GB1559543A

GB1559543A - Wire insertion tool

Info

Publication number: GB1559543A
Application number: GB1938677A
Authority: GB
Original assignee: Bunker Ramo Corp
Current assignee: Bunker Ramo Corp
Priority date: 1976-05-19
Filing date: 1977-05-09
Publication date: 1980-01-23
Also published as: FR2352473A1; DE2722299A1

Description

(54) WIRE INSERTION TOOL (71) We, BUNKER RAMO CORPORATION, a Corporation organised and existing under the laws of the State of Delaware, United States of America, of 900 Commerce Drive, Oak Brook, Illinois, 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: The present invention relates to tools for inserting wire in nondeforming insulation piercing terminals disposed in a terminal retaining body, and more particularly to manually operated tools for inserting a single wire at a time.

Many terminal blocks and connectors are being manufactured which employ nondeforming insulation piercing terminals. Such terminals are channels of generally U-shapzd cross-section and usually include a plurality of projections extending inwardly from the side walls thereof. The projections are shaped to part the insulation of a wire inserted therebetween and make electrical contact with the inner conductor of the wire.

Terminals of this type allow for rapid wir. ing of terminal blocks and connectors, since the insulation need not be stripped from the conductor prior to its insertion into the terminal, and the terminal need not be crimped or deformed in order to penetrate the insulation.

In practice, all of the wires to be connected to a particular terminal retaining body are installed in a jig surrounding the terminal retaining body, and subsequently all of the wire are inserted in their respective terminals simultaneously. This allows for very rapid wiring of a large number of multiconductor connectors or terminal blocks. However, the machinery used for these operations is complicated and bulky and it is not suited for field service or wiring changes involving only a small percentage of the number of wires connected to the terminal retaining body. Additionally, the devices of the prior art are particularly adapted to wiring a single size and shape terminal retaining body. As a result, a great number of these machines would be required to service the wide variety of shapes and sizes of terminal retaining bodies commonly in use. Furthermore, the devices of the prior art have found themselves to be particularly susceptible to faulty connections due to incomplete insertion of the wire into the terminal.

According to the present invenion there is provided a wire insertion tool for inserting a wire in a non-deforming insulation piercing terminal disposed in a terminal retaining body, said tool comprising two handles, each of said handles having a first and second end and including a grip portion adjacent said first end thereof ; a pivot member pivotally connecting said two handles at a pivot point remote from said first end; two jaw members, each jaw member being pivotally connected adjacent its second end to a respective one of said two handles ; and being longitudinally slideably coupled to the other of the handles at a point between the pivot point and the first end of the other handle ; insertion means on said first jaw member for engaging a wire to be inserted in a terminal; engaging means on said second jaw member for engaging a portion of the terminal retaining body spaced from the terminal in the direction in which the wire is to be inserted, whereby relative approaching movement of said grip portions of said handles toward each other effects a corresponding movement of said first and second jaw members toward each other to cause a wire engaged by said insertion means to be moved in the insertion direction relative to a terminal retained in a terminal retaining body engaged by said engaging means; limiting means for prohibiting movement of said handles and said jaw members in a direction counter to said approaching movement; and release means for releasing said limiting means when a predetermined distance between said insertion means and said engaging means has been reached, whereby said jaw members may be separated after the wire has been fully inserted in the terminal.

Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a typical terminal retaining body; Figure 2 is a plan view of a portion of the terminal retaining body showing a wire installed therein ; Figure 3 is a perspective view of a porticn of a tool according to the present invention in position to insert a wire into one of the terminals of a terminal retaining body; Figure 4 is a front elevational view of a first embodiment of the present invention; Figure 5 is an exploded view of a first embodiment of the present invention Figure 6 is a front elevational view of a second embodiment of the present invention: Figure 7 is an exploded view of a second embodiment of the present invention ; Figure 8 is a partial perspective view of an alternate embodiment of the second jaw member ; Figures 9 and 10 are plan views of a portion of the second and first jaw members, respectivelv, showing alternate positioning of the alignment member and insertion member, respectively ; Figure 11 is a plan view of a portion of an alternate embodiment of the first jaw member.

