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Patent Searching and Data


Title:
A GUIDE TOOL
Document Type and Number:
WIPO Patent Application WO/2007/034134
Kind Code:
A1
Abstract:
A light-weight and/or disposable guide tool (20) having means for locating at least one part (8) (preferably at least two parts 8, 12) of a modular conductor connector of the type in which connection of electrical conductors (100, 101) is effected by pressing them into engagement with conductive connector elements of the connector, the tool providing guide means (40, 41) for use in guiding the conductors into position in register with respective conductive connector elements during assembly of the modular conductor connector, and providing means for retaining the at least one part (preferably at least two parts) of the modular conductor connector in an assembled position in preparation for the application (preferably by hand pliers) of a force of sufficient magnitude to effect electrical connection of the conductors. The tool may be made of light-weight material, preferably plastics material, sufficiently light to be supported, together with the said part(s) of the modular connector, by telecommunication wiring conductors, at least when respective conductors are retained in position in register with a few (or at least half, or all) of the conductive connector elements of the modular connector; and/or the tool may be made of low-cost material intended to be discarded, or to be retained in assembly together with the connector part(s), after the electrical connection of the conductors has been effected.

Inventors:
ALONSO NICOLAS CONRADO (ES)
APARICI BALLESTER CARLOS (ES)
Application Number:
PCT/GB2006/003287
Publication Date:
March 29, 2007
Filing Date:
September 06, 2006
Export Citation:
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Assignee:
TYCO ELECTRONICS RAYCHEM SA (ES)
TYCO ELECTRONICS LTD UK (GB)
ALONSO NICOLAS CONRADO (ES)
APARICI BALLESTER CARLOS (ES)
International Classes:
H01R43/01; H01R4/24
Foreign References:
GB1223430A1971-02-24
EP0476590A11992-03-25
US20050071992A12005-04-07
US5683268A1997-11-04
Attorney, Agent or Firm:
JAY, Anthony, William (European Patent Department Faraday Roa, Dorcan Swindon Wiltshire SN3 5HH, GB)
Download PDF:
Claims:

CLAIMS

1. A light-weight and/or disposable guide tool having means for locating at least one part (preferably at least two parts) of a modular conductor connector of the type in which connection of telecommunication wiring conductors is effected by pressing them into engagement with conductive connector elements of the connector, the tool providing guide means for use in guiding the conductors into position in register with respective conductive connector elements during assembly of the modular conductor connector, and providing means for retaining the at least one part (preferably at least two parts) of the modular conductor connector in an assembled position in preparation for the application of a force of sufficient magnitude to effect electrical connection of the conductors, wherein the tool is made of light-weight material, preferably plastics material, and is sufficiently light to be supported, together with the said part(s) of the modular connector, by the telecommunication wiring conductors, at least when respective conductors are retained in position in register with all of the conductive connector elements of the modular connector; and/or the tool is made of low-cost material intended to be discarded, or to be retained in assembly together with the connector part(s), after the electrical connection of the conductors has been effected.

2. A guide tool according to claim 1, wherein the tool is made of light-weight material, preferably plastics material, and is sufficiently light to be supported, together with the said part(s) of the modular connector, by the telecommunication wiring conductors, at least when respective conductors are retained in position in register with half of the conductive connector elements of the modular connector.

3. A guide tool for use with a modular conductor connector of the type in which connection of conductors is effected by pressing them into engagement with conductive connector elements of the connector, the tool having means for locating at least two parts of the modular conductor connector in a stacked relationship with one another, guide means for use in guiding the conductors into position in register with respective conductive connector elements during assembly of the modular conductor connector, and means for retaining the at least two parts of the modular conductor connector in the said stacked relationship in preparation for the application of a force of sufficient magnitude to effect electrical connection of the conductors.

4. A guide tool according to claim 3, wherein each of the said two parts of the modular connector carries an array of the conductive connector elements each element for receiving one of the conductors.

5. A guide tool for use with a modular conductor connector of the type in which connection of conductors is effected by pressing them into engagement with conductive connector elements of the connector, the tool having means for locating at least one part (preferably at least two parts) of the modular conductor connector, guide means for use in guiding the conductors into position in register with respective conductive connector elements during assembly of the modular conductor connector, and means for retaining the at least one part (preferably at least two parts) of the modular conductor connector in preparation for the application of a force, between the said guide tool and the said part(s) of the modular connector, of sufficient magnitude to effect electrical connection of the conductors, wherein the guide tool includes means for transferring the said force to the said conductors guided by the said guide means, thereby to engage and thus connect the conductors with the conductive connector elements of the modular connector.

6. A modular conductor connector having at least two parts each with an array of conductive connector elements, each conductive connector element for receiving an individual conductor, at least one of the said connector parts having guide means for use in guiding the conductors into position in register with respectiev conductive connector elements during assembly of the modular connector, each of the said connector parts having cooperating means for locating the other of the said connector parts and co-operating means for retaining the said other part in position in preparation for the application of a force of cufficient magnitude to effect electrical connection of the conductors.

