RACEWAY IDC CONNECTOR

Cross Reference to Related Application

[0001] This application claims priority from U.S. Provisional Patent Application No.

60/939,425, filed May 22, 2007, the entire disclosure of which is hereby incorporated by reference.

Field of the Invention

[0002] The present invention relates generally to electrical connectors and, more particularly, to a dual-sided insulation displacement contact ("IDC") connector for use in field-wiring and factory-wiring, capable of being installed in a raceway, outlet strip, and other electrical field installations.

Background of the Invention

[0003] Electrical connectors are used to connect many types of insulated wires, and enable technicians to connect insulated wires without having to strip and crimp the wires. Typically, an IDC connector may be a housing with channels for wires to pass through, a cover, and one or more IDC's. IDC's comprise an electrically conductive material, and may have a "U" shape on one or more sides. IDC's may pierce through the wire insulation when a force is applied between the wire and the IDC. After the IDC pierces the wire insulation of a first wire, the IDC contact may make electrical contact with the first wire. The opposite end of the IDC from the end in contact with the first wire may be positioned around or along a second wire, and force may be applied between the second wire and the IDC. The IDC may pierce the insulation of the second wire, and electrical contact may be made between the first and second wires through the IDC.

[0004] One problem that exists when terminating wires using an IDC connector is that a great deal of force may be required for the field technician to properly push down the cover onto the connecter and thereby terminate the connections. Pushing down on a cover of an IDC

connector may create the force between the wire and the IDC contact needed for the IDC to pierce the wire insulation. However, the force required to pierce the wire insulation may be large, so that it is uncomfortable or inconvenient for the field technician to terminate the contacts.

[0005] An additional problem is that, typically, the field technician must install a connector on each side that is to be terminated. For instance, a first wire or set of wires may be installed into one side of the housing corresponding to one end of one or more IDC's, and a second wire or set of wires may be installed into a second side of the housing corresponding to the opposite end of one or more IDC's. This takes time and, as previously stated, may require a great deal of physical effort on the part of the technician to properly terminate the wires. [0006] Another problem is that after terminating the IDC, it may be desirable to place the connector in a field configuration, i.e., on a raceway, in an electrical box, in an outlet strip, or another configuration. Connectors that are not adapted to be easily installed in such field configurations may require extra time from the field technician to complete the installation. Summary of the Invention

[0007] A dual-sided IDC connector for use in connecting electrical components to field wiring is described. One side of the IDC connector may have wires from an electrical component that are terminated and installed in the factory. A second side of the IDC connector may be field-wired in an end-wiring or a through-wiring configuration. [0008] Terminating the electrical component wiring to the IDC connector in the factory or at a time before field installation of the electrical component may reduce the time and labor necessary to install and terminate IDC connectors. Because the factory wiring may be already installed in a first side of the IDC connector, the field technician may only need to install the field wiring in a second side of the IDC connector.

[0009] The IDC connector may be easily mounted to existing raceways, outlet strips, and junction boxes. This may increase efficiency, as less time is required to install the connectors after the wiring has been terminated. Brief Description of the Drawings

[0010] Fig. 1 is a front upper right exploded view of an IDC connector, in accordance with an embodiment of the present invention;

[0011] Fig. 2 is a front upper right perspective view of an IDC connector having factory wiring and field through-wiring, in accordance with an embodiment of the present invention; [0012] Fig. 3 is a front upper right perspective view of an IDC connector having factory wiring and field end-wiring, in accordance with an embodiment of the present invention; [0013] Fig. 4 is a front upper right perspective view of the IDC connector, with the field- wired cover open, in accordance with an embodiment of the present invention; [0014] Fig. 5 is a front view of the IDC connector showing one of the field-wired covers in the open position, and another field-wired cover rotated over the field housing before being coupled to the field housing, in accordance with an embodiment of the present invention. [0015] Fig. 6 is a front upper right perspective view of the IDC connector with the field- wired cover closed, in accordance with an embodiment of the present invention; [0016] Fig. 7a is a top plan view of an IDC connector having field end-wiring with the field covers in the open position, in accordance with an embodiment of the present invention; [0017] Fig. 7b is a top plan view of an IDC connector having field end-wiring with the field covers in the closed position, in accordance with an embodiment of the present invention; [0018] Fig. 8a is a top plan view of an IDC connector having field through-wiring with the field covers in the open position, in accordance with an embodiment of the present invention;

[0019] Fig. 8b is a top plan view of an IDC connector having field through-wiring with the field covers in the closed position, in accordance with an embodiment of the present invention;