Referring to Figures 1 and 2, a typical terminal retaining body 3 includes body member 7 and insulating dividers 5 separating individual U-shaped insulation piercing terminals 1. Each terminal 1 includes a plurality of projections 9 extending inwardly from the side walls. When a wire 11 is forced into the terminal 1, the projetions 9 separate the insulation 13 and make electrical contact with the conductor 15. In Figure 2, the insulation has been partially cut away to better show the conductor.

Figure 3 shows a portion of the tool according to the present invention in place on the terminal retaining body 3. First jaw member 21 supports insertion tab 23 in engagement with a wire to be inserted in a terminal. Second jaw member 31, including alignment member 35 and engaging surface 33, press against the terminal retaining body 3 at a position spaced, along the wire inserting direction, from the terminal into which the wire is to be inserted. Insertion tab 23 contains notches 25 positioned to receive projections 9 of the terminal. First jaw member 21 and second jaw member 31 include recesses 27 and 37, respectively, to make room for the wires already connected to the other terminals.

Figures 4 and 5 show a first embodiment of the present invention in which the handles 40 and 42 are essentially flat. The handles 40 and 42 include gripping sections 51 and 49, respectively, and are pivoted around a pivotal member 53 which passes through holes 41 and 43 of handles 42 and 40, respectively. handle has an essentially circular end 50 and 52 concentric with the pivot holes 41 and 43. The circular ends of each handle include two diametrically opposite holes 45-48 angularly spaced from two diametrically opposite curved slots 65-68. The holes and slots are disposed on the handles so that studs 55-58 extending through a hole 45-48 in ose e handle align with a slot 65-68 in the other handle. In this way, the handles 40 and 42 may be pivoted through an angle determined by the length of the slots 65-68.

Jaw members 21 and 31 are sandwiched between the two plates on either side of the pivot member 53 and include holes 22 and 32 through which studs 58 and 55 re spectively, pass. Jaw members 21 and 31 further include slots 24 and 34, through which studs 57 and 56 extend. In this manner, jaw member 21 is pivotally connected to handle 42 through stud 58 and longitudinally slideably connected to handle 40 through stud 57. Likewise, jaw member 31 is pivotally connected to handle 40 through stud 55 and longitudinally slideably connected to handle 42 through stud 56.

Whsn handles 40 and 42 are pivoted about pivotal member 53 so that gripping sections 49 and 51 are brought closer to gether, stud 58 is brought closer to stud 55, and stud 56 is brought closer to stud 57.

This causes jaw members 21 and 31 to approach one another.

The tool may have a ratchet mechanism including pawl 79 engageable with plate 73 having teeth 75. The plate 73 is connected to handle 40 through stud 57 which passes through hole 72. The pawl 79 is pivotally connected to handle 42 through stud 58 which passes through hole 89 of the pawl.

Spring 81 biases the pawl 79 towards the teeth 75 and is connected between post 84 of the pawl and post 83 of the spring mounting plate 77 which is connected to move with handle 42 by means stud 58 and pivotal member 53 which pass through holes 78 and 75 respectively.

The pivcta ! member 53 and the studs 55 through58 are held in place by screws 70 and 85-88, respectively.

One of the jaw members ma include stop screw 93 and locking nut 5 which limit the travel of the jaw members toward each other so that they do not damage the terminal or terminal retaining body.

A spring 96 may be provided having a central hole 99 through which pivotal member 53 passes. Spring ends 97 and 98 engage jaw members 31 and 21, respectively, and bias the two jaw members away from each other.

The above-described embodiment is very inexpensive to manufacture, since all of the major parts may be stamped out of sheet material. The resulting tool is also light, compact, and easy to use. Furthermore, the ratchet mechanism is constructed so that as the gripping sections 49 and 51 of handles 42 and 40 are brought together, the pawl 79 engages successive ones of teeth 75 and prohibits movement of the gripping sections of the handles away from each other to remove the tool from the terminal, untif the pawl has reached the last of the teeth 75, which corresponds to a predetermined distance between insertion tab 23 and engaging surface 33. The distance is chosen to assure complete insertion of the wire in the terminal. At this time, the pawl 79 is momentarily rotated out of engagement with the teeth 75 to allow the jaw members to move away from each other. Since each different size of terminal retaining body 3 may require a different spacing between the insertion tab 23 and the engaging surface 33 to fully insert the wire in the terminal a plurality of plates 73 may be provided with the tool, or each plate 73 may include one or more additional sets of teeth 82 as shown in dotted lines in Figure 4. In the latter case, the plate 73 is removed from the tool, flipped over, and, replace on the tool so that pawl 79 engages teeth 82. Of course, stop screw 93 must be reset each time plate 73 is change.

