US1722739A - Method of manufacturing connection plugs - Google Patents

Description

July 30, 1929. B. K. FORD l 1,722,739

METHOD OF MANUFACTURING vCONNECTION PLUGS Filed July 27, 1927 Patented July 30, @29

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This invention relates to method of manufacturing connecting plugs, and more paring plugs which are designed to engage jack contactsattached to other conductors and which jaclr contacts may be fiXedly positioned. fr plurality of individually insulated conductors of this type assembled under commony sheath to constitute a' flexible strand termed a cord is frequently used in telephone exchanges for interconnecting elec-Y trical circuits of 'telephoneswitchboards; ln such cases the connecting plugattached to the cord is usuallyprovided with contacting portions which are insulated from each other7 individually connected with the conductors of the cord and designed to engage cooperating contacting portions or springs. Vof a jack terminal secured in the telephone switchboard. Due to the continual insertion and withdrawal by a switchboard operator of the plugin and from thejacls yof the switchboard the plug is subjected to considerable wear7 stress and strain and their replacement may therefore be quite frequent.

The primary objectof this invention is the provision ofa method ofmanufacturing a connecting plug for electrical conductors whereby it may be quickly and Vsecurely as sembled inv'an expeditious, efficient and'economical manner. Y

In accordance with ject the present invention Vcontemplates a method of manufacturing a connecting plug,

consisting of a'plurality of contacting eie-L ments which are insulated from eachother and which are provided with conducting portions positioned in 'the body portion of the plug to receive thevends of theI electrical conductors and enclosed by an insulating sleeve. Integral with the body portion is aihollow projecting portion through which, and insulated therlfrom, the`r conducting portions of the contacting elements extend. The conducting portion of onel of the contacting elements which specifically constitutes the tip of the connecting plug assembly, consists of a steel wire, such as music wire, provided at one end with a series of circularly arranged the aforementioned ob-v isev.- semi no. acaeea.

depressions in which the metal of the tip contion will more fully appear' from the acompanying detailed description takenA in connection witn theaccompanying drawing which illustrates one embodiment thereofyin which VFig. lispan elevation of an electrical conf necting plug manufactured vin accordance with the limproved method shownr attached toacord; y

2 is a section onthe line 2 12 thereof looking in the direction indicated by the arrows; je ,l 4

Fig 3 is a perspective viewv of the center p1n; f

Fig. l is an enlarged section on the line i-l of Fig. 3 looking in the direction indicated by the arrows; Y j

Figs. 5 and 6 are enlarged perspective views of the tipcontact and dead.collar;A

Fig. 7 Ais a perspective view oflan insulating member, and f Fig. 8 is an enlarged section on. the linev 8-8 o'fFig. 2 looking in the direction indicated by the arrows. 'l f rThis invention is particularly applicable to the manufacture of a connecting plug struc-l ture for telephone cords and in the embodi-v nient illustrated in .tlie drawings is of the' three conductor-typeythat is, it provides for.

the extension of suitable contacts Vof the ack. I

' (not shown) ofthreeconductors. 'lhe plug consists of al tubular, bodyportion 10 and aV projecting sleeve portion ll, ofless -diameter thanvthe portion'l()7 which is adapted to be inserted in a jack terminal to make electricalV Y contact with certain contact springs thereof.

The body portion l0 is-cut away intermediate its ends as shown at l2 to form a web portion ias for the purpose of affording access to its in terior at pointswhere conductors of the cord are tobe' connected to certain terminals to be referred to hereinafter. Carried within the f bore of the sleeve portion l1 is an insulating sleeve 13, a conducting sleeve 14, an insulating sleeve and a 'center pin 1,6k mounted one within the other in the sequence named.1 The kinsulating,sleeve 13 has formed on the outer -end thereof` (Fig. 2) a flangedportion 17,

while the inner en-d thereof extends along the bore ofthe sleeve portion 11`and terminates adjacent the inner shoulder of the bore of the body portion 10. The outer end of the conducting' sleeve 14 is formed with an enlarged ring portionv 18 which is'insulated from thev outer end ofv thersleeve portion 11 by the iianged portion 17 of the insulating sleeve v13,

'while the inner end of the sleeve 14 is Closed `forthe purpose of providing 'a supporting portion for a screw 2O for securing one of the l portion thereof.

