Insertion tool for insulation piercing contact

Claim 2

A tool for mounting an insulation covered electrical conductor in a contact member of a connector unit, the contact member having one end shaped to receive the free end of a conductor, being elongated and comprising at least one terminal flange with an insulation piercing notch disposed laterally across the contact spaced apart from the end portion and including an upper enlarged portion with upwardly diverging sides and a lower portion with narrow sides, said tool comprising: conductor engaging means for pressing the conductor into the contact member and notch including tool support means for receiving a conductor insertion force, and an insertion blade carried on said tool support means having a width less than the width of the upper portion of the channel for insertion therein, said insertion blade including an edge portion for engaging the conductor and projections extending from said edge portion in the direction of insertion and spaced for insertion between the sides of the insulation piercing notch, said projections shaped for entry into the lower portIon of the contact member.

Claim 3

The insertion tool set forth in claim 1, for a connector unit having a pair of spaced resilient strain relief members for gripping the conductor spaced from one end of the contact member, wherein said insertion blade includes a conductor engaging portion having a width less than the width of said edge portion for forcing the conductor between the resilient strain relief members.

Claim 4

The insertion tool as set forth in claim 1, comprising movable means slidably carried on said insertion blade including cutting means on said movable means for receiving the conductor and forward extending means for engaging the bottom of the contact member and sliding the movable means to cut the conductor.

Claim 5

The insertion tool as set forth in claim 1, comprising a cutting member and a first cutting edge on said cutting member shaped to substantially embrace the conductor, a second cutting edge adjacent said edge portion of said insertion blade, and mounting means mounting said cutting member for movement relative said blade to sever the conductor with said first and second cutting edges.

Claim 6

The insertion tool as set forth in claim 4, comprising biasing means urging said first and second cutting edges apart.

Claim 7

The insertion tool as set forth in claim 1, comprising a handle carried on said tool support means for manual operation of said tool.

Claim 8

The insertion tool as set forth in claim 1, comprising a tool guide extending beyond said insertion blade and including a guide edge for slidingly engaging the connector unit to guide and align said insertion blade with respect to the notch.

Claim 9

The insertion tool as set forth in claim 7, including conductor guide means on said tool guide for receiving and maintaining the conductor relatively straight with respect to the connector unit.

Claim 10

The insertion tool set forth in claim 1, wherein each of said projections includes a generally flat conductor engaging surface and a side surfaces angularly disposed with respect to said flat surface.

Claim 11

The insertion tool set forth in claim 9, wherein said side surfaces are angularly disposed at acute angles with respect to said flat surface.

Claim 12

The insertion tool set forth in claim 10, comprising a pair of convergently directed surfaces on each side of said insertion blade for each of said projections intersecting respective ones of said side surfaces to form notches about said projections.

Claim 13

The insertion tool set forth in claim 10, wherein said side surfaces are disposed at approximately 32* with respect to said flat surface.

Claim 14

The insertion tool set forth in claim 12, comprising a pair of convergerdly directed surfaces on each side of said insertion blade at approximately 45* with respect to said edge portion and intersecting said side surfaces to form notches about said projections.

Claim 15

A tool for mounting an insulation covered electrical conductor in a conductor confining channel of a connector unit, the channel having one end channel shaped to receive the free end of a conductor, the connector unit including a contact member comprising at least one terminal flange with an insulation piercing notch disposed laterally across the channel spaced apart from the end portion and including an upper enlarged portion with upwardly diverging sides and a lower portion with narrow sides, said tool comprising: conductor engaging means for pressing the conductor into the channel and notch including an insertion blade including a lower edge portion having a width greater that the width of the lower portion of the notch and less than the width of the channel enlarged portion for limiting entry into the channel, and at least one extension projecting beyond said edge and having a width less than the width of the lower portion of the notch for entry into the lower portion of the notch; conductor cutting means disposed a predetermined distance from said extension for receiving the free end of the conductor and including meAns for engaging the unit upon mounting of the conductor to operate said cutting means to cut the conductor to form a new free conductor end; and means supporting said conductor engaging means and said cutting means for moving said lower edge and extension into the channel.

Claim 16

A tool for mounting an insulation covered electrical conductor in a conductor confining channel of a connector unit, the channel having one end channel shaped to receive the free end of a conductor, the connector unit including a contact member comprising at least one terminal flange with an insulation piercing notch disposed laterally across the channel spaced apart from the end portion and including an upper enlarged portion with upwardly diverging sides and a lower portion with narrow sides, said tool comprising: conductor engaging means for pressing the conductor into the channel and notch including an insertion blade including a lower edge portion having a width greater that the width of the lower portion of the notch and less than the width of the channel enlarged portion for limiting entry into the channel, and at least one extension projecting beyond said edge and having a width less than the width of the lower portion of the notch for entry into the lower portion of the notch; conductor cutting means disposed a predetermined distance from said extension for receiving the free end of the conductor and including meAns for engaging the unit upon mounting of the conductor to operate said cutting means to cut the conductor to form a new free conductor end; and means supporting said conductor engaging means and said cutting means for moving said lower edge and extension into the channel.

Claim 17

A tool according to claim 14, wherein said cutting means comprises a first cutting edge on said insertion blade and a second cutting edge on said unit engaging means slideable with respect to and cooperable with said first cutting means to cut the conductor.

Claim 18

A tool according to claim 14, comprising a handle secured to said supporting means for manual insertion of the conductor.