Figures 6 and 7 show an alternate embodiment of the present invention having handles 140 and 142 of U-shaped crosssection. These handles are pivotally connected by pivotal member 153 which passes through holes 141 and 143. The pivotal area of handle 140 is divided into two spaced essentially parallel plates, 151 and 152. Likewise, the pivotal area of handle 142 is divided into plates 149 and 150.

Jaw members 121 and 131 are disposed between plates 149 and 152. Plate 151 is located on the opposite side of plate 149 from the jaw members, and plate 150 is located on the opposite side of plate 152 from the jaw members. Pin 155 extends through hole 145 in plate 151, hole 132 in jaw member 131 and hole 145 in plate 152, pivotally connecting jaw member 131 to handle 140. Similarly, pin 158 extends through hole 148 in plate 149, hole 122 in jaw member 121 and hole 148 in plate 150, pivotally connecting jaw member 121 to handle 142. Pin 156 extends through hole 146 in plate 149, slot 134 in jaw member 131 and hole 146 in plate 150, longitudin- ally slideably coupling jaw member 131 to handle 142. Similarly, pin 157 extends through hole 147 in plate 151, slot 124 in jaw member 121, and hole 147 in plate 152, longitudinally slideably coupling jaw member 121 to handle 140. Pivotal member 143 and pins 155-158 are secured by lock rings 170 and 185-188. As in the previously described embodiment, as the handles are squeezed together, jaw members 121 and 131 are caused to move towards each other.

Stop screw 193 and locking nut 195 may be included on one of the jaw members to limit the movement of the jaw members towards each other.

A linear ratchet mechanism may be used, including ratchet pawl 179 pivoted around screw 190 extending through hole 189 in the pawl and through hole 178 of jaw member 121. The pawl 179 is biased towards the linear ratchet arm 173 by spring 181 attached to post 184 of pawl 179. The linear ratchet arm 173 is attached to jaw member 131 by screw 191 and includes teeth 175 and alternate teeth 182. This embodiment of the tool may be adapted for use with different sized terminal retaining bodies by removing the screw 191 and reacing or inverting arm 173.

Springs 196 connected between each handle and a respective jaw member may be used to bias the jaw members away from each other.

Jaw member 121 includes insertion tab 25 identical to the previously described tab of the same number. Likewise, jaw member 131 includes engaging surface 33 and alignment member 35 identical to the previously described elements of the same number. Jaw members 121 and 131 also include recesses 127 and 137 similar to recesses 27 and 37 of the previously described embodiment.

Although more expensive in construction, this embodiment of the present invention is more comfortable in use and sturdier than the previously described embodiment.

Figure 8 shows an alternate embodiment of engaging surface 33 which includes a further alignment member 39, cooperating with alignment member 35, to position the jaw member 31. Alignment member 35 is intended to engage the end of insulated dividers 5 of the terminal retaining body 3 as shown in Figure 3. Alignment member 39 is designed to partially enter a terminal I in line with the terminal into wh ch the wire is to be inserted. The member 39 extends a distance from the surface 33 which is short enough so that the member 39 does not damage the projections 9 of the terminal 1.

Although Figures 3 through 8 show insertion tabs 25 and alignment members 33 and 39 disposed so that the longitudinal axes of the jaw members 21 and 31 are parallel to the longitudinal axis of the terminal 1, this is not a necessary feature of the present invention. Figures 9 and 10 show alternate positioning for alignment member 35 and insertion tab 25, respectively, which allow the longitudinal axes of the jaw members to be angularly spaced from the longitudinal axis of the terminal when the tool is in use. Similarly, Figure I I shows an alternate embodiment for the jaw members particularly jaw member 121, in which the jaw member is bent near the insertion tab end. The alternate embodi ments shown in Figures 9 through 11 allow the tool to be used on terminal retaining bodies having large numbers of wires already connected or which are located in an enclose area allowing limited access to the terminals.

