US 6,737,584 B2Grant
Electrical cable connector
Issue Date:2004-05-18
•24 Claims
•22 Drawing Sheets
Abstract
By providing two integrated components, an outer housing and an inner sleeve member having cable engaging arms, with the inner sleeve member being securely mounted to the outer housing in a manner which prevents its separation from the housing, an efficient, easily manufactured and assembled cable connector is realized. In one preferred embodiment, the inner sleeve member incorporates a plurality of locking members which extend through portals formed in the housing to enable the fully assembled cable connector to be quickly and easily lockingly engaged and securely mounted in a receiving hole of a junction or outlet box. If desired, the sleeve member may also incorporate radially extending curved grounding/conductivity tabs mounted to the sleeve member and constructed for extending through additional portals formed in the housing. By employing this construction, a grounding path or an electrical conductivity path is automatically established between the cable connector and the junction/outlet box when the connector is mounted thereto. Finally, a further preferred embodiment also incorporates a gasket member in combination with the housing and the sleeve member to achieve a cable connector which is rain tight or moisture tight.
Metadata
Assignee
- Bridgeport Fittings, Inc.
Inventor
- Kenneth M. Kiely
Application Information
Application Number:US 10/414,529
Filing Date:2003-04-15
Priority Date:2001-05-01
Art Unit:7
Classifications
IPC:
H02G 318
Field of Search:
174 65 R174 65 SS174 64174153 G174153 R174152 G174151174 31 R174 35 GC174 35 R174 91248 5616 2116 22439471439604
Patent Drawings (22 sheets)
Description
Related Applications
[0002] This application is a continuation-in-part application of U.S. patent application Ser. No. 10/183,109, filed Jun. 26, 2002 U.S. Pat. No. 6,555,750 for an ELECTRICAL CABLE CONNECTOR which is a continuation-in-part of U.S. patent application Ser. No. 09/846,954, filed May 1, 2001 entitled ELECTRICAL CABLE CONNECTOR, now U.S. Pat. No. 6,444,907, issued Sep. 3, 2002.
Technical Field
[0003] This invention relates to electrical connectors, and more particularly, to electrical connectors constructed for securing metal sheath cables to junction boxes and/or outlet boxes.
Background Art
[0004] In the field of wiring homes and buildings, whether for new construction or for improvements or expansion, substantial development and product improvements have been made. Typically, these improvements are directed to enabling installers to securely mount any desired wiring in any desired location in the most efficient and quickest manner.
[0005] In any particular installation or location, various cables must be interconnected to each other as well as connected to the primary power supply in a suitable power distributing junction box or fuse box. In each of these instances, metal sheath cables, within which the electric power carrying wires are contained, must be securely mounted to the housing of the junction box or outlet box, or connected to appropriate devices, in a protected area.
[0006] In order to enable installers to securely mount metal sheath cables to any desired junction box or outlet box, numerous prior art connectors have been developed. However, in spite of the substantial effort that has been expended in developing such connectors, these prior art systems all have drawbacks or difficulties which prevent their universal adoption and use.
[0007] In general, the industry has long sought to have a single cable connector which is quickly and easily secured to the end of the metal sheath cable and, once installed, is capable of preventing unwanted movement or dislodgement of the cable from the connector. In addition, the cable connector, with the cable secured therein, must be quickly mountable in secure engagement with any desired junction box or outlet box. Finally, all of these attributes must be achieved in a connector which is inexpensive, in order to enable its acceptance, use, and wide-spread adoption.
[0008] Although many prior art connectors have been developed which provide one or more of the attributes detailed above, no prior art connector has been developed which is capable of satisfying all of these long-sought requirements. Consequently, a long-felt need continues to exist for a cable connector meeting these requirements.
[0009] Therefore, it is a principal object of the present invention to provide a connector for use with metal sheath cables which provides secure, rapid engagement and retention of the cable in the connector.
[0010] Another object of the present invention is to provide a cable connector having the characteristic features described above which is also quickly and easily secured to any desired junction box or outlet box in a manner which assures secure retained engagement therewith.
[0011] Another object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable, once mounted to the connector, is incapable of dislodgement or withdrawal.
[0012] Another object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable connector is capable of being produced and assembled quickly and easily, thereby providing an inexpensive product.
[0013] Another object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable connector automatically provides grounding and/or an electrical flow path through the junction box or outlet box when mounted thereto.