Claim 19

A tool for mounting an insulation covered electrical conductor in a conductor confining channel of a connector unit, the channel having one end channel shaped to receive the free end of a conductor, the connector unit including a contact member comprising at least one terminal flange with an insulation piercing notch disposed laterally across the channel spaced apart from the end portion and including an upper enlarged portion with upwardly diverging sides and a lower portion with narrow sides, said tool comprising: conductor engaging means for pressing the conductor into the channel and notch including tool support means for receiving a conductor insertion force, and an insertion blade carried on said tool support means having a width less than the width of the upper portion of the channel for insertion therein, said insertion blade including an edge portion for engaging the conductor and projections extending from said edge portion in the direction of insertion and spaced for insertion between the sides of the insulation piercing notch, said projections shaped for entry into the lower portion of the channel, and means for holding and carrying the conductor for aligning the conductor with the channel.

Claim 20

A tool for mounting an insulation covered electrical conductor in a conductor confining channel of a connector unit, the channel having one end channel shaped to receive the free end of a conductor, the connector unit including a contact member comprising at least one terminal flange with an insulation piercing notch disposed laterally across the channel spaced apart from the end portion and including an upper enlarged portion with upwardly diverging sides and a lower portion with narrow sides, said tool comprising: conductor engaging means for pressing the conductor into the channel and notch including tool support means for receiving a conductor insertion force, and an insertion blade carried on said tool support means having a width less than the width of the upper portion of the channel for insertion therein, said insertion blade including an edge portion for engaging the conductor and projections extending from said edge portion in the direction of insertion and spaced for insertion between the sides of the insulation piercing notch, said projections shaped for entry into the lower portion of the channel, and means for holding and carrying the conductor for aligning the conductor with the channel.

Claim 21

A tool for mounting an insulation covered electrical conductor in a conductor confining portion of a connector unit, the portion extending longitudinally and having one end shaped to receive the free end of a conductor, the connector unit including a contact member comprising a pair of terminal flanges with longitudinally spaced apart insulation piercing notches disposed laterally across the portion and spaced apart from said one end, each of said notches including an upper enlarged portion with upwardly diverging sides and a lower portion with narrow sides, said tool comprising conductor engaging means for pressing the conductor into the conductor confining portion and lower portion of the notches including tool support means for applying a conductor insertion force, and an insertion blade carried on said tool support means, said insertion blade including an edge portion and a pair of projections extending from said edge portion in the direction of insertion and spaced for insertion into said insulation piercing notches, each of said projections including a generally flat conductor engaging surface and side surfaces angularly disposed with respect to said flat surface.

Claim 22

A tool for mounting an insulation covered electrical conductor in a conductor confining portion of a connector unit, the portion extending longitudinally and having one end shaped to receive the free end of a conductor, the connector unit including a contact member comprising a pair of terminal flanges with longitudinally spaced apart insulation piercing notches disposed laterally across the portion and spaced apart from said one end, each of said notches including an upper enlarged portion with upwardly diverging sides and a lower portion with narrow sides, said tool comprising conductor engaging means for pressing the conductor into the conductor confining portion and lower portion of the notches including tool support means for applying a conductor insertion force, and an insertion blade carried on said tool support means, said insertion blade including an edge portion and a pair of projections extending from said edge portion in the direction of insertion and spaced for insertion into said insulation piercing notches, each of said projections including a generally flat conductor engaging surface and side surfaces angularly disposed with respect to said flat surface.

Claim 23

The tool set forth in claim 18 including means for holding and carrying the conductor for aligning the conductor with the channel.

Claim 24

A tool for mounting an insulation covered electrical conductor in a contact member of a connector unit, the contact member having one end shaped to receive the free end of a conductor, the contact member being elongate and comprising at least one terminal flange with an insulation piercing notch disposed laterally across the contact and spaced apart from the end portion, said tool comprising: an insertion blade for engaging and pressing the conductor into the contact member, said insertion blade including a first cutting edge; cutting means cooperable with said insertion blade including a cutting member having a second cutting edge shaped to substantially embrace the conductor and a portion for engaging said connector unit; and mounting means mounting Said cutting member for movement relative said blade to sever the conductor with said first and second cutting edges in response to the engagement of said portion with said connector unit and movement of said first and second cutting edges toward each other, and said portion includes a projection for extending into the elongate contact member to aid in aligning the insertion tool as the tool carries the conductor toward the contact.

Claim 25

A tool for mounting an insulation covered electrical conductor in a contact member of a connector unit, the contact member having one end shaped to receive the free end of a conductor, the contact member being elongate and comprising at least one terminal flange with an insulation piercing notch disposed laterally across the contact and spaced apart from the end portion, said tool comprising: an insertion blade for engaging and pressing the conductor into the contact member, said insertion blade including a first cutting edge; cutting means cooperable with said insertion blade including a cutting member having a second cutting edge shaped to substantially embrace the conductor and a portion for engaging said connector unit; and mounting means mounting Said cutting member for movement relative said blade to sever the conductor with said first and second cutting edges in response to the engagement of said portion with said connector unit and movement of said first and second cutting edges toward each other, and said portion includes a projection for extending into the elongate contact member to aid in aligning the insertion tool as the tool carries the conductor toward the contact.

Claim 26

An insertion tool according to claim 20, comprising means defining a transverse slot in said cutting member, said transverse slot extending from the exterior of said cutting member to said second cutting edge as a passageway for receiving a conductor.

Claim 27

The insertion tool as set forth in claim 20, comprising biasing means urging said insertion blade and said cutting member apart.

Claim 28

The insertion tool as set forth in claim 22, comprising a second projection extending from said cutting member, and wherein said biasing means comprises a spring which bears against said projection and a portion of said insertion blade.