FIELD OF THE INVENTION The invention relates generally to interconnection devices such as termination modules for telephone and data communication and more particularly to a device which can terminate wires for interconnection (such as between a subscriber and a telephone company) and which can be used outdoors.

BACKGROUND OF THE INVENTION Different types of terminal interconnection devices for telephone customers (subscribers) are known in the art, e. g., a telephone terminal interconnection interface device is described in U. S. Patent 4,741,032. This device is suitable for being connected

to and between a local-line telephone subscriber and a telephone company by means of a closed circuit which comprises an array of cavities in its design for the various terminal interconnections-of customers. However, even though the design is sophisticated, it does not include features to provide a good sealing and with protection against internal moisture, wind and weather.

An improvement in the prior art is described in U. S. Patent 5,355,408. This reference discloses a terminal interconnection interface device which provides such connections and makes it possible for the subscribers to be tested individually for flaws, temporarily disconnecting their line from the closed-circuit telephone company. As to moisture or the environment, the device includes features for protection against the environment using sealing covers; however, the sealing is not always adequate.

SUMMARY AND OBJECTS OF THE INVENTION It is in object ofthe invention to provide an interconnection device with protection against wind, weather and moisture which is simple to use, for terminating wires, and which provides simple testing with a user-friendly interface.

It is another object of the invention to provide an interconnection device which provides wire retention, preferably with the electrical contact, prior to termination of the wire.

It is still another object of the invention to provide an interconnection device with an interface for easy termination of wires, weather protection after termination and which provides an automatic disconnection of the interconnection by a simple lifting of a cover part.

It is a further object of the invention to provide an interconnection device with an interface for the easy termination of wires and with an enclosure which facilitates the use of a gel in the enclosure for protecting the interconnection from the weather.

It is still another object of the invention to provide an interconnection device with an interface for easy termination of wires, which allows wire termination without the use of a tool, preferably by closing a cover.

It is still another object ofthe invention to provide an interconnection device which supports various types of drop wires and provides a waterproof enclosure and which is easy to use, economical to manufacture and simple in design.

According to the invention a communications systems interconnection device is provided including a housing including a base part and a cover part. The cover part is movable relative to the base part between an opened position and a closed position A first terminal element is connected to one of the base part and the cover part. The first terminal element has an insulation displacement contact and a contact part. A second terminal element connects to one of the base part and the cover part. The second terminal element has an insulation displacement contact and has a contact part. A connecting element is connected to the other of the base and the cover part. The connecting element includes a contact part making contact with the first terminal element contact part and another contact part making contact with the second terminal element contact part to electrically connect the first terminal element to the second terminal element in a closed position of the cover part. The first terminal element is disconnected from the second terminal element in the opened position of the cover part. Normally several first terminal elements (telephone line company terminal elements) are provided and several second terminal

elements (subscriber line terminal elements) are provided.

The terminal element insulation displacement contacts each may include a first contact leg and a second contact leg. The first contact leg cooperates with the second contact leg to define a contact slot and with an upper wire retention part in the form of a hoop connecting the first contact leg to the second contact leg.

The contact part of each terminal element is preferably a fork shaped contact defining a contact part contact slot. The connecting element may include a contact bar which extends into the fork to contact the first terminal element contact part at the contact slot in the closed position of the cover part.

The terminal elements are preferably formed of a single integral piece such as a sheet metal piece.

The housing preferably includes another cover with pressing parts for pressing a wire retained by the upper wire retention part of the first terminal element into the insulation displacement contact of the first terminal element.

The housing defines a weather resistant enclosure with interior walls defining one or more gel pockets. One or a set of the first terminal elements (e. g., telephone company wire connecting terminals) is disposed in one gel pocket with gel therein and one or a set of the second terminal elements (subscriber terminals) is disposed in another gel pocket with gel therein. A space is preferably provided between these gel pockets defining a ground bar space. The space adjacent to each of the gel pockets of the base part preferably defines a wire management space.

