openings 52 opening thereto. The openings 52 are in the form of slots and are aligned on a one-to-one basis with associated ones of the conductorreceiving troughs 49. Each of the terminal receivingslots 52is parallelto andcommunicates with an associated one of the conductorreceiving troughs 49. Each of the slots 52 is of a length slightly less than the length of that portion of the associated terminal 33 which is to be received therein. The shortening of the slots 52 from the overall length of the well 51 forms abutments 53 (see FIGURE 4, for example).

The construction of the partitions 48 as shown in FIGURES 6,7 or 8 causes the centre lines of the troughs 49 formed therebetween to be misaligned slightly with the centre lines of the terminal-receiving openings. Hence, the longitudinal axes of the conductors 32 received within the troughs 49 will not be aligned precisely with the blades of the terminals 33.

For example, the longitudinal centre line of each of the troughs 49 adjacent the longitudinal centre line of the housing 40 is approximately 0.002 inch out of alignment with the associated blades 33 which are on 0.040 inch spacing. The outermost blades 33 may be misaligned approximately 0.066 inch from their associated conductors 32. This does not affect adversely the electrical engagement of the blades 33 with the tinsel ribbon 36 which connection may be effected slightly off centre of the conductor as well as along the centre line because of the helical wrapping of the tinsel conductor 36 about the core 35.

The dielectric housing 40 is also formed with a plurality of fins 54 (see FIGURES 2, 3 and 9) upstanding from a bottom surface 56 of the well 51 to which the terminal-receiving slots 52 open and are spaced on centres of approximately 0.040 inch. The fins 54 are aligned between adjacent terminal-receiving slots 52 with the external contacting components 27 of the jack 26 received between the associated fins and thereby guided into engagement with portions of the terminals 33 (see FIGURE 13).

Prior to the insertion of the plug 24 into the jack 26, free end portions of the external contacting portions 27 extend at an angle in the range of 30O to 45 to the horizontal as viewed in FIGURE 13. Advantageously, upon insertion of the plug 24 into the jack 26, the initial deflection of the free end portions of the contacting portions 27 is accomplished by their engagement with associated ones of a plurality of wire-lifters 57 (see FIGURES 2 and 4) formed integrally with the housing 40.

The burden of initially deflecting the contacting portions 27 is borne by dielectric material of the housing thereby avoiding abrasion of the surfaces of the contacting portions with the associated terminals. This extends the life of the terminals 33 and preserves the integrity of the contacting surfaces for engagement in the operative position shown in FIGURE 13.

Finally, the housing 40 has a stiffener 58 (see FIGURE 3)spanning between and connected integrally with side walls of the well 51 oriented toward the cord-input end 42 of the housing 40. The stiffener 58 strengthens the plug 24 to resist undue bending during the actuation of conductor strain-relief means described hereinafter.

As can best be seen in FIGURE 4, the portion of the cavity 46 adjacent the cord-input end 42 communicates with the main portions of the conductor-receiving troughs 49 through a tapered transition section 61 having a shoulder 62. The partitions 48 are constructed to extend along a sloping face 63 of the tapered transition section 61.

In assembling the plug 24 to the cord 23, a portion of the cord jacket 31 of the cord is stripped to expose a predetermined length of each of the insulated conductors 32. The cord 23 is inserted into the input aperture 44 and into the cavity 46 until the conductors 32 are moved along associated ones of the walls which define the conductor-receiving troughs 49 extending down the sloping face 63.

The portions of the partitions extending down the sloping face 63 assist in separating and guiding the conductors 32 into the main portions of the associated ones of the troughs 49. In order to accomplish the separation of the conductors 32, the end portions of the partitions 48 facing into cavity 46 are feathered to present dividing edges to the inserted cord 23.

As the conductors 32 are moved laterally off the sides of the face 63, the jacketed portion of the cord 23 is moved into the cavity 46.

When the cord 23 has been advanced such that the conductors 32 are received in the troughs 49, the leading end of the jacket 31 is in engagement with the shoulder 62 (see FIGURE 5).

