Electrical connector insertion tool having a specially configured probe with visual indicator

Abstract

 An insertion tool which utilizes a specially configured insertion probe for installing or assembling electrical contacts into an electrical connector. The insertion probe tip is geometrically shaped and constructed to be fixedly received within the electrical contact barrel. Also, a vivid red colored visual indicator strategically positioned behind the insertion probe tip functioning as a barometer to the Operator or Assembly so as to correct the insertion depth or travel of the insertion probe.

Description

Background of the Invention

1. Field of the Invention

[0001] This invention relates to an electrical contact insertion tool used on the assembly of electrical connectors and more particularly to a Mil-C-26500 type connectors with rubber grommet having sealing webs with a smaller minimum wire seal as required on environment resistant Mil-C-26500 connectors.

[0002] Past efforts for installing electrical contacts in an electrical connector using conventional insertion tools has resulted in the following problems or discrepancies.

1) Cut or slice or torn seal webbing on connector rubber grommet.

2) Unseated or improperly installed electrical contacts in electrical connector retention clips or collets.

3) Operator or assembler's hand accidentally stabbed by the probe tip.

Summary of the Invention

[0003] Accordingly, one object of the present invention is to provide an insertion tool for installing electrical contacts into an electrical connector in which the integrity of the seal webbing on the electrical connector rubber grommet will be long lasting and exceedingly reliable during the entire assembly life of the environment resistant type electrical connectors.

[0004] Another object of the invention is to provide an insertion tool which will essentially eliminate cut, sliced or torn seal webbing and/or rubber grommet.

[0005] Yet another object of the invention is to provide a highly visual indicator whereby installing multitude of electrical contacts into electrical connector will result in the elimination of unseated or improperly installed contacts.

[0006] It is a further object of this invention to provide an insertion tool conductive to robotic and automated insertion of electrical contacts in the assembly of electrical connectors.

Brief Description of the Drawing(s)

[0007] 

Fig. 1 is a plan view of an electrical contact insertion tool 3 consisting of the present embodiment probe 1 and handle 2.

Fig. 2 is a side elevation (with parts in section) of the specially configured probe 1 showing the non-conventional geometrical shape and construction of the probe tip 5. Also, shown in this illustration is a vivid red colored visual indicator 4.

Fig. 3 is an end view of Fig. 2 illustrating the unique shape and construction of the probe tip 5 extending beyond center 6.

Fig. 4A is a side elevation of an electrical insertion tool with its handle 2 and conventional probe 10, illustrating position of the probe tip 7 on electrical contact barrel 9 when inserting electrical contact 8 into electrical connector (not shown).

Fig. 4B is the same as Fig. 4A except the illustration is for the present embodiment insertion tool with vivid red colored visual indicator 4.

Fig. 5A is an isometric view with detailed sectionalized view illustrating the assembly of electrical contact 8 into an electrical connector 11 using insertion tool 3 having a specially configured probe 1 with red colored visual indicator 4 and handle 2. Note location of probe tip 5 on contact barrel 9.

Fig. 5B is a sectionalized view highlighting movement on insertion probe 1 in rubber grommet 15 having seal webbing 14.

Fig. 5C is basically the same as Fig. 5B with parts concluding to a full insertion travel of arrow 12 to achieve proper electrical contact 8 location in electrical connector 11 retention clip or collet 13.

Description of a Preferred Embodiment

[0008] This invention relates to an insertion tool 3 used in installing electrical contacts 8 onto an electrical connector 11. As is conventional, insertion tool do not effect performance and integrity of the assembled electrical connector 11.
The present embodiment insertion tool 3 utilizes an insertion probe 1 whereby electrical connector 11 with seal webbing 14 for environment resisting property will not be damaged nor compromised. A specially configured probe tip 5 on the insertion probe 1 is built to fit the contour of the inside of the electrical contact barrel 9. To achieve maximum connection or straightness between insertion probe 1 and electrical contact 8, the probe tip 5 is shaped to its allowed maximum geometry 6 in relation to the inside diameter of the electrical contact barrel 9. Furthermore, for this illustration a vivid red colored visual indicator 4 is added to assure correct usage of the insertion tool 3. Stated somewhat differently, electrical contact 8 being inserted or installed into an electrical connector 11 as shown in Fig. 5 requires a constant or measured insertion travel 12. This constant insertion travel 12 is the direct equivalent of the electrical contact 8 being fully seated or inserted into the retention clip or collect 13 of the electrical connector 11. It can be understood that the Operator or Assembler installed thousands of these electrical contacts 8 resulting to Operator fatigue (physical) and/or distraction (mental). When this happens, the insertion travel 12 changes or varies. A variation of more than minus 0.005 inch from the insertion travel 12 will result to unseated or improperly installed electrical contacts 8. The functionality of the vivid red colored visual indicator 4 is clearly illustrated in Fig. 5.

[0009] When the present illustrative embodiment insertion tool 3 is being removed after the insertion of the electrical contact 8 into the electrical connector 11, it can be pointed out that the geometrical shape 6 of the probe tip 5 will not be damage or cut or slice the seal webbing 14 of the rubber grommet 15 on the electrical connector 11.

Claims

1. An insertion tool 3 including an insertion probe 1 having interchangeable contact means for engaging electrical contact 8,

coupling means for advancing said contact means to produce engagement;

said coupling means including an insertion probe tip 5 of geometrically shape 6 for contact means; and,

said contact means enabling said insertion probe tip 5 to retain said coupled relationship with said electrical contact 8.

2. An insertion tool 3 according to claim 1 having interengageable contact means,

coupling means including said insertion probe tip 5 fixedly received within an electrical contact barrel 9.

3. An insertion tool 3 according to claim 1 in which said insertion probe 1 includes a colored visual indicator 4 fixedly positioned behind the probe tip 5 which provides a predetermined amount of advancement or insertion travel 12 on said insertion tool 3.

4. An insertion tool 3 according to claim 3 whereby said colored visual indicator 4 establishes the installed location of said electrical contact 8 during assembly.

5. An insertion tool 3 according to claim 1 in which said insertion probe tip 5 is disposed so as not to cut, slice or tear seal webbing 14 or rubber grommet 15 on electrical connector 11.

6. A method for installing electrical contacts in an electrical connector having a rubber grommet with sealing webs comprising the steps of:

providing an insertion tool having an indicator for measuring predetermined insertion travel of said electrical contacts into said electrical connector;

configuring the probe tip of said insertion tool to fit the contour of the inside of the barrel of said electrical contacts; and,

advancing said contacts into said electrical connector with said insertion tool said predetermined insertion travel distance without damaging said rubber grommet with sealing webs.

Drawing