7. A guide tool according to any preceding claim, further including means for relieving strain on the conductors.

8. A guide tool according to any od claims 2 to 7, having a weight such that the conductors are able to support the guide tool.

9. A guide tool according to any preceding claim, adapted for use with a support member, the support member being either incorporated into the guide tool or being separable therefrom.

10. A guide tool according to any preceding claim made of one or more of plastics, zamack, steel, and aluminium.

11. A guide tool according to any preceding claim, further including means for releasing the assembled conductor connector after effecting connection of the conductors.

12. A guide tool according to any preceding claim, further having means for aligning the parts of the modular conductor connector with respect to each other.

13. A guide tool according to any preceding claim, adapted for use with telecommunication conductors.

14. A guide tool according to any preceding claim, wherein the tool is formed as a part of the modular conductor connector.

15. A kit of parts comprising a guide tool having means for locating one or more parts of a modular conductor connector of the type in which connection of conductors is effected by pressing them into engagement with conductive connector elements of the connector, guide means for use in guiding the conductors into position in register with respective conductive connector elements during assembly of the modular conductor connector, and means for retaining at least two parts of the modular conductor connector together in an assembled position in preparation for the application of a force of sufficient magnitude to effect electrical connection of the conductors, and a modular conductor connector of the said type.

16. A kit of parts comprising a guide tool having means for locating at least one part of a modular conductor connector of the type in which connection of conductors is effected by pressing them into engagement with conductive connector elements of the connector, guide means for use in guiding the conductors into position in register with respective conductive connector elements during assembly of the modular conductor connector, and means for retaining the at least one part of the modular conductor connector in preparation for the

application of a force of sufficient magnitude to effect electrical connection of the conductors, and a modular conductor connector of the said type.

17. A kit of parts according to either of claims 15 or 16, wherein a part of the modular conductor connector is preliminarily assembled to the guide tool.

18. A method of electrically connecting conductors comprising the steps of: a) positioning a first part of a modular conductor connector in a guide tool, b) positioning at least two conductors on the first part of the modular conductor connector in register with respective conductive connection elements thereof, c) positioning a second part of a modular conductor connector in the guide tool such that the at least two conductors are located between the first and second parts of the modular conductor connector, and the whole assembly is retained in position by the guide tool, and d) pressing together the parts of the modular conductor connector, by application of force between the first and second parts of the modular conductor connector, such that the at least two conductors are brought into electrical connection.

19. A method of electrically connecting conductors comprising the steps of: a) positioning at least two conductors on the first part of a modular conductor connector, which has been preliminarily assembled to a guide tool, in register with respective conductive connection elements thereof, b) positioning a second part of a modular conductor connector on the guide tool such that the at least two conductors are located between the first and second parts of the modular conductor connector, and the whole assembly is retained in position by the guide tool, and c) pressing together the parts of the modular conductor connector, by application of force between the first and second parts of the modular conductor connector, such that the at least two conductors are brought into electrical connection.

20. A method of electrically connecting conductors comprising the steps of: a) positioning at least two conductors on a guide tool which has been formed as a first part of a modular conductor connector, in register with respective conductive connection elements thereof,

b) positioning a second part of a modular conductor connector on the guide tool such that the at least two conductors are located between the first and second parts of the modular conductor connector, and the whole assembly is retained in position by the guide tool, and c) pressing together the parts of the modular conductor connector, by application of force between the first and second parts of the modular conductor connector, such that the at least two conductors are brought into electrical connection.

21. A method of connecting conductors in a modular conductor connector according to any of claims 18 to 20 further comprising the step of removing the assembled modular conductor connector from the guide tool after connection of the conductors has been effected.

22. A method of connecting conductors in a modular conductor connector according to any of claims 18 to 21 wherein immediately before, immediately following or simultaneously with the step of positioning the at least two conductor wires a step of relieving the strain on at least one conductor is effected by passing the conductor through strain relieving means formed as part of the modular conductor connector.

23. A method of connecting conductors according to any of claims 18 to 22, wherein the force is applied at only one place along a length of the guide tool and/or first or second part of the modular conductor connector.

24. A method of connecting conductors according to any of claims 18 to 22, wherein the force is applied at more than one place along a length of the guide tool and/or first or second part of the modular conductor connector.

25. A method of connecting conductors according to claim 24, wherein the force is applied sequentially, or substantially simultaneously, at more than one place along the length of the guide tool and/or first or second part of the modular conductor connector.

26. A method of connecting conductors according to any of claims 18 to 25, wherein the force is applied by a tool, preferably by a pair of pliers.