Also, as can be seen in FIGURE 4, the walls of the cavity 46 are formed to include a groove 66 longitudinally thereof. The groove 66 is designed to mate with cords having the ridge 34 formed externally of the jacket to ensure that the cord 23 is inserted properly into the plug 24 such that the conductors 32 are properly oriented with respect to the jack 26 when the plug is inserted thereinto.

The unipartite housing 40 is constructed advantageously with means for providing strain relief for the jacket and for the individual conductors 32. This permits the use of a onepiece moulded plug rather than two parts assembled to the cord 23. As can best be seen in FIGURES 2 and 11, the housing 40 is constructed with an opening or well 69 which is adjacent the cavity 46. The well 69 has disposed therein a jacket-anchoring member 70, which includes internally facing surfaces 71 and 72 intersecting along an edge 73. The anchoring member 70 is connected to the housing 40 through a plastics hinge 74 oriented toward the free end 41 of the housing 40 and extending from a wall 75, and by a severable web or frangible portion 76 oriented toward the cord-input end 42. Referring to FIGURE 2, it is seen that the member 70 extends across the width of the opening 69. The anchoring member 70 also has a surface 77 which protrudes slightly, e.g., 0.055", into the cavity 46 beyond into the plug 24 such that the conductors 32 an adjacent inwardly facing surface 78 of the remainder of the housing adjacent the cord input aperture 44.

The web 76 is connected to the surface 78 by a step or connecting surface 79 (see FIGURE 11). The web 76 supports the anchoring member 70 in its initial position to permit insertion at a cord end into the cavity 46. But for this, the member 70 could descend into the cavity either under its own weight or by forces imparted to the housing 40 during handling thereby obstructing entrance of the cord end.

As can best be seen in FIGURE 11, the web 76 is constructed such that the dimension "dl ", adjacent a wall 81 is substantially less than the dimension "d2 '7 of the hinge 74 adjacent the wall 75. Moreover, while the inwardly facing surface of the web 76 is parallel to the surface 78, the outwardly facing surface of the web is sloping so that the thickness of the web adjacent the main portion of the anchoring member 70 exceeds "do". This controls the separation of the member 70 from the housing 40 to be adjacent the cord-input end 42 so that the anchoring member may be moved pivotally about the intended hinge 74 to engage the cord jacket 31. Further, this ensuresthat the separation occursadvantageously adjacent the wall 81 thereby avoiding any unwanted burrs that could impede the movement of the member to the actuated position.

When the anchoring member 70 is moved to an actuated position (see FIGURE 12), the web 76 together with the adjacent portion of the step 79 create a rounded trailing edge of the hinged member 70 to be formed and curled counter-clockwise, advantageously into engagement with the contour of the cord 23. Since this is the portion that most firmly engages the cord, it is most advantageous that the burrs or edges are not opposed to the direction of the pulling forces anticipated during use thereby avoiding tearing the material comprising the jacket 31.

This structural arrangement is not possible if the hinge 74 were oriented toward the cordinput end 42. To design a connecting surface 79 into that arrangement would creat, undesirably, and undercut which cannot be moulded. In this design, the major core pin (not shown) need only be stepped and can easily be removed.

The anchoring member 70 is moulded to include a wedge-shaped stop 82 extending from and centrally disposed of the surface 71 (see FIGURES 2 and 11) and includes two surfaces 83 and 84. The stop 82 which is to form an important part of the jacket latching arrangement is formed on the surface 71 adjacent the edge 73; however, the edge 73 of the anchoring member 70 is discontinuous and is chamfered along a portion thereof in alignment with the stop 82 to form a bevel 86 (see FIGURE 11).

It should be understood that the plugs 24 used to terminate large members of conductors may require lengthened anchoring members 70 and desirably a plurality of stops 82.

The general surface 72 of the anchoring member 70 is formed with two surfaces 87 and 88 (see FIGURES 11 and 12) connected by a step 89. The configuration assumes importance in the anchoring of the cord 23.