[0020] Fig. 9 is an illustration of a typical installation of the IDC connector to an outlet, in accordance with an embodiment of the present invention;

[0021] Fig. 10 is an illustration of a typical installation of the IDC connector to a receptacle- type outlet, in accordance with an embodiment of the present invention; [0022] Fig. 1 1 is an illustration of a typical installation of the IDC connector to an outlet strip base mounted to a wall, in accordance with an embodiment of the invention; [0023] Fig. 12 is an illustration of a typical installation of the IDC connector to a surge suppressor, in accordance with an embodiment of the present invention; [0024] Fig. 13a is an illustration of a typical field-wiring of the IDC connector in a raceway with a faceplate, in accordance with an embodiment of the present invention; [0025] Fig. 13b is an illustration of a typical placement of an IDC connector in a raceway with a faceplate, in accordance with an embodiment of the present invention; [0026] Fig. 13c is an illustration of a typical placement of an installed IDC connector into a raceway with a faceplate, in accordance with an embodiment of the present invention; and [0027] Fig. 13d is an illustration of a typical installation of the faceplate over an IDC connector in a raceway, in accordance with an embodiment of the present invention.

Detailed Description of the Preferred Embodiments

[0028] Fig. 1 is a front upper right expanded view of an insulation displacement contact

("IDC") connector 101. The IDC connector 101 has a factory housing 105, a factory cover

103, a field housing 1 1 1, field covers 1 15, and IDC's 321.

[0029] The factory housing 105 may have two side walls, a front wall 333, and an end wall

31 1. One or more factory wire apertures 303 may be located on the front wall 333 and the end wall 31 1 of the factory housing 105.

[0030] The factory housing 105 is shown in Figs. l-13d as having factory wire apertures 303 only on the front wall 333. Frequently, wires from electrical components may be installed into an IDC connector in an end-wiring configuration. In this case, it may be desirable to have a solid end wall 311, as shown in Figs 1-13d.

[0031] Alternatively, factory wire apertures 303 may be located on the end wall as shown with respect to the front wall 333. Wiring from the electrical component may be installed in a through-wiring configuration, and the wires may pass through the factory wire apertures

303 on the front wall 333 and the end wall 31 1.

[0032] The factory wire apertures 303 hold the factory-installed wiring as it enters the factory housing 105. Factory guide walls 309 are located inside the factory housing 105. The factory guide walls 309 are shown in Fig. I as being interrupted by the factory IDC guides

305. The number and location of the interruptions in the length of the factory guide walls

309 may depend on the number, size, and location of IDC's 321 and the IDC apertures 313.

The factory guide walls 309 may be parallel to the side walls of factory housing 105. The factory guide walls 309 may separate and guide the factory-installed wiring to the desired position. IDC apertures 313 may be located on the bottom surface of the factory housing

105, and may allow the IDC's 321 to pass through the bottom surface of the factory housing

105 in order to make electrical contact with the factory wiring.

[0033J Factory IDC guides 305 are located inside the factory housing 105 over the IDC apertures 313. The factory IDC guides 305 may guide the IDC's 321 into position and may prevent the IDC 321 from bending in response to forces exerted on the IDC 321 from the wiring as the IDC 321 pierces the wire insulation to make contact with the wire. The IDC apertures 313 and factory IDC guides 305 are preferably staggered to allow the IDC connector 101 to be narrower. Fig. 1 shows the IDC's 305 staggered so that the IDC's 321 progressively move from left to right in a direction away from the front wall 333. However, the IDC's 305 may be located in any configuration. Additionally, Fig. 1 shows an IDC connector 101 with positions for three wires; however, any number of wires and IDC's 321 may be used.

[0034] A factory cover 103 may be sized to fit over the factory housing 105. The factory cover 103 may have factory cover wire restraints 307 positioned to align with the factory wire apertures 303. The factory cover wire restraints 307 may prevent the factory wiring from moving away from the factor wire apertures 303 when the factory cover 103 is installed. [0035J The field housing 1 1 1 has two side walls, a front wall 335, and a back wall 337. One or more field wire apertures 323 may be located on the front wall 335 and the back wall 337 of the field housing 11 1. Field wiring may commonly be installed in an end-wiring or in a through-wiring configuration. One or more field wire apertures 323 may be located on the front wall 335 and back wall 337. The field wire apertures 323 may hold the factory-installed wiring as it enters the field housing 1 1 1.

[0036] Field guide walls 405, discussed further with respect to Fig. 4, are located inside the field housing 11 1. The field guide walls 405 may be parallel to the side walls of the field housing 1 1 1. The field guide walls 405 may separate and guide the field-installed wiring to the desired position.