The cover may have a wall defining a gel pocket. The connecting element is disposed in the cover with gel therein. The gel pocket wall of the cover has a portion

extending into a recess defined in the base part adjacent to the gel pocket and into a recess defined in the base part adjacent to the another gel pocket whereby upon closing the cover gel in the cover gel pocket comes into contact with gel in the gel pocket and gel in the cover gel pocket comes into contact with gel in the another gel pocket.

The base part and/or the cover may have wall parts of reduced thickness defining knockouts for forming wire passages upon removal of the wall parts of reduced thickness.

The base part may also have a wall extension with a wall knockout part and another knockout part on an opposite wall whereby a substantially similar device may be connected to the device with wall extension aligned with opposite wall knockout part to define a connection channel for connecting the interior of one device to another.

A wire strain relief part including a ramp structure may be provided in a wire management region of the base part. The ramp structure has a ramp surface and an opening on an opposite side of the ramp surface. A tie element is passed through the opening for tying a wire to the ramp structure with the wire held to the ramp surface.

The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: Figure 1A is a perspective view of the interconnection device

according to the invention showing the device in an open position; Figure 1B is a perspective view of the interconnection device according to the invention showing the device in an open position, wherein gel is provided in some locations; Figure 2 is a partial, broken away perspective view, showing details of the base housing part of the interconnection device according to the invention wherein gel is provided in some locations; Figure 3 is a perspective view of the interconnection device according to the invention showing the device in an closed position; Figure 4 is a perspective view of a network (e. g. telephone company) side termination contact element; and Figure 5 is a perspective view of a subscriber side termination contact element; Figure 6 is a perspective view of a two contact bridge element; and Figure 7 is a perspective view of a three contact bridge element.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings in particular, the invention includes an interconnection device generally designated 10. The interconnection device 10 is a compact, plastic, hinged container with termination elements for connecting telephone cables or other communications lines. The interconnection device 10 is adapted to be used outdoors and to protect the terminated wires and the interconnection from the weather.

The device 10 has a base part 12 as well as a lower cover 14 and an upper cover

16. The base part 12 houses and supports terminal elements 20 and 30 and the lower housing has terminating parts 74 and 75 which cooperate with the terminal elements 20 and 30. However, the terminal elements could be disposed in the cover (e. g. the lower cover 14) and the terminating parts 74 and 75 could be placed in the base part 12.

The lower housing part has an upper set of hinge pins 13 and a lower set of hinge pins 19. The upper housing part has two hinge members 17 which include recesses for receiving the respective sets of pins 13. This forms the hinge connection between the upper cover 16 and base part 12. Likewise, the lower cover 14 includes a hinge member 15 with recesses for receiving the set of pins 19. Preferably, the upper housing part 16 is a single molded piece, the base part 12 is a single molded piece and the lower housing part 14 is a single molded piece. The interconnection of pins 13 with hinge member 17 is effected with a snap action as the pins snap into the recesses. Likewise the interconnection of pins 19 with hinge member 15 is effected with a snap action as the hinge pins 19 snap into the recesses of hinge member 15.

Each terminal element 20 includes two different insulation displacement contact parts, namely IDC 22 and IDC 24 to provide a double contact. The two different IDC parts of each terminal element 20 allow two potentially different wire types to be used.

For example, IDC 22 may be provided for AWG 18 wire and IDC 24 may be provided for 22-24 gauge wire. This offers additional flexibility and allows various different possibilities for termination. Specifically, the passage ofthe wires is limited by the outside diameter of the wire. The outside of the 18AWG wire is about 4mm in diameter while the 22-24 AWG wires are about lmm in diameter. Wires are to pass through the hoops 125 and/or 127. The smaller wire (e. g., lmm) can pass through hoop 125 and into hoop 127,

to be positioned for termination. However, a larger wire (e. g., 4mm), when pushed through hoop 125, uses the secondary IDC part 24 as a stop and cannot be positioned over the secondary contact slot 124. This allows the smaller lmm wires (e. g., 22-24 AWG) to pass all the way through over to the second contact slot 124. Each terminal element 20 also includes a contact part 26. The IDC part 22, the IDC part 24 and contact part 26 are electrically connected by bus element 129 as shown in Figure 4. Preferably, each terminal element 20 is formed of a single stamped sheet metal piece. The terminal element 20 is then disposed in the base part 12.