The forces applied to the anchoring member 70, and pivotal movement thereof, causes the portion thereof adjacent the intersecting externally facing surfaces 71 and 72 to be compressed as it is moved along the side of the wall 81 of the opening 69. As the intersecting edge 73 of the surfaces 71 and 72 passes beyond the surface 78, a portion of the surface 71 snap locks under a lip formed by a portion of the surface 78 (see FIGURES 5 and 12). The extent of the engagement of the anchoring member 70 with the surface 78 is a minimum of about 0.008 inch. Although there is some compression of the anchoring member 70 during this movement, once it is moved out of engagement with the side wall 81 of the opening 69, its elastic properties facilitate spring-back to generally its initial configuration with an accompanying catching under the lip surface 78.

When the anchoring member 70 is moved to the actuated position, the surface 84 of the stop 82 engages the wall 81 approximately at the time portions of the surfaces 71 adjacent the edge 73 snap-lock under the surface 78. The surface 84 of the stop 82 and the portion of the surface 71 cooperate in their engagement with the wall 81 and the surface 78 to maintain the anchoring member 70 in continuing locked engagement with the cord 23 and the housing 40.

This arrangement enhances the ability of the plug 24 to provide strain relief for the jacket 31 and which surprisingly continues to be effective with use of the cord 23. The stop 82 is maintained in locking engagement with the wall 81 when retrograde forces are applied to the cord 23 by the customer.

The configuration of the surface 72 is such that when the anchoring member is moved into the actuated position, the surface 88 is aligned with a tangent to a portion of the cord-input aperture 44 (see FIGURE 12). This provides an amount of continuous support for the cord 23 when the cord is flexed toward the plug surface 43 and hence tends to relieve excess stresses in the vicinity of the web 76.

The unitary dielectric housing 40 is also formed with means to provide strain relief for the conductors 32. An opening 91 (see FIGURES 2, 4 and 11) extends transversely across a portion of the housing 40. A conductor anchoring member in the form of a restraining bar 92 which is constructed of a dielectric material spans opening 91. The conductor restraining bar 91 is spaced from the end walls of the opening 91. A portion of the conductor restraining bar 92 is spaced from the main portion of the housing 40 by slots 93 and 94.

Another portion of the restraining bar 92 is integral with the walls of the opening 81 through connecting portions 96 and 97.

The relative depths of the slots 93 and 94 are important to the effectiveness of the bar 92.

The bar 92 is formed integrally with the housing such that the slot 94 is of substantially greater depth than that of the slot 93. This arrangement will cause the bar 92, which cannot because of space limitations be constructed identical to the anchoring member 70, to in fact become reformed under application of forces into a configuration similar to that of the pivotally actuated anchoring member 70.

The restraining bar 92 is reformed or upset within the opening 91 to provide a strain relief element 99 (see FIGURE 12) which is in engagement with each of the individual conductors 32. Forces are applied to the restraining bar 92 through a specially designed tool 100 (see FIGURE 12). The bar 92 fractures through the portion 97 oriented toward the cord-input end 42 and effectively locks the element in engagement with the conductors 32-32.

The use of the one-piece or unipartite dielectric housing 40 affords certain advantages.

It permits an operator to simply insert a jacketed cord 23. Heretofore, separate or hinged portions (see U.S. Patent 3, 835, 445) were mated together to secure the cord jacket and the conductors 32 within the assembled dielectric body. Finally, the terminals 33 are inserted into the assembled dielectric body.

In using such a connecting device embodying the invention, there is no required bonding of mating portions with accompanying problems of alignment and quality of the bond. Moreover, the housing 40 has provisions moulded therewith for securing the cord 23 to the plug for alleviating strain relief on the cord jacket 31 and the conductors 32 during customer use.

The jacket-anchoring member 70 and the conductor restraining bar 92 not only secure the plug 24 to the cord 23 but also provide strain relief for the jacket and the conductors, respectively.

In this way, the terminals 33 function only to make electrical contact with the conductors 32 and are not required to retain the conductors and resist the forces imparted to the conductors or the cord during customer use. The forces on the conductors 32 occur notwithstanding the anchoring of the jacket 31 with the member 70.