27. A method of connecting conductors according to any of claims 18 to 26, wherein additional parts of the modular conductor connector and other conductors are positioned intermediate between the first and second parts of the modular conductor connector.

28. A method of connecting conductors according to any of claims 18 to 27, wherein the conductors are telecommunication wires.

29. A method of electrically connecting conductors in a modular conductor connector releaseably held in a guide tool, the modular conductor connector comprising at least first and second parts locating at least two conductors therebetween for electrical connection, wherein force is applied at only one place along a length of the guide tool and/or first or second part of the modular conductor connector to provide electrical connection between the at least two conductors.

30. A guide tool substantially as hereinbefore described with reference to the accompanying drawings.

*********************************

Description:

A GUIDE TOOL

The present invention relates generally to a guide tool for use as an aid to assembling modular conductor connectors such that electrical connections may be effected between various conductors. Although the present invention is not limited to use in the telecommunications sector, this sector is a good example of where such a device may be useful. This is because in this sector a great deal of electrical wiring is used to create telecommunications networks. These electrical wires are typically of relatively small diameter (for instance less than lmm). Further, bundles of such wires typically contain many hundreds of wires. Connections between various wires within these bundles need to be made initially to set-up the network and subsequently to alter it due to changing requirements. These connections are typically, but not exclusively, made in places to which it is difficult to gain access such as manhole chambers within the pavement of a street, or in junction boxes at high levels on telegraph poles. Accordingly, to create connections between various wires it would be desirable to have a tool which made the task as simple as possible.

In this technical field modular conductor connectors known by the commercial name "Ampstack" have achieved considerable success. Electrical connections between conductors are made using these modular conductor connectors by means of a jig and a tool, an example of which is described in US 3,859,724. Force is applied using the tool to press together the various parts of the modular conductor connector such that electrical connection is effected between the various conductors. However, this known equipment is comparatively heavy (it can weigh up to 2kg), is costly since it is made from precision moulded metals and is bulky to carry around. In particular, the equipment is difficult to use by an operator in awkward places such as at height up telegraph poles, because the jig needs to be placed on a stable supporting surface, such as the ground, while the tool is used to provide the necessary force to press together the various parts of the modular conductor connector. Further, the jig is relatively heavy. To overcome this problem an operator will typically bring the electrical wiring down to ground level to effect the connections and then carry the electrical wires back up the pole. Alternatively, a junction box containing a number of such modular conductor connectors has to be lifted out of a manhole chamber before work can commence using the pavement as the stable supporting surface.

Accordingly, there is a need for an improved way of enabling electrical connections to be made between various conductors using such modular conductor connectors.

In one aspect the invention provides a guide tool having means for locating at least one part of a modular conductor connector of the type in which connection of conductors is effected by pressing them into engagement with conductive connector elements of the connector, guide means for use in guiding the conductors into position in register with respective conductive connector elements during assembly of the modular conductor connector, and means for retaining the at least one part of the modular conductor connector in preparation for the application of a force of sufficient magnitude to effect electrical connection of the conductors.

In one embodiment the guide tool has a base and two arms, one at either longitudinal end and extending transversely of its length away from the base, which may be manufactured from injection moulded plastics. The tool has means for locating the components of a modular conductor connector on it. These means could take the form of slots or grooves running along the length of the two arms in which associated projections or tongues on the components of the modular conductor connector slidingly fit. Other ways of locating the components are of course possible, such as the slots or grooves being located on the components and the projections or tongues located on the arms. Alternatively, it would be possible to have only one arm at one end of the base. Another possibility would be to have at least one locating pin provided on the base for engagement with components of the modular conductor connector. Whatever way is used the intention is that the guide tool has means for aligning the parts of a modular conductor connector with respect to each other. It is intended that this is in a temporarily fixed and aligned relation.

In use, the modular conductor connector effects electrical connection between various conductors in the manner set out for example in GB 1 497 629 (the contents of which are hereby included by reference). Typically, the modular conductor connector will comprise a first part and a second part. Between these first and second parts intermediate parts may be positioned. It is possible to have more than one intermediate part. By careful alignment of the various parts of the modular conductor connector together with the conductors to be connected electrical connection can be made between the various conductors when sufficient force is applied between the first and second parts of the modular conductor connector to move them towards one another to an engaged or conductor connecting position, as will be explained in more detail below.

The guide means for guiding the conductors may be arranged along at least one longitudinal side of the guide tool. These guide means can take the form of fins arranged substantially parallel to one another such that slots are formed between adjacent fins wide

enough to allow a conductor wire to pass between them. The fins may extend perpendicularly away from the base in a similar direction to the arm(s) or pin(s) as described above. However, the fins could in fact lie at any angle to the base including lying in the same plane as the base. When a conductor wire is placed within a slot it is guided across a part of the modular conductor connector. The fins may extend from the base of the tool and extend to approximately the same distance away from the base as the arm(s) or pin(s). Accordingly, the slots between the fins may guide several layers of conductors. The fins may also extend to the other side of the base of the tool as will be described below.