Each terminal element 30 includes one insulation displacement contact part 32 as well as a contact part 36. The IDC 32 is provided for the subscriber wire and may be for example provided to accept 22-24 gauge wire. The IDC part 32 and the contact part 36 of each terminal element 3 0 are electrically connected at shown in Figure 6. Each terminal element 30 is preferably formed of a single stamped sheet metal piece.

Figure 4 shows terminal element 20 in a perspective view. The IDC part 22 has a first contact leg 121 and a second contact leg 121'defining a contact slot 122. An upper wire retaining element 125 is provided in the form of a hoop which connects the first contact leg 121 to the second contact leg 121'. This allows a wire to be retained in position, waiting for the cover 14 to be closed to terminate the wire to the IDC 22. The contact legs 121 and 121' have a sharp edge stamped into them at the top of the"V"shaped channel of the contact slot 122. This acts as a method to reduce the insertion force by cutting into the insulation like a knife. This also limits the amount of play for the wire during termination such that it does not

slide. All of these factors lead to a more reliable and consistent termination. The IDC part 24 also has a first contact leg 123 and a second contact leg 123'defining a slot 124. An upper wire retaining element 127 is provided in the form of a hoop which connects the first contact leg 123 to the second contact leg 123'. The contact legs 123 and 123'have a sharp edge stamped into them at the top ofthe"V"shaped channel of the contact slot 124.

This acts as a method to reduce the insertion force by cutting into the insulation like a knife as described above. The contact element 26 is advantageously provided in the form of a fork structure with parts 126 defining a contact slot. The connection bar or bus to element 129 connects the contact element 22, the contact element 24 and contact element 26.

Figure 5 shows a perspective view of the terminal element 30. The IDC 32 includes a first contact leg 131 and a second contact leg 131'and a third contact leg 131" to form two contact slots. A retaining element 135 in the form of a hoop is provided connecting the leg 131 to be leg 131'. The retaining element 135 allows a subscriber wire (or two subscriber wires) to be retained in position waiting for the cover 14 to be closed to terminate the wires. As can be seen in Figure 5, the IDC 32 is a double slot contact with two V-shaped channels to assist in positioning and cutting the contacts.

The lower cover 14 includes the termination parts 74 which act to urge the telephone company wires or network wires into insulation displacement contact parts 22 or 24 of one of the terminal elements 20. Likewise, the parts 75 act to urge subscriber line wires into the associated insulation displacement contact 32 of the terminal element 30.

Specifically, the wires are disposed in a predefined position, e. g., in the hoop 125 or 135 within the base part 12. The lower cover 14 is subsequently closed. This causes the part

74 to terminate the telephone company side wires with either insulation displacement contact 22 or 24 and this causes the parts 75 to terminate the subscriber side wires with insulation displacement contact 32.

The base part 12 includes an outer side will 11 which acts to form part of the enclosure of the device 10. At an upper edge of the wall 11 a lip structure 11'is provided which cooperate's with a lip structure 16'of the side walls of the upper housing 16 and which cooperate with a lip structure 14'ofthe side walls of the lower housing 14. The lip structure 11'is provided just inwardly of the lip structure 14'and 16'so as to provide an overlap and to facilitate the weather proof nature ofthe enclosure provided by device 10.

The side walls 11 are provided with knockout parts 76,78,48 and 50. The knockout part 76 is provided based on a weakened or less thick material part allowing knockout part 76 to be removed. This allows a cable to be passed through the side wall 11 (e. g. the telephone company cable). The housing preferably also includes an opening 82 in the base 12 which provides access to a cable through the base 12 (e. g. the telephone company cable). If the opening 82 is used, the knockout part 76 is maintained in its place to maintain the enclosure of the device 10. In a similar manner knockout parts 78 are provided for the in-house cable or subscriber cable. Preferably openings 80 are also provided for the subscriber cable. The individual subscriber lines may either be passed through the openings after knockout part 78 are removed or the openings 80 may be used.

The housing wall 11 also includes the knockouts 48 and 50. When these knockouts 48 and 50 are removed, a passage may be provided from one device 10 to an adjacent similar or identical device 10. In this way, the devices may be combined in a modular manner.