While the pressure on the jacket 31 may prevent the insulation 37 of the conductors 32 from moving relative to the jacket, the pressure is not sufficient to prevent the nylon core 35 and ribbon 36 from moving relative to the insulation thereof during customer use. This occurs because the insulation 37 is tubed over the core 35 and tinsel ribbon 36 wrapped about the core.

Forces applied to the cord 23 by the subscriber tend to cause the core 35 and ribbon 36 to move slideably within the insulation 37. This movement, if unchecked, could cause the tinsel ribbon to be torn at the engagement thereof with portions of the terminals 33. The configuration of the restraining bar 92 and the different depth slots 93 and 94 results in the formation of a restraining member of surprisingly excellent performance characteristics.

The moulding of the housing 40 with the ability to be able to precisely confine the conductors 32 in the troughs 49 is especially importa 26 in the handset 22 and ensures integrity of the connection during customer use.

Each one of the terminals 33 is made from an electricity conductive resilient material such as phos hor bronze and, as can be seen from FIGURE 2, has a flat conductive portion 121 with at least one contact or insulation-piercing tang 122 protruding therefrom. The tangs 122 provide electrical connection between the conductive portion of the conductor 32 and the associated ones of the terminals 33.

Each of the terminals 33 also has an edge surface 123 having curved crowns 124 or predetermined radii. The crown 124 nearest the free end 41 of the housing 40 functions to complete the connection between the associated externalcontacting component 27 illustrated in FIGURE 13, and positioned in the telephone jack 26.

Provision is also made for properly seating the terminals 33 within the associated terminalreceiving slots 52. Each of the terminals 33 is formed with shoulders 126 having necked-down portions 127 that terminate in barbs 128. As we indicated hereinbefore, the overall length of the terminal 33 between the outermost parts of the barbs 128 is greater than that of the length of the terminal-receiving slot 52. When the terminal 33 is inserted into the associated terminal-receiving slot 52, the barbs 128 penetrate the dielectric material which defines the slot to anchor the terminal (see FIGURE 5).

The extent to which the terminal 33 is inserted into the associated slot 52 is determined by the operation of an apparatus (not shown) used to insert the terminals. Generally, that apparatus is controlled to insert the terminals 33 within the associated ones of the terminalreceiving slots 52 such that the shoulders 126 are spaced above the abutments 53.

The extent to which the terminal 33 is inserted into the associated terminal receiving slot 52 is controlled to also ensure that adequate electrical engagement is effected between the terminal tangs 122 and the conductors 32. If the depth of insertion is lacking the tangs 122 may not engage one or both generally diametrically opposed portions of the helical tinsel ribbon 36. On the other hand, If the depth of insertion is too great, the shoulders 126 could rupture the abutments 53. It is important that the tangs 122 engage the top or closest portion of the tinsel ribbon 36, be moved through the core 35 through the bottom portion of the helically wrapped tinsel ribbon, and into engagement with the flat bottom portions of the troughs 49 (see FIGURES 5 and 13).

The arrangement of the tangs 122 with di electric material is a further reason for the flat bottom configuration of the troughs 49. If the bottoms were V-shaped, difficulties may arise in causing the tangs 122 to become embedded in the dielectric material.

While the terminals 33 have been shown in a flat or blade-like configuration, it should be obvious that they could be in the form of pins (not shown). Of course, the terminal-receiving openings 52 would then be moulded to accommodate the pins (not shown) rather than the blade-like terminals 33.

It will be appreciated that housing 40 may be controlled to accommodate an end portion of a flat cord 23 without the necessity of removing the jacket from an end portion thereof. The cavity 46 would be moulded without the conductor-receiving troughs 49 and such that a leading end portion of the cord 23 would be inserted into the cavity. The cavity 46 would be constructed to communicate with the terminalreceiving slots 52 and may or may not open to the free end 41 of the housing 40. After the end portion of the cord 23 is inserted into the cavity, the terminals 33 are driven into the slots 92 into engagement with the conductors. Since the cord 23 is flat, and assuming that the cord is inserted properly into the cavity 46, the conductors are aligned properly with the terminals 33.