The means for retaining the parts of the modular conductor connector in an assembled position in preparation for the application of a force of sufficient magnitude to effect electrical connection of the conductors may comprise projections at or adjacent an end of one or both arms. The projections may extend substantially parallel with the base so that when the components of the modular conductor connector have been positioned on the base they are held in place by them. The means for retaining the parts of the modular conductor connector may be releasable, for which purpose the arms may be resiliently flexible and such release may be achieved, for example, by providing wings or tabs at or adjacent a free end of each arm and extending away from the arms in a direction substantially parallel to the base. These wings or tabs allow for the arms to be slightly flexed, by an application of force, such that the projections move away from the modular conductor connector so that they no longer impede the movement of the modular conductor connector so that it can be removed from the tool. Other ways of releasing the components are possible such as hinged, sliding or rotating projections or elements located at the free end of each arm which may be moved toward and away from the modular conductor connector. In one embodiment, the guide tool further includes means for relieving strain on the conductors. These strain relieving means may be gripping portions formed in conjunction with the guide means discussed above. For instance, each fin may have an inclined portion along one side such that the width of the slot between an inclined portion and an adjacent fin is reduced by comparison to the width of the slot between adjacent fins without an inclined portion. It would be possible to have inclined portions on both sides of each fin such that the width of the slot between an inclined portion on one fin and an inclined portion on an adjacent fin is reduced by comparison to the width of the slot between adjacent fins without inclined portions. By a reduction of the width of the slot in this way a conductor can be releaseably gripped by the gripping portion. The width of the slot may be reduced along the whole length

of one side of the fins such that several layers of conductors may be releaseably gripped therein. Other means of gripping the conductor are also possible such as for example a sliding or rotating plate which can trap the conductors or wires between itself and the side of the tool. The strain relieving means may be located along both or just one side of the tool. Alternatively or in addition, the fins may include inclined portions along their longitudinal ends. If such gripping portions were provided along both longitudinal edges and sides of the fins then a conductor wire can be gripped in two or four places depending on whether the gripping portions were provided along only one or both sides of the tool. In use it is sometimes preferable to position a first set of conductors on a component of the modular conductor connector through the guide means and then bend them through 90 degrees such that they extend perpendicularly away from the base of the tool. This can aid the utilisation of the tool in that one set of wires can be bent out of the way so that other parts of the modular conductor connector and other sets of wires can be added. The gripping portions may extend all the way along the longitudinal ends and sides of the fins such that each one can accommodate more than one conductor.

The guide tool may be produced to have a weight such that the conductors are able to support the guide tool. For instance, the guide tool could be made from injection moulded plastics such that the tool is comparatively lightweight, especially compared to the metal jig of the prior art. However, other materials could also be possible such as aluminium, steel, or lightweight alloys such as zamack.

Since the guide tool is comparatively light, once conductors have been located in the tool and gripped by the gripping portions, it is expected that the tool, including any of the modular conductor connector components, may be supported by the conductors. This would be particularly useful in situations where a connection is to be made between various conductors away from a suitable surface on which the equipment of the prior art may be placed. For instance, if an operator were at a level above ground, for example after climbing a telegraph pole, he could place the various parts of the modular conductor connector, together with the various conductors, in the guide tool and know that once he releases his hold on the assembly it will not place so much strain on the conductors as to bend the conductors or move them out of position. In other words the stiffness of an array of usual conductor wires is sufficient to hold the various parts of the modular conductor connector and the connectors in place. The strain relieving means hence relieve any strain on the wires as they pass across the relevant part of the modular conductor connector.

The guide tool may be adapted for use with a support member, the support member being either incorporated into the guide tool or being separable therefrom. This could be used to support the tool, for instance, off the ground to a more ergonomical height or to support the tool off the side of a telegraph pole. In one embodiment the support could be incorporated into the guide tool such that it is all one component.

In one embodiment the guide tool is suitable for use with telecommunication conductors. Further it is possible for the guide tool to be formed as a part of the modular conductor connector. For example, the tool could have connector elements, as well as the guide means and strain relieving means as described above, incorporated into it such that further parts of the modular conductor connector are positioned and aligned relative to the tool together with the conductors to be connected. Once the various parts of the modular conductor connector have been pressed together in a similar manner to that described above the electrical connections are effected. This embodiment would eliminate the need for a separate tool which may or may not be removed from the assembled modular conductor connector after electrical connection has been effected. In this embodiment it is possible that in addition to the guide tool formed as a part of the modular conductor connector, only one other part of a modular conductor connector is located therein.

