Electrical connection cable and manufacturing method thereof

Details Electrical connection cable and manufacturing method thereof Electrical connection cable and manufacturing method thereof

1999-06-08

2001-01-23

Bradley, Paula (Department: 2833)

Electrical connectors

Contact comprising cutter

Insulation cutter

C439S403000, C439S402000

Reexamination Certificate

active

06176730

ABSTRACT:

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to an electrical connection cable manufacturing method, and in particular to a method for manufacturing an electrical cable that connects electrical wires to conductive terminals by insulation displacement technique.
2. The Prior Art
Computers are now widely used in all facets of society. Data transferred to/from computer based devices is usually accomplished by means of connection cables. The connection cables usually comprise a length of electrical cable comprising a number of electrical wires with at least one connector attached thereto. Conventionally, the connection cable is made by providing an insulative housing in which a number of channels are defined. Conductive pins are received and retained in the channels with ends of the pins extending beyond the housing. The end of each conductive pin is connected to one of the electrical wires thereby establishing electrical engagement therebetween. The conductive pin is usually manually soldered to the corresponding wire. However, this process results in a low manufacturing efficiency and defective products that leads to high manufacturing costs of the connection cable.
It is thus desirable to have a more efficient electrical connection cable manufacturing method.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide an efficient electrical connection cable manufacturing method.
Another object of the present invention is to provide an electrical connection cable manufacturing method that requires a limited amount of manual labor.
A further object of the present invention is to provide an electrical connection cable manufacturing method that produces a connection cable at a reduced cost.
Still another object of the present invention is to provide an electrical connection cable wherein terminal pins of a connector thereof are electrically connected to a conductive core of a wire by a positive displacement technique.
To achieve the above objects, a method for manufacturing an electrical connection cable in accordance with the present invention comprises the steps of (1) providing a first insulator defining a plurality of channels for receiving and retaining conductive pins, a tail section of each pin having a sharpened edge; (2) providing a second insulator defining a plurality of channels for receiving a leading end of an electrical wire, each channel having a slot communicating therewith; and (3) bringing the first and second insulators toward each other whereby the tail ends of the pins are inserted into the corresponding slots of the channels of the second insulator and the sharpened edge of each pin cuts through an insulative sheath of the wire to electrical engage a conductive core thereof.
An electrical connection cable manufactured in accordance with the present invention comprises a cable portion having an end to which a connector portion is mounted. The cable portion comprises at least one electrical wire having a conductive core enclosed by an insulative sheath. The connector portion comprises an insulative housing defining a channel therein corresponding to each of the wires. A leading end of the wire is received in the channel. The connector portion further comprises a conductive pin having a terminal section extending beyond the channel. The conductive pin also comprises a tail section having a sharpened edge cutting through the insulative sheath and physically contacting the conductive core to establish electrical engagement therebetween.


REFERENCES:
patent: 4133594 (1979-01-01), Laverick et al.
patent: 4564254 (1986-01-01), Van Alst
patent: 5069638 (1991-12-01), Schalk

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