In use, any of the above described em bodiments is positioned on the terminal re taining body so that the engaging surface 33 is contacting the side of the terminal re taining body opposite the terminal into which the wire is to be inserted, as shown in Figure 3. To fully insert the wire in the terminal, the gripping sections 49 and 51 of the handles are squeezed together until the end of the stop screw 93 contacts the jaw member 31 and the ratchet pawl 79 releases from the teeth 75 of ratchet plate 73. After insertion is completed, the force on the handles is relaxed and the spring 96 pushes the jaw members 21 and 31 away from each other, allowing the tool to be removed from the terminal retaining body 3.

As can be seen from the above descrip- tion, the present invention provides a tool which is very simple in use and which makes secure connections every time it is used. Additionally, the tool may be readily adapted for use with terminal retaining bodies of various sizes.

From the foregoing, it can be readily realized that this invention can assume various embodiments. Thus, it is to be understood that the invention is not limited to the specific embodiments described herein, but is to be limited only by the appended claims.

Claims

WHAT WE CLAIM IS :- 1. A wire insertion tool for inserting a wire in a non-deforming insulation piercing terminal disposed in a terminal retaining body, said tool comprising two handles, each of said handles having a first and second end and including a grip portion adjacent said first end thereof; a pivot member pivotally connecting said two handles at a pivot point remote from said first end; two jaw members, each jaw member being pivotally connected adjacent its second end to a respective one of said two handles; and being longitudinally slideably coupled to the other of the handles at a point between the pivot point and the first end of the other handle; insertion means on said first jaw member for engaging a wire to be inserted in a terminal; engaging means on said second jaw member for engaging a portion of the terminal retaining body spaced from the terminal in the direction in which the wire is to be inserted, whereby relative approaching movement of said grip portions of said handles toward each other effects a corresponding movement of said first and second jaw members toward each other to cause a wire engaged by said inser tion means to be moved in the insertion direction relative to a terminal retained in a terminal retaining body engaged by said engaging means; limiting means for prohibiting movement of said handles and said jaw members in a direction counter to said approaching movement; and release means for releasing said limiting means when a predetermined distance between said insertion means and said engaging means has been reached, whereby said jaw members may be separated after the wire has been fully inserted in the terminal.
2. The tool as claimed in claim I further comprising stop means prohibiting said jaw members from further approaching movement after said predetermined distance has been reached.
3. The tool as claimed in claim 1 or 2 for use with terminals having two side walls and a plurality of insulation piercing projections extending inward from the side walls, wherein said insertion means includes an extending tab sized to fit between the side walls, said tab including a plurality of notches positioned to receive the projections.
4. The tool as claimed in claim 1, 2 or 3 wherein said engagement means includes alignment means for maintaining proper positioning of the tool with respect to the terminal retaining body.
5. The tool as claimed in claim 4 wherein said alignment means and said insertion means are disposed such that the longitudinal axes of said jaw members are angularly spaced from the longitudinal axis of said terminal when the tool is positioned on the terminal retaining body.
6. The tool as claimed in claim 1, 2,3, 4 or 5 wherein said handles are substantially flat, parallel and spaced apart, and said jaw members are disposed therebetween.
7. The tool as claimed in claim 1, 2,3, 4 or 5 wherein said handles are substantially U-shaped and portions of each of said handles are disposed on either side of said jaw members.
8. The tool as claimed in claim 1,2,3, 4,5,6 or 7 further comprising resilient means biasing said grip portions of said handles away from each other.
9. The tool as claimed in any of claims 1 to 8 wherein said limiting means includes a ratchet pawl and a ratchet plate having at least one set of teeth engageable by said pawl.
10. The tool as claimed in claim 9 wherein said plate has a plurality of sets of teeth disposed thereon, each of said sets selectively engageable with said pawl for selectively determining a different value for said predetermined distance.
11. A tool substantially as hereinbefore described with reference to the accompanying drawings.