Although the tool may be produced and sold separately from the modular conductor connector, alternatively a kit of parts may be provided comprising a guide tool having means for locating one or more parts of a modular conductor connector of the type in which connection of conductors is effected by pressing them into engagement with conductive connector elements of the connector, guide means for use in guiding the conductors into position in register with respective conductive connector elements during assembly of the modular conductor connector, and means for retaining at least two parts of the modular conductor connector together in an assembled position in preparation for the application of a force of sufficient magnitude to effect electrical connection of the conductors, and a modular conductor connector of the said type. This kit of parts may comprise such a tool wherein part of the modular conductor connector is preliminarily assembled to it.

In a different aspect, the invention also provides a guide tool having means for locating one or more parts of a modular conductor connector of the type in which connection of conductors is effected by pressing them into engagement with conductive connector elements of the connector, guide means for use in guiding the conductors into position in register with respective conductive connector elements during assembly of the modular conductor connector, and means for retaining at least two parts of the modular conductor

connector together in an assembled position in preparation for the application of a force of sufficient magnitude to effect electrical connection of the conductors, and a modular conductor connector of the said type.

The guide tool may be manufactured in various sizes to accommodate respective components of modular conductor connectors. Typical sizes accommodate and allow connection of 10 pairs, 10 + 10 pairs, 20 pairs and 25 pairs, however, of course any number of pairs of wires or conductors are of course possible from 1 to 1000 or more. Further, if additional intermediate layers are provided between the first and second parts of the modular conductor connecter then it is possible to make the same electrical connection between more than two wires.

The tool guide is suitable for use with modular conductor connectors which are able to handle straight splices, pluggable splices and half-tap splices. Self-Ixirnming of excess conductors is possible by the inclusion of knife blades. It is also possible to use the connectors to effect so-called "make before break" connections to avoid any interruption of working circuits. The connectors may also comprise access holes for the electrical testing of terminated conductors and be fully compatible with other manufacturer's connectors. Flame retardant modular conductor connectors and connectors are possible.

In a further aspect the invention provides a method of electrically connecting conductors comprising the steps of positioning a first part of a modular conductor connector in a guide tool, positioning at least two conductors on the first part of the modular conductor connector in register with respective conductive connection elements thereof, positioning a second part of a modular conductor connector in the guide tool such that the at least two conductors are located between the first and second parts of the modular conductor connector and the whole assembly is retained in position by the guide tool, and pressing together the parts of the modular conductor connector by application of force between the first and second parts of the modular conductor connector, such that the at least two conductors are brought into electrical connection.

In yet another aspect, the invention provides a method of electrically connecting conductors comprising the steps of positioning at least two conductors on the first part of a modular conductor connector, which has been prelirninarily assembled to a guide tool, in register with respective conductive connection elements thereof, positioning a second part of a modular conductor connector on the guide tool such that the at least two conductors are located between the first and second parts of the modular conductor connector and the whole assembly is retained in position by the guide tool, and pressing together the parts of the

modular conductor connector by application of force between the first and second parts of the modular conductor connector, such that the at least two conductors are brought into electrical connection.

In the previous two aspects the methods may further comprise the step of removing the assembled modular conductor connector from the guide tool after connection of the conductors has been effected. This step is optional because the tool may be considered to be disposable and therefore may be left in position with the modular conductor connector following electrical connection.

In a yet further aspect, the invention provides a method of electrically connecting conductors comprising the steps of positioning at least two conductors on a guide tool which has been formed as a first part of a modular conductor connector, in register with respective conductive connection elements thereof, positioning a second part of a modular conductor connector on the guide tool such that the at least two conductors are located between the first and second parts of the modular conductor connector and the whole assembly is retained in position by the guide tool, and pressing together the parts of the modular conductor connector by application of force between the first and second parts of the modular conductor connector, such that the at least two conductors are brought into electrical connection.

It should be understood that immediately before, immediately following or simultaneously with the step of positioning the at least two conductor wires, in the methods discussed above, a step of relieving the strain on at least one conductor may be effected by engaging the conductor with strain relieving means formed as part of the modular conductor connector. Such strain relief means may be provided by gripping portions located along the side or sides of the tool as discussed above. This strain relief could be achieved by placing a conductor through the gripping portion on one side before positioning it on or across the relevant part of the modular conductor connector. Alternatively, the conductor could be positioned across the modular conductor connector initially and then be pushed into the gripping portion. Another possibility is that the conductor is simultaneously positioned across the relevant part of the modular conductor connector and pushed into the gripping portion.

The various parts of the modular conductor connector may be held connected to one another by means of clips, snap-beads, interference fits or other such well known means.