[0037] IDC apertures 331 are located on the bottom surface of the field housing 111, and allow the IDC's 321 to pass through the bottom surface of the field housing 111 to make electrical contact with the field wiring.

[0038] Field IDC guides 403, discussed further with respect to Fig. 4, may be located inside the field housing 1 11 over the IDC apertures 331, and may guide the IDC's 321 into position and prevent them from dislocating or bending excessively after they are inserted into IDC apertures 313, 331. The IDC apertures 331 may be staggered to allow the IDC connector 101 to be narrower, and may be aligned with the IDC apertures 313 of the factory housing 105. [0039] A field cover face 327 may be located on one or more sides of one or more field covers 1 15. The field cover face 327 may secure the field-installed wiring and may also prevent unwanted dust and other particles located in the environment outside the raceway IDC connector 101 from entering the field housing 1 1 1.

[0040] Latches 329 may be located on each of the field covers 1 15. The latches 329 may couple the field covers 115 to the field housing 11 1, discussed further with respect to Figs. 4 and 5. Alternatively, the field covers 1 15 may be coupled to the field housing 111 by gluing, a retention clip, or by another coupling method known in the art.

[0041] The field housing 1 1 1 shown in Fig. 1 has three field covers 1 15 attached to the field housing 1 1 1 by three field hinges 1 13. The number of field covers 1 15 may vary, and may depend on the number of wires in the field housing 11 1, although the number of field covers 1 15 and the number of wires in the field wiring do not necessary need to be equal. For instance, a single field cover 1 15 may push down one or more wires onto one or more IDC's 321.

[0042] The IDC's 321 may be inserted into the IDC apertures 331 of the factory housing 105. The field housing 111 may be placed on top of the factory housing 105. The opposite ends of the IDC's 321 may inserted into the IDC apertures 313 of the factory housing 105. The

factory IDC guides 305 and the Held IDC guides 403, discussed further with respect to Figure 4, may guide the IDC's 321 into position and may prevent them from dislocating or bending excessively after they are inserted into IDC apertures 313, 331. The field housing 11 1 and the factory housing 105 may be attached by ultra-sonic welding, gluing, a retention clip, or another coupling method known in the art.

[0043] The factory wiring may be installed into the factory housing 105 by laying the factory wires along factory guide walls 309. In an end-wiring configuration, the factory end wall 31 1 may be solid in order to protect the ends of the factory-installed wiring that are exposed after they are cut for installation into factory wire apertures 303 of the factory housing 105. Alternatively, in a through-wiring configuration, the factory end wall 311 may have factory wire apertures 303 through which factory wiring may pass.

[0044] The factory housing 105 and the factory cover 103 may be attached by ultra-sonic welding, gluing, a retention clip, or by any other suitable coupling method known in the art. When the factory cover 103 is pushed down onto the factory housing 105 during attachment, the factory cover wire restraints 307 may exert pressure on the wire insulation. The pressure from the factory cover 103 during installation may cause the IDC's 321 to pierce through the insulation of the factory-installed wiring and to make electrical contact with the factory- installed wires.

[0045] The raceway IDC connector 101 may be included within a factory terminated device, for example, in the electrical or control box on the device. The field wiring may be installed by a field technician into the field housing 111 when the device that includes the IDC connector 101 is installed in the field.

[0046] The field wiring may be installed into the field housing 1 1 1 by laying the field wires along the field guide walls 405, discussed further with respect to Figs. 4 and 5. In an embodiment in which the field covers 1 15 are attached to the field housing 105 with flexible

plastic hinges, the Held covers 1 15 may be individually rotated into position over the field housing 1 1 1 and pushed down over the field housing 111 to couple the field housing 11 1 to the field covers 115. When the field covers 115 are pushed down onto the field housing 111, the field cover wire restraints 315, discussed further with respect to Fig. 4, may exert pressure on the wires, causing the IDC's 321 to pierce through the insulation of the field-installed wiring and to make electrical contact with the field-installed wires.

[0047] The IDC connector 101 may be sized to fit into standard-sized electrical raceways for convenient field installation.

[0048] Fig. 2 is a front upper right perspective view of an IDC connector having factory end- wiring and field through-wiring, in accordance with an embodiment of the present invention. The through-wiring configuration shown in Fig. 2 has factory wiring entering the IDC connector 101 and the coupled field wiring extending from both sides of the IDC connector 101.

[0049] The factory housing 105 houses the factory wiring, made up of, for example, three power wires of either 120V AC or 230V AC. The factory cover 103 and the factory guide walls 309 may hold the factory wiring in place.