The base part 47 also includes an extension 47 which can extend into adjacent device 10

(e. g. into the space left by knockout 48) to provide a weather protected channel from one device 10 to the next. The part 49 of the lower cover 14 facilitates the formation of this weather protected channel. With this arrangement of adjacent devices 10, with the weather protected channel defined by base part 47 and lower housing part 49, telephone wires may enter a first device and extend through openings 82 or 76. Two of the wires may then be used to terminate at terminal contact 20 in the first device 10. At least two of the other wires are passed (e. g., around post 46) and are extended into the weather protected channel defined by base part 47 and lower housing part 49 and thereby extended into the second device 10 for termination to terminal contacts 20 of the second device 10.

The base part 12 also includes ramps 40,42 and 44. The ramp 40 is provided to receive two or more wires of a telephone cable or similar electrical communications wires.

The wires are preferably tied to the ramp 40 by an appropriate tie member, which passes through opening 41 and may be maintained in position, around the telephone cable wires, by using channels 41'. The angled portion 40'of the ramp 40 provides the strain relief function, particularly when the wires are tied down with the tie member using opening 41 and channels 41'. Specifically, after the wires are appropriately tied down and terminated to IDC element 22 or 24, a pulling on the wires from the outside of the device 10 primarily exerts a force on the ramp 40, thereby avoiding the application of force to the wire terminated at terminal 22 or 24. The post 46 may provide further strain relief whereby the wires (conductors) are crossed over, around the post 46, thereby providing further strain relief.

The ramps 42 and 44 similarly include angled parts 42'and 44'as well as associated openings 43 and 45. A channel is also provided for each ramp, namely channel 43'and 45'

to facilitate the tying down of the individual wires or groups of wires to the ramp structure 42 and 44 respectively. This provides strain relief as a pulling of the wire, after being tied down to a ramp and terminated, will result in most of the force being applied to the tie element or the ramp, with little force being applied at the IDC 32.

The housing 12 includes wall portions 52 which define a space. Two terminal elements 20 are provided disposed within the wall portions 52. Two openings 54 are provided in the wall portions 52. The openings 54 are for the passage of wires into the IDC 22 or 24. The wall parts 52 also include openings 56 which provide electrical connection access to a space 58. A protection element such as an over voltage/over current device, resistor/capacitor testing device or other device may be disposed in the space 52. Such a device may be soldered to the contacts 26 through the openings 56. The device disposed in space 52 may be surrounded by potting compound or the like for protection. The space 98 with the terminal contacts 20 is preferably filled with a gel as shown in Figure 1B.

The base part 12 has wall parts 53 which define a space for receiving the terminal elements 30. Additionally, another space 60 is defined. The wall parts 53 have openings 55 to allow wires (conductors) to extend from the ramps 42,43 into a region for termination IDCs 32. This space is preferably filled with a gel as shown in Figure 1B.

The base part 12 has a nut portion 84 which is a seat for a nut, which is disposed in the nut portion 84 from the back side of the base 12. This nut portion 84 cooperates with a support part 82, which is provided as part of the lower cover 14. The openings of the support part 82 and nut part 84 are aligned when the lower cover is closed allowing a bolt to be passed through the opening, for connection with the nut, to fix in the lower

cover 14 to the base 12 in a closed position.

The upper cover 16 has an enclosure or space 70 provided by wall 90 as shown for example in Figure 1A. In Figure 1B the space 70 is shown filled with gel. The space 70 is provided with a two position contact 62 and a three position contact 66. The two position contact 62 has a contact part 63 and a contact part 64 connected by base part 61.

The three position contact 66 has a contact part 65, a content part 67 and a contact part 68 connected by base part 69. Fig. 6 shows the two position contact 62 with contact parts 63 and 64. Fig 7 shows the three position contact 66 with the contact parts 65,67 and 68.