Force is applied between the first and second parts of the modular conductor connector by means of a tool which in one embodiment could be a pair of pliers. However, other tools could of course be used such as a mole wrench or merely by placing the guide tool against a resilient surface and tapping the upper part of the modular conductor connector with anything

hard enough to impart a force (e.g. a hammer). Another possibility is that a special tool is used to squeeze together the first and second parts of the modular conductor connector. However, in typical use it is expected that a simple pair of pliers will be used to impart the force since such a pair of pliers would form part of the usual array of equipment carried by a user. The force from the pliers may be applied at only one place along a length of the guide tool and/or first or second part of the modular conductor connector. Alternatively, the force may be applied at more than one place along a length of the guide tool and/or first or second part of the modular conductor connector. Further, the force may be applied simultaneously, or sequentially, at more than one place along the length of the guide tool and/or first or second part of the modular conductor connector.

The pliers would be placed around the combination of tool and modular conductor connector such that one face of the jaw contacts the first part of the modular conductor connector and the other contacts the outside face of the base of the tool. Closing of the pliers will bring the two jaws together and apply force to the various parts of the modular conductor connector thus effecting electrical connection between the various conductors or wires. The pliers may be applied approximately at the centre of the length of the guide tool/modular conductor connector assembly. It is expected that force at this point would be sufficient to squeeze the various components of the modular conductor connector together such that they were effectively held in place by the means discussed above and that electrical connection was effected between the various conductors. However, if necessary force may be applied at several points along the length of the tool/modular conductor connector assembly either simultaneously by means of a wider pair of pliers or other suitable tool or could be applied in sequence starting at one end for instance and working along the length.

As discussed above, it is possible to have additional parts of the modular conductor connector and other conductors positioned intermediate between the first and second parts of the modular conductor connector. This would allow further layers of conductors to be included within the eventual complete assembly and provide further connections between various conductors. The tool could be used as described, or if necessary further adapted, such that it may effect electrical connection of telecommunication wires. Ia another aspect, the invention provides a method of electrically connecting conductors in a modular conductor connector releaseably held in a guide tool, the modular conductor connector comprising at least first and second parts locating at least two conductors therebetween for electrical connection, wherein force is applied at only one place along a

length of the guide tool and/or first or second part of the modular conductor connector to provide electrical connection between the at least two conductors.

The present invention and its advantages will be better understood by referring, by way of example, to the following detailed description and the attached figures, in which: Figure 1 is a perspective view of a modular conductor connector and associated conductor bundles of the type with which the guide tool of the invention is to be used,

Figure 2 is an exploded side view of the modular conductor connector of Figure 1,

Figure 3 is a perspective view of conductive connector elements forming part of the connector of Figure 1 with a wire conductor shown between them, Figure 4 is a perspective view of the two connection elements of Figure 3 shown electrically connected together to connect two wire connectors,

Figure 5 is a perspective view of a guide tool in accordance with one embodiment of the invention,

Figures 6 to 10 show a sequence of perspective views of a guide tool and the assembly of a modular conductor connector in accordance with one embodiment of the invention,

Figure 11 is a side view of a guide tool according to one embodiment of the invention,

Figure 12 is a plan view of one embodiment of the guide tool,

Figure 13 is a cut-away perspective view of a guide tool together with a modular conductor connector and conductor wires, Figure 14 is a different cut-away perspective view of a guide tool together with a modular conductor connector and conductor wires,

Figure 15 is a perspective view of a guide tool with an assembled modular conductor connector, and

Figure 16 is a perspective view of a guide tool and a removed assembled modular conductor connector.

Although the words "lower" and "upper" and other such orientational words are used in the following description with regard to the various parts of the modular conductor connector and the tool, they should not be considered to be limiting but are used with respect to the orientation of the tool and modular conductor connector as shown in the drawings. It should be further understood that it would of course be possible to hold the guide tool in any orientation such that the various components of the modular conductor connector are fitted into the tool from below or the side.

Figure 1 shows an assembled modular conductor connector 10 of the type suitable for use with a tool of the invention together with three bundles of wires 6, 6'. 6" which have had

connections effected between individual connector wires (not shown). As shown, the assembled modular conductor connector 10 comprises a lower part 8, surmounted by two intermediate parts 10, 10a and an upper covering part 12.

Figure 2 is a side view of a modular conductor connector as shown in Figure 1 in an exploded form with wires being omitted for clarity purposes. The various parts 8, 10, 10a, 12 fit together by means of tabs or projections and corresponding slots or grooves (not shown).

Figures 3 and 4 are perspective views of one way of effecting electrical connections between conductors 100, 101, within the modular conductor connector. Figure 3 shows a conductor wire 100 ready to be received in a lower element 46 as will be described in more detail below.

The element 46 has a wire receiving portion 48 and a wire receiving slot 54 extending inwardly from its free end 52, the lower end of the portion 48 being connected by a neck 56 to a receptacle portion 50 having a web 58 from which depend the side walls 60 which are in the form of parallel plates. The portions 48 may have pointed tips, as shown, or blunt tips, not shown. The side walls 60 have inwardly extending aligned slots 62 which are constructed at their open ends by rounded projections 64. The slots 62 of each element 46 are dimensioned to receive a portion 48 of another element 46 so that the elements 46 can be electrically coupled together in stack formation as shown in Figure 4. It will be apparent that more than two layers of elements 46 may be stacked. Each layer is associated with a part of the modular conductor connector such that for instance the lower element 46 is associated with the lower intermediate part 10 and the upper element 46 is associated with the upper intermediate part 10a as shown in Figure 2.