` Mounted upon the insulating sleeve 15 isa dead collar 22`of conducting material, which is insulated onr its inner end from the adjacent end surface ofthe portion 18 of the sleeve 14 by any insulating washer 23 and on its outer end by a similar vwasher 23 from the inner end surface of a tip vmember 24, the member is .fitted tight on the center pin 16 so that it must lbe slightly forced wlienassembl-ed thereon.

The flat end faces of the dead collar 22 are lznurled as shown at 25 (Fig. 6) also the inner Y flat end face vof the tip member 24 is knurled as shown at 26 (Fig. 5). The purpose of the lniurling of these faces of the 'collar 22 and tip Y member 24 is'to prevent the rotation of the washers r23 and the' collar 22 relative to each otheror to otlierparts of the plug during a subsequent profiling or finishingoperation to be referred to hereinafter. It will be ap'- parent in the completed plug as well as during the operation just referred to wherein the various parts axially vdisposed upon the center pin 16 are maintained under compression one against the other, that the knurled metal end faces of the collar 22 andtip member 24 will y be'pressed into the adjacent end faces of the comparatively soft material composing the washers 23, thus securely locking the'washers and collar 22 from rotation.

Referring to Figs. 2, 3 and 4, particularly F ig. 4, it will be observedthat the outer end (Figs. 2 and 3) of the center pin 16, which is madev of a material similar to music wire for the purpose of providing a maximum stiffness or rigidity to the plug, is provided with four equally `spaced shallow notches 29, two of the notches appearing in Figs. 2 and v3. In assembling the plug, the tip member 24 is staked on the center pin 16 in such la manner that the peripheral surface of the bore thereof is lodged or forced down into the notches r29 to completely fill them with the metal composing the tip and thereby lirmly securing the latter member from relative vvmovement in all directions on the pin 16. Between the peripheral surface of the bore of the body portion 10'and the peripheral surface of that portion of the sleeve' 14 ext-ending thereinto is lan insulating sleeve 27 which is an extension of the insulating sleeve 13, the two sleeves overlapping as shown at 28.

Electrically weld-ed to tliefrigh't end of thev center pin 16, before `the assemblage lof the plug, is aterminal plate 30 2) provided with a right angle shoulder 31, which is rounded at its upper end sur-face as viewed in Figs. 2, 3 and 8 to conform to the'curv'a'- relay electrical path between the body portion 10 and the shoulder 31. One end ofthe shell' v32 engages a'shoulder33 ff'ormed'on the body portion 10 adjacent its1 inner end, the opposite end extending toa point adjacent Aa shoulder 34 provided on the body portion 1Q in forming the sleeve portion 11 thereof, and is iiXed to the body portion 10 by a screw 35 (Fig. 1).

The outer vertical faceof the. shoulder 31 of the plate 3 0 as well as the lower face of the latter is yspaced from thesurfaces of the body portion 10 produced in the forming of the web portion 12 thereof by an insulating mem- 'ber 36 (Fig. 7) provided with a rightangle arm 37, the arm serving to insulate. the inner end surface of the conducting sleeve 14 from the plate 30, the sleeve 14 being cut away to` 1 'conform to the web portion 12 of the body 10, as will readily be understood.-k VThe niember 36 is provided with a suitable slot 38 `for that portionof the centerl pin V16 which is welded to the plate 30. A screw 39 similar to the screw 2O threaded into theV closed end of the conducting sleeve 14 is threaded into.'

the plate 30 for securing another one of the three conductors to the center pin 16.