WHAT WE CLAIM IS: 1. An electrical connector for terminating a cord having a plurality of insulated conductors, the connector including a unipartite dielectric housing having a cavity that opens to at least one end of the housing for receiving and for substantially enclosing an end portion of a said cord, the housing having a portion adjacent the cavity and connected to the remainder of the housing toward the other end thereof, the connected portion being moveable from an initial position in a well in the housing at least partially into the cavity whereby first and second portions of the moveable portion engage an inwardly facing surface of the cavity toward said one end of the housing and a wall of the well adjacent the inwardly facing surface, respectively, to lock the moveable portion in a position for securing a said cord in the housing, the latter being adapted to receive a plurality of electrically conductive terminals for permitting electrical contact thereto external to the housing and for effecting electrical contact in the cavity with the conductors of a said cord.

2. A connector as claimed in claim 1, wherein the housing includes a plurality of terminalreceiving openings communicating with the cavity and the exterior of the connector.

3. A connector as claimed in claim 1 or 2, wherein the moveable portion is connected through a connecting portion at one end thereof and through a frangible portion at the other end thereof to the housing toward the other and the one end thereof, respectively, whereby application of force to the moveable portion causes its other end to separate from the housing.

4. A connector as claimed in claim 3, wherein the frangible portion is such that after separation thereof from the housing it provides a curvable extension to the moveable portion, whereby, in use, a blunt curved portion of the extension

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **.

26 in the handset 22 and ensures integrity of the connection during customer use.

Each one of the terminals 33 is made from an electricity conductive resilient material such as phos hor bronze and, as can be seen from FIGURE 2, has a flat conductive portion 121 with at least one contact or insulation-piercing tang 122 protruding therefrom. The tangs 122 provide electrical connection between the conductive portion of the conductor 32 and the associated ones of the terminals 33.

Each of the terminals 33 also has an edge surface 123 having curved crowns 124 or predetermined radii. The crown 124 nearest the free end 41 of the housing 40 functions to complete the connection between the associated externalcontacting component 27 illustrated in FIGURE 13, and positioned in the telephone jack 26.

Provision is also made for properly seating the terminals 33 within the associated terminalreceiving slots 52. Each of the terminals 33 is formed with shoulders 126 having necked-down portions 127 that terminate in barbs 128. As we indicated hereinbefore, the overall length of the terminal 33 between the outermost parts of the barbs 128 is greater than that of the length of the terminal-receiving slot 52. When the terminal 33 is inserted into the associated terminal-receiving slot 52, the barbs 128 penetrate the dielectric material which defines the slot to anchor the terminal (see FIGURE 5).

The extent to which the terminal 33 is inserted into the associated slot 52 is determined by the operation of an apparatus (not shown) used to insert the terminals. Generally, that apparatus is controlled to insert the terminals 33 within the associated ones of the terminalreceiving slots 52 such that the shoulders 126 are spaced above the abutments 53.

The extent to which the terminal 33 is inserted into the associated terminal receiving slot 52 is controlled to also ensure that adequate electrical engagement is effected between the terminal tangs 122 and the conductors 32. If the depth of insertion is lacking the tangs 122 may not engage one or both generally diametrically opposed portions of the helical tinsel ribbon 36. On the other hand, If the depth of insertion is too great, the shoulders 126 could rupture the abutments 53. It is important that the tangs 122 engage the top or closest portion of the tinsel ribbon 36, be moved through the core 35 through the bottom portion of the helically wrapped tinsel ribbon, and into engagement with the flat bottom portions of the troughs 49 (see FIGURES 5 and 13).

The arrangement of the tangs 122 with di electric material is a further reason for the flat bottom configuration of the troughs 49. If the bottoms were V-shaped, difficulties may arise in causing the tangs 122 to become embedded in the dielectric material.