The portion 48 of the lower element extends into the slot 62 in the side wall 60 of the upper element 46. The portion 48 is angularly displaced, to the extent of 90 degrees, from the side wall 60 about an axis extending in the direction of the slot 54 and through the neck 56, whereby the planes of the portions 48 and side walls 60 are perpendicular to one another.

A series of elements 46 are arranged in an array in the lower part and any intermediate parts of the modular conductor connector and arranged such that when the various parts of the modular conductor connector are aligned the various elements are also aligned such that when force is applied to the overall assembly the wire 100 is forced into the wire receiving slot 54 by means of force provided by various parts of the modular conductor connector. In Figure 4 an upper wire conductor 101 is shown which has been forced into wire receiving slot 54 by means not shown but which would be provided on the underside of the upper part 12 of the modular conductor connector 10. Once the two conductor wires 100, 101 have both been

forced into their respective wire receiving slots 54 and the two elements 46 have been interlocked as shown in Figure 4 an electrical connection is effected between the two wires since by forcing the wire conductors 100, 101 into their respective wire receiving slots 54, any insulation surrounding the wire conductors is parted by the wire receiving slot due to its width being narrower than the external diameter of the electrical conductor wire within the insulation which surrounds it.

Figure 5 is a view of the tool according to the invention. Figures 6 to 10 show a sequence of perspective views of a guide tool 20 illustrating the sequence of steps in assembling a modular conductor connector. The base 25 provides a platform upon which the various parts of the modular conductor connector may be stacked. These parts are placed between two rows of fins 30 and two upstanding arms 26. Each arm 26 is resilient and has a wing 27 and a projection 28. The projection 28 retains the parts of the modular conductor connector within the tool 20. The release of the assembled modular conductor connector will be explained below. The fins are relatively thin elements having a curved surface distal from the base 25 of the tool 20. The fins 30 have a leading edge proximal to the face of the base which accepts the parts of the modular conductor connector, and a following edge distal from the leading edge. The base 25 together with the arms 26 and the array of fins 30 create a cavity into which parts of the modular conductor connector may be placed, as discussed below. The fins also act as guide means for guiding conductor wires 100, 101 in relation to the tool and modular conductor connector 10. From the leading edge of each fin 30 extend two leaves 32a, 32b diverging away from this edge. Adjacent pairs of such divergent leaves 32a, 32b define a series of narrow slots 40. These slots 40 act as both guide means and strain relieving means. Further, each fin 30 also has bifurcated outer edge portions 34a, 34b located at the following edge. These leaves 32a, 32b and bifurcated portions 34a, 34b are also visible in Figures 11 to 13. These slots may act as stress relieving means and guide means for the conductor wires 100, 101. This is because they grip the wires 100, 101 in a similar manner to slots 40 and thus are able to support the weight of the tool 20 as will be described below.

In Figure 6, the guide tool of Figure 5 is shown together with a lower part 8 of the modular conductor connector having been placed in position so that it lies against the upper surface of the base 25.

In Figure 7 a first layer of wires or conductors 100 is shown laid across the lower (or first) part 8 of the modular conductor connector. The wires may be seen to pass through the guide slots 40 and are shown bent through 90 degrees such that they then pass through guide

slots 41. Once a few of the wires have been placed across and through each of the slots 40 and then bent downwards and through slots 41 the whole of the tool may thus be supported since the tool is made of lightweight plastics. However, it should be understood that it is not essential for the wires 100 to be gripped by both slots 40, 41 since only one array of slots would still provide sufficient strain relief to the conductors such that the tool and the modular conductor connector could be supported by the conductors.

Two intermediate layers 10, 10a are then placed on top of the lower part 8, as shown in Figure 8, such that the layer of conductors is sandwiched between the lower intermediate layer 10 and the lower part 8. The two intermediate layers could be replaced by a single intermediate layer or indeed be replaced by any number of intermediate layers.

A second layer of conductor wires 101 is then placed across the upper surface of the upper intermediate layer 10a as shown in Figure 9. These wires are gripped by slots 40 such that they are held in position and have any strain relieved from them as they pass cross the modular conductor connector. In Figure 10 an upper part 12 of the modular conductor connector is shown in position. This sandwiches the second layer of conductor wires 101 between itself and the upper surface of the upper intermediate layer 10a. The upper part 12 of the modular conductor connector is held in place within the tool 20 by projections 28 which extend inwardly from the top of arms 26 located at each end of the tool 20. Force is then applied between the upper part 12 and the lower part 8 of the modular conductor connector by, for instance, squeezing the tool guide 20 and the upper part 12 of the modular conductor connector between the jaws of a pair of pliers or other such tool. This forces the various parts of the modular conductor connector towards one another such that electrical connections between the selected wires 100,101 are effected. The connections are made, for instance, as described in relation to Figure 1 to 4 so that for example, an electrical connection is made between a wire in layer 100 and a respective wire above in layer 101.