When the upper cover 16 is closed, the contact 62 provides an electrical connection between an inner contact 26 and the middle contact 36. This provides a connection between parts of the telephone company line and the corresponding part of the subscriber line. In a similar manner, the three position contact 66 provides a connection between the outer contact 26 and the two outer contacts 3 6 when the upper cover is closed. This again provides a connection between parts on the telephone company line and corresponding part of the subscriber line. This arrangement also allows a single telephone company line to be connected to more than one subscriber line.

The base part 12 has a space 140 between the space 98 and the space 99 (between wall 52 and wall 53). This provides space for a ground bar strip 200. Further, the base part 12 is provided with grooves 142,144,146 and 148. The grooves 142 is shaped so as to receive a wall part 162 of the lower housing 14. The groove 46 is shaped to receive a wall part 166 of the lower housing 14. In a similar manner, the groove 144 is shaped to receive a wall part 164 of wall 90 which defines the space 70. The groove 148 is shaped to receive a wall part 168 of wall 90 which defines the space 70. The structure allows the

respective wall part two enter the respective groove which forces the gel in one space such as space 70 to come into contact with gel in the other space such as in space 98. This place is the gel under pressure and ensures good sealing and good weather protection.

The lower cover 14 includes cable part 94 which defines a space 96. A shown in Figure 1B, this space 96 may be filled with a gel. The space 96 is provided with a plurality of elements or parts 74 which act to terminate wires disposed at the IDC elements 22 or 24 and 32. Specifically, the part 74 defines wire pressing surfaces which act to press the wire when the cover 14 is closed. Gaps are provided between the elements 74 to allow the tops or hoops 125 of IDC elements 22 and 24 to pass between the wire pressing surfaces of the parts 74 as the lower housing 14 is closed. For the subscriber side termination parts 75 are provided which define a gap. The hoops of the IDC 32 passed into the gap as the parts 75 press in the wire, upon closing the lower housing 14.

As noted above, each of the base part 12, the lower cover 14 and the upper cover 16 are preferably individual molded elements, such as formed with an injection molding system. The lower cover 14 is connected to the base part 12 with the pins 19 insert into the recesses of page part 19. The upper cover 16 is connected to the base part 12 with the pins 13 snapped into recesses of the hinge part 17. The two terminal elements 20 are disposed in the space defined by wall element 52 and the terminal elements 30 are disposed in the space defined by wall elements 53. The two position contact 62 is disposed in the upper cover 16. As can be seen in Figure 3A, the upper cover 16 has molded positioning parts 93 which help position and hold the two position contact 62. The three position contact 66 is also disposed in the upper cover 16 as shown in Figure 1A. The positioning parts 94 help position and hold the three position contact 66. Preferably after the various

contacts are disposed in the base part 12 and upper cover 16, gel is provided in the device 10. Gel is provided in space 70, in the space 98 defined by wall 52, in the space 99 defined by wall 53 as well as in the space 96.

In operation, the device is provided to a user or installer in an assembled state as discussed immediately above. The telephone wire, with at least two conductors, is inserted through the opening 82 or the knockout 76 is removed and the wires are inserted through the space provided after the removal of knockout 76. The wire is extended into the hoop of IDC 22 or 24 of the associated terminal element 20 and are aligned with openings 54 of the wall part 52. A strap is then applied to the wires by extending the strap (e. g. the tie) through opening 41 and channel 41'of ramps 40. At the subscriber side, subscriber wires are provided through openings 80 or through the space left after knockouts 78 are removed. The wires are extended to the hoops of the contacts 32 and aligned with the openings 55 in wall 53. The wires are then strapped to the ramps 42 and/or 44 using a tie which passes through the opening 43 or 44 and is provided in channel 43'or 45'. The lower cover 14 is then closed whereby the pressing surfaces of part 74 and pressing surfaces of part 75 press the respective wire into the respective IDC (e. g. of contacts 22 and 32).

As can be seen in Figure 5 the terminal element 30 has an IDC 32 which is a double slot structure. In positioning the wires before termination the two of the wires may be disposed in the central contact to common the wires together. The upper cover 16 may then be closed which provides the interconnection between the telephone company lines and the subscriber lines.

The invention provides the advantage that the upper cover may be opened which

disconnects the telephone company from the subscriber line connection. Further, the contacts 26 and 36 are then accessible for testing.

While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.