While the terminals 33 have been shown in a flat or blade-like configuration, it should be obvious that they could be in the form of pins (not shown). Of course, the terminal-receiving openings 52 would then be moulded to accommodate the pins (not shown) rather than the blade-like terminals 33.

It will be appreciated that housing 40 may be controlled to accommodate an end portion of a flat cord 23 without the necessity of removing the jacket from an end portion thereof. The cavity 46 would be moulded without the conductor-receiving troughs 49 and such that a leading end portion of the cord 23 would be inserted into the cavity. The cavity 46 would be constructed to communicate with the terminalreceiving slots 52 and may or may not open to the free end 41 of the housing 40. After the end portion of the cord 23 is inserted into the cavity, the terminals 33 are driven into the slots 92 into engagement with the conductors. Since the cord 23 is flat, and assuming that the cord is inserted properly into the cavity 46, the conductors are aligned properly with the terminals 33.

WHAT WE CLAIM IS: 1. An electrical connector for terminating a cord having a plurality of insulated conductors, the connector including a unipartite dielectric housing having a cavity that opens to at least one end of the housing for receiving and for substantially enclosing an end portion of a said cord, the housing having a portion adjacent the cavity and connected to the remainder of the housing toward the other end thereof, the connected portion being moveable from an initial position in a well in the housing at least partially into the cavity whereby first and second portions of the moveable portion engage an inwardly facing surface of the cavity toward said one end of the housing and a wall of the well adjacent the inwardly facing surface, respectively, to lock the moveable portion in a position for securing a said cord in the housing, the latter being adapted to receive a plurality of electrically conductive terminals for permitting electrical contact thereto external to the housing and for effecting electrical contact in the cavity with the conductors of a said cord.
2. A connector as claimed in claim 1, wherein the housing includes a plurality of terminalreceiving openings communicating with the cavity and the exterior of the connector.
3. A connector as claimed in claim 1 or 2, wherein the moveable portion is connected through a connecting portion at one end thereof and through a frangible portion at the other end thereof to the housing toward the other and the one end thereof, respectively, whereby application of force to the moveable portion causes its other end to separate from the housing.
4. A connector as claimed in claim 3, wherein the frangible portion is such that after separation thereof from the housing it provides a curvable extension to the moveable portion, whereby, in use, a blunt curved portion of the extension

contacts the cord.
5. A connector as claimed in any preceding claim, wherein the housing includes a conductorrestraining portion separated partially from the housing by first and second slots extending different depths towards the cavity and being such that, in use, application of force to the conductor-restraining portion causes it to fracture from the more extensive one of said slots to the cavity and to move along the fracture line and be reformed into engagement with the conductors in the cavity and into locking engagement with the housing.
6. A connector as claimed in any preceding claim wherein said one end of the housing has a curved flared entrance portion,, and the moveable portion is such that, when in its cordsecuring position, a portion thereof is aligned with a tangent to the flared entrance.
7. A connector as claimed in any preceding claim, wherein the cavity terminates at a wall toward the other end of the housing.
8. A connector as claimed in any one of claims 1 to 6, wherein the cavity opens toward the other end of the housing.
9. A connector as claimed in preceding claim, wherein the housing includes conductorreceiving troughs in the cavity.
10. A connector as claimed in claim 9, wherein the troughs are between a plurality of parallel partitions in a portion of the cavity.
11. A connector as claimed in claim 10 wherein the partitions extend completely between opposed surfaces of the cavity.
12. A connector as claimed in claim 10 wherein the partitions extend partially between opposed surfaces of the cavity.
13. A connector substantially as herein described with reference (i) FIGURES 1 to 5, 9 and 11 to 14; or (ii) to (i) as modified by FIGURE 6, 7 or 8; or (iii) to (i) as modified by FIGURE 10, or to (ii) as modified by FIGURE 10 of the accompanying drawings.
14. A connector as claimed in any preceding claim including a said plurality of terminals associated therewith.
15. A connector as claimed in claim 14 with a said cord assembled thereto, the moveable portion and, it provided, the conductor-restraining portion having been moved to its or their actuated positions, and said terminals making electrical contact with said conductors in the cavity.