[0050] The field covers 115 may be placed over the field housing 1 1 1 and coupled to the field housing 1 1 1 to secure the field wiring. The through-wiring tab 407, discussed further with respect to Figs. 4 and 5, may be crushed when the field covers 1 15 are coupled to the field housing 1 11. Alternatively, the through-wiring tab 407 may be removed before the field wiring is laid into the IDC connector 101 by the field technician, for example, by pinching the through-wiring tab 407 with pliers and pulling the tab off the IDC connector 101. The through-wiring tabs 407 may have perforations to aid the field technician in removing the through-wiring tabs 407.

[0051] Fig. 3 shows an end-wiring configuration, whereby the field wiring is terminated inside the field housing 1 1 1, and extends from only one side of the IDC connector 101, in accordance with an embodiment of the present invention. The end-wiring configuration may be installed similarly to the through-wiring configuration discussed with respect to Fig. 2, except that the field wiring may be terminated within the field housing 1 1 1. The through- wiring tabs 407, discussed further with respect to Figs. 4 and S, may remain intact and may protect the field wiring from dust and other particles in the environment of the IDC connector 101.

[0052] Fig. 4 is a front upper right perspective view of the IDC connector 101, with the field- wired cover open. The factory wiring is not shown in Fig. 4; however, in a typical installation the factory wiring would extend from the factory wire apertures 303. [0053] Retaining rims 409 are located on the side wall of the field housing 1 1 1. Latches 329, shown in further detail in Fig. 5, may couple with the retaining rims 409 to hold the field covers 1 15 in place, in accordance with an embodiment of the present invention. [0054] The field guide walls 405 are shown in Fig. 1 as being interrupted by the field IDC guides 403. The number and location of the interruptions in the length of the factory guide walls 309 may depend on the number, size, and location of IDC's 321 and the IDC apertures 331.

[0055] The through-wiring tabs 407 may be located inside the field wire apertures 323 on the field front wall 335. The through-wiring tabs 407 may preferably be made of a plastic that may be crushed by the pressure of the field wiring when the field covers 1 15 are installed over the field housing 1 1 1. Alternatively, as discussed with respect to Fig. 4, the through- wiring tabs 407 may be made of a plastic that may be removed by a field technician. For example, the through-wiring tabs 407 may have perforations to aid the field technician to remove the through-wiring tabs 407. The through- wiring tabs 407 may prevent unwanted

dust and other particles located in the environment outside the IDC connector 101 from entering the field housing 1 1 1 in the end-wiring configuration discussed with respect to Fig. 2.

[0056] Fig. 5 is a front view of the IDC connector showing one of the field-wired covers in the open position, and another field-wired cover in the closed position, before being coupled to the field housing 11 1 by the field technician. The field cover face 327 may be tapered to guide the cover into place after it has been rotated over the field housing 1 1 1. Saddle guides 503 may guide the field cover 115 over the wires as it is rotated over the field housing 1 11. [0057] The front field cover 1 15 is shown in Fig. 5, positioned over the field housing 111. In order to couple the field cover 1 15 to the field housing 1 1 1, the field technician may push the field cover 1 15 onto the field housing 1 1 1 using channel lock pliers or an equivalent tool. The latch 329 may snap over the retaining rim 409, thereby coupling the field cover 1 15 with the field housing 11 1. As discussed with respect to Figs. 1-3, the field covers 115 may also be coupled in other ways.

[0058] Using a plurality of field covers 1 15 may reduce the physical effort required by the field technician to couple each field cover 1 15, because the field technician may be piercing through fewer wire insulations each time a field cover 115 is coupled to the field housing 1 1 1. Any number of field covers 1 15 may be used, and the number may be as many as the number of wires contained in the field housing 1 1 1.

[0059] Fig. 6 is a front upper right perspective view of the IDC connector 101 with the field covers 1 15 coupled to the field housing 1 1 1. In this view, the field covers 115 have all been rotated over the field housing 1 1 1 and locked into place by the field technician. Field cover recesses 325 are shown on the field covers 1 15. Field cover recesses 325 may assist the field technician in coupling the field covers 1 15 to the field housing 1 1 1. The field wiring and the factory wiring are not shown.