Another of the. three conductors constitut-i ing the cord' 21 is maintained in electrical contact with the peripheral wall of a threaded-portion 40 of thebore of the body portion 10 at its inner end by'turning back the' bared conductor which is lirmly held in' elec# trical contact with thethreaded portion by the cord which is threaded tl'iereinto. The

screws 39 and 21 'each secure onelofthec'cnlio ductors to the center pin 16 to which is staked the tip member24'and the conductingsleeve cured another cord in the manner hereinbefore referred to. The tip contact, the ring portion and the sleeve portion of the body, respectively, being included in what are generally termed the tipff ring. and sleeve circuits in telephone exchange circuits.

During the iinal assemblage of the connecting plug herein described the tip member 24:, dead collar 22, insulating washers 23 at either end of the latter, conducting sleeve 14 and insulating sleeve 13 are maintained under pressure against the left end of the sleeve portion 11 of the plug body 10 and simultaneously therewith the shoulder v31 of the plate 30, which is welded to the center pin 16 is pressed against the arm 37 of the insulating member 36 in turn backed by a vere ltical surface (Fig. 2) of the body portion 10 formed at one end of the cut away or web portion 12 thereof. This pressure brings the various parts close together and serves to press the knurled metal end faces of the collar 22 and tip member 24 into the adjacent faces of the washers 28, as hereinbefore described, thusA securelyV locking these partsV together. Vfhile the aforementioned parts are under compression suitable means is'employed to stake the tip member 2a ontothe center pin 16, as liereinbefore described, thus forcing the metal of the tip member into the notches 29 and securely locking the parts while under compression to the body portion 10. After completion of the assemblage the sleeve portion 11 of the body portion 10, together Vwith the portion of the plug extending from the left end thereof 2), is polished oi' pro-l filed to provide a desired contour for insertion in the jacks of the switchboard. The center pin 16 with the terminal plate 80,-secured thereto is mounted within thebody 10 by inserting it through the opening formed in the body in' producing the web portion 12 thereof. Y

It will be obvious that a connecting plug manufactured in accordance with the hereinbefore described method results in a plug of the hereinbefore described type which is adequate to stand the wear, stress and strain to which plugs of this type are subjected, thus holding their replacement down to a minimum.

l/Vhat is claimed is:

1. rPhe steps in the methodr of manufactun ing electrical connecting plugs, which consists informing an a'pertured body with a web portion thereon, positioning a pin provided with an angular extension alongthe i i apei ture oi tne body by inserting it through the o iening formed in the body in producing the web portion thereof with the extension disposed adjacent asurface of the body atone y end of the web portion thereof, positioning an apertured contact on the pin adjacent an outer end surface of the body, insulating the contact and the pin including the angular eX- tension thereof from the body, and then compressing t-he severa-l parts ina direction parallel to the longitudinal axis of the body and while under such compression rigidly uniting the contact to the pin.

2. rlhe steps in the method of manufacturing electrical connecting plugs, which consists in forming an apertured body with a web portion thereon, positioning a pin proi vided with an angular extension along the aperture of the body with the extension disposed adjacent a surface ofthe body at one end of the web portion thereof, positioning an apertured Contactl on the pin, insulating i the Contact and the pin including the angular extension thereof from the body,A and then rigidly uniting the several. parts by lodging l material of the contact in the peripheral surface of the pin while the several parts are under compression in a direction parallel to the longitudinal axis of the body.

3. A method of manufacturing electrical connectingplugs, which consists'in assem-.

bling a plurality of contacting members on an element having an indentation, positioning an end member over the identation, and swagingthe material thereof into the indentatioirto form a rigid mounting.`

4;. A method of. manufacturing electrical connecting plugs, which consists in assembling a plurality of contacting members on an element, insulating the contacting mem-V bers, compressing the contacting .members with an end meinberinserted on the element, and swaging the end member to lock it' to the element. n j

5. A method of manufacturing electrical connecting plugs, whichconsists in assembling a plurality of apertuiedcontacting ymembers on an element provided with peioo ripheral depressions, compressing the 'contacting members longitudinally of the element, and causing an end contacting member to lill said depressions to form a rigid mounting.

In witness whereof, I hereunto subscribe my name this 15th dayofoJuly A. D., A1927.

BEN'KING noni).

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