Although wires are shown crossing the various levels of the modular conductor connector it is possible to terminate a wire such that a wire only extends away from one side of the modular conductor connector. In this way, it is possible to make a connection with a single new wire to an existing live conductor wire, without interruption of the original circuit. For instance, if the existing wire is placed across the modular conductor connector in the first layer of wires 100 and the second new wire is placed hi the corresponding position in the layer 101 above, when force is provided to the modular conductor connector an electrical

connection would be made between the existing circuit and the new wire without breaking the existing circuit.

Although the tool described in regard to the figures has a modular conductor connector with four layers, it would be possible to have just two layers, a first lower part 8 and a second upper part 12 sandwiching wires therebetween. Connections could be made by connecting elements 46 similar to those described in regard to Figures 1 to 4 but having electrical connection with associated elements in the same level of the modular conductor connector rather than between different levels.

Figure 11 shows a side view of a guide tool 20 according to the present invention. The guide tool 20 is shown without any of the component parts of the modular conductor connector positioned within it for clarity purposes. The tool has already been described above with regard to Figure 5. However, in Figure 11 it may be seen that because of their height the fins 30 are able to provide guide means and strain relief to conductor wires 100, 101 no matter across which part of the modular conductor connector they have been placed. In other words, the conductors 101 placed on a part 10a of the modular conductor connector which is further away from the base 25 than conductors 100 placed on a first part 8 may still be guided and gripped by the strain relief means.

Figure 12 is a plan view of the tool shown in Figure 11. Parts of the modular conductor connector have been omitted for clarity. A first layer of conductor wires is indicated by one particular conductor wire 100. In reality, of course, there could be an array of wires 100 in place, however, the modular conductor connector will of course connect merely only two wires 100, 101 if necessary. It is seen that the wire 100 passes through slot 40 and is gripped by leaves 32a and 32b. Further, the wire is then bent through 90 degrees towards the base and underside of the tool 20 passing through slot 41 defined by bifurcated portions 34a, 34b. Accordingly, this wire 100 is gripped in two places either side of the tool 20, (in other words in four places in total). By bending the wires away from the surface of the tool which accepts the parts of the modular conductor connector they are kept out of the way and do not get entangled with any subsequent layer of wires. A second layer of conductor wires 101 is shown passing through and gripped in slot 40 such that this conductor wire 101 is gripped at only one point on either side of the tool 20 (in other words in two places in total).

Figure 13 shows a different perspective view, which has been cut away to improve clarity, of a guide tool 20 including several parts of a modular conductor connector. The base 25 of the guide tool 20 is shown upon which a lower part 8, an intermediate part 10, a further intermediate part 10a and an upper part 12 are stacked. As is seen, a first layer of conductor

wires 100 passes between the lower part 8 and the first intermediate part 10 such that they are sandwiched therebetween. These conductor wires 100 are placed across the guide tool 20 and then bent through 90 degrees so that they are held out of the way. These wires 100 are gripped between leaves 32a, 32b in slot 40 and again after turning through 90 degrees between bifurcated portions 34a, 34b in slot 41. A second layer of conductor wires 101 is placed between the upper intermediate layer 10a and the upper part 12 of the modular conductor connector such that they are sandwiched therebetween. These wires 101 are gripped between leaves 32a, 32b in slots 40.

Figure 14 shows a different perspective view, this time without the fins 30 and without some of the wires to improve clarity. It is seen that notches 41, 42 are provided in the intermediate parts 10, 10a to allow for the conductor wires 100, 101 to pass through.

When all the various components of the modular conductor connector have been placed together with the various layers of conductor wires within the guide tool 20, force is applied between the upper part 12 and the base 25 of the tool 20 in order to bring the various parts together. This effects electrical connection between the two layers of conductor wires by means of the connector elements 46 described above in relation to Figures 3 and 4. Further, the various parts of the modular conductor connector are held together by such means as snap beads to prevent them coming apart which may thus have an adverse effect on the electrical connection effected between the wires 100, 101. To remove the completed modular conductor connector 10 from the tool 20 wings 27 are pushed down and away from the upper part 12 in the directions shown by arrows "A" in Figure 15. By moving the wings 27 in this manner the arms 26 flex slightly, due to their resilience, thus moving projections 28 away from the upper part 12 of the modular conductor connector and allowing the unit 10 to be removed as shown in Figure 16.




 
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