[0060] Fig. 7a is a top perspective view of an IDC connector 101 having field end-wiring with the field covers in the open position. The field wiring may be cut to fit within the length of the field housing 111. The field wiring may be laid into the field housing 1 1 1 and pushed down under the wire retainers 305. The field covers 1 15 may each be rotated over the field housing 1 1 1. The field technician may couple each field cover 115 individually using Channel Lock® pliers or an equivalent tool. FIg. 7b shows the IDC connector 101 having field end-wiring with the field covers 1 15 coupled to the field housing 111. [0061] Fig. 8a is a top perspective view of an IDC connector 101 having field through-wiring with the field covers in the open position. The field wiring may be laid into the field housing 1 1 1 and pushed down under the wire retainers 305. The field wiring may be placed within the field wire apertures 323 on the field back wall 337, and over the through-wiring tab 407. The field covers 115 may each be rotated over the field housing 111. The field technician may couple each field cover 1 15 individually using Channel Lock® pliers or an equivalent tool. The pressure from the wires may crush the thin wall of the through-wiring tab 407, allowing the field wiring to extend from both ends of the field housing 111. Alternatively, as discussed with respect to Fig. 4, the through-wiring tabs 407 may be removed by the field technician. Fig. 8b shows the IDC connector having field through-wiring with the field covers 1 15 coupled to the field housing 1 1 1.

[0062] Fig. 9 is an illustration of a typical installation 901 of the IDC connector 101 to an outlet 903. A typical outlet 903 may have factory wiring installed. The IDC connector 101 may be terminated to the factory wiring extending from the outlet 903. The field wiring may be terminated to the IDC connector 101 in an end-wiring configuration as described with respect to Fig. 3. An outlet 903 is shown in Fig. 9; however, any type of electrical receptacle may alternatively be used.

[0063] Fig. 10a is an illustration of a typical installation of the IDC connector 101 to a receptacle-type outlet 1003. A typical outlet 1005 for installation into an encased outlet strip may have factory wiring and is shown in Fig. 10a installed in outlet strip 1005. The IDC connector 101 may be terminated to the factory wiring extending from the outlet 1003. The field wiring may be terminated to the IDC connector 101 in an end-wiring configuration as described with respect to Fig. 3. The TDC connector 101 may be inserted into the outlet strip 1005, as shown in Fig. 10b. Alternatively, the IDC connector 101 may be installed into a junction box. An outlet 1003 is shown in Figs. 10a and 10b; however, another type of electrical receptacle may be used.

[0064] Fig. 1 1 is an illustration of a typical installation of the IDC connector 101 to an outlet strip base 1 103 mounted to a wall. A typical outlet 1107 for installation into an outlet strip base 1 103 may have factory wiring and is shown in Fig. 1 1 installed in outlet strip base 1 103. The IDC connector 101 may be terminated to the factory wiring extending from the outlet 1 107. The field wiring may be terminated to the IDC connector 101 in an end-wiring configuration, as described with respect to Fig. 3. The IDC connector 101 may be mounted into the outlet strip base 1 103. Alternatively, the IDC connector 101 may be installed into a junction box. An outlet 1 107 is shown in Fig. 1 1; however, any type of electrical receptacle may be used. The outlet strip cover 1 105 is mounted over the components installed on the outlet strip base 1103.

[0065] Fig. 12 is an illustration of a typical installation of the IDC connector to a surge suppressor. A typical outlet 1 107 for installation into an outlet strip base 1103 may have factory wiring and is shown installed in outlet strip base 1 103. A first IDC connector 1201 that may be factory-terminated to an outlet receptacle 1107 and a second IDC connector 101 that may be factory-terminated to a surge suppressor 1203. The first IDC connector 1201 may be field-wired to a second IDC connector 101 in a through-wiring configuration as

described with respect to Fig. 2. The first and second IDC connectors 101, 1201 may then be mounted into the outlet strip base 1103. Alternatively, the IDC connectors 101, 1201 may be installed into a junction box. An outlet 1107 is shown in Fig. 12; however, another type of electrical receptacle may be used. The outlet strip cover 1105 may be mounted over the components installed on the outlet strip base 1103.

[0066] Figs. 13a-d illustrate a typical field-wiring of the IDC connector 101 in a raceway 1311 with a faceplate 1303. An IDC connector 101 may be factory-wired to an outlet receptacle 903 with a faceplate 1303. Power wiring 1305 may be field-installed into the power channel 1307 of a raceway 1311. As shown in Fig. 13b, the IDC connector 101 may be field-installed onto the power wiring 1305 in a through-wiring configuration as described with respect to Fig. 2. As shown in Fig. 13c, the assembly of the outlet receptacle 903 and the faceplate 1303 may be mounted onto the power channel 1307. As shown in Fig. 13d, the power channel cover 1309 may be installed over the power channel 1307 to hide and protect the wiring.

[0067] It should be understood that the illustrated embodiments are examples only and should not be taken as limiting the scope of the present invention. The claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all embodiments that come within the scope and spirit of the following claims and equivalents are claimed as the invention.