[0014] A further object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable connector is self-centering when mounted in a receiving hole and provides a pre-loaded, spring biasing holding force thereto.
[0015] Another object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable connector is rain and/or moisture tight to enable its use outdoors or in other high moisture environments without difficulty.
[0016] Other and more specific objects will in part be obvious and will in part appear hereinafter.
Summary of the Invention
[0017] By employing the present invention, all of the difficulties and drawbacks of the prior art systems have been overcome, and an efficient, easily manufactured and assembled cable connector is realized. Furthermore, using the cable connector of the present invention, any desired metal sheath cable is quickly and easily secured to the connector and mounted in place, with complete assurance that the unwanted movement or withdrawal of the cable from the connector is virtually eliminated.
[0018] In its preferred embodiment, the cable connector of the present invention comprises two integrated components, an outer housing and an inner sleeve member. As detailed herein, the inner sleeve member is securely mounted to the outer housing in a manner which prevents its separation from the housing. As is more fully detailed below, the inner sleeve member is preferably press fitted into the housing in order to provide the desired secure, integrated affixation of these components. However, if desired, other securement methods well known in the industry may also be used.
[0019] Preferably, the outer housing comprises a generally hollow cylindrical shape constructed with two spaced, co-axial, radially extending flanges formed on the outer surface thereof, directly adjacent one end of the housing. The spaced distance between the flanges is constructed to enable well known locking rings to be mounted and retained therebetween. Although numerous locking rings are found in the prior art, one such ring is taught in Pratesi U.S. Pat. Nos. 5,189,258 and 5,342,994, while other rings are taught in Arlington's U.S. Pat. Nos. 6,043,432; 6,080,933; and 6,335,488.
[0020] Typically, a locking ring is mounted between the radially extended flanges, with the flange spaced away from the end of the housing comprising a larger diameter than the other. With the locking ring mounted in place, the housing is able to be quickly and easily affixed to any receiving hole in any desired junction box or outlet box for secure, mounted engagement therewith.
[0021] In the preferred embodiment, the inner sleeve member is constructed in a generally hollow cylindrical shape with at least two arm members integrally formed therewith, each of which angularly slopes inwardly from the cylindrical wall of the sleeve member. In addition, each arm member comprises a distal end portion which is angularly disposed relative to the arm member in at least one direction and preferably in two directions. Finally, in the preferred embodiment, each distal end portion is split in two sections and terminates with an arcuately curved terminating end.
[0022] By employing this construction, with the angular relationships detailed below, each arm member is able to be pivoted in a first direction out of the travel paths of the cable when the sheath cable is inserted therein. In this way, the cable is able to be quickly and easily advanced through the sleeve member. However, once the sheath cable has been fully advanced into the sleeve member, the arm members return to their original position and become securely engaged wit the outer wall of the sheath cable, preventing the cable from being removed or withdrawn from the sleeve member.
[0023] Furthermore, by employing the preferred embodiment of the present invention, the arcuate curved end of each arm member fully engages the outer surface of the cable throughout the entire width of the arm member. In addition, as stated above in the preferred embodiment, the distal end portion of each arm member may be split or bifurcated into two separate finger members, with each finger member preferably comprising two separate and independent angular relationships relative to the major portion of the arm member. By employing this construction, the distal end portions of the arm members are both pitched and sloped, relative to the major portion of the arm member, providing secure, locking engagement with the cable in a plurality of positions.
[0024] By designing the slope and/or pitch angles to be substantially equivalent to the slope of the spiral juncture of the metal on the metal sheath cable, each finger of each arm member of the inner sleeve member engages the metal sheath cable directly along the juncture between the metal section, which is defined by the narrow portion or minor diameter of the cable. In this way, secure move-free engagement of the cable is realized and movement of the sheath cable relative to the sleeve member is prevented. Furthermore, by combining the slope and/or pitch angles with an arcuately curved end which matches the curvature of the cable, secure engagement of each finger of each arm member with the cable throughout the entire width of the arm member is achieved.
[0025] If desired, the two arm members may be formed at different positions along the axial length of the sleeve member. In this way, the cable engaging end of each arm member interconnects with the metal sheath cable at different longitudinal spaced locations along the length of the cable.
[0026] By constructing the inner sleeve member in the preferred manner, each arm member is able to engage the minor diameter of the spiral shaped juncture between the metal portions of the cable. In this way, secure engagement with the optimum area of the cable is provided and completely controlled movement-free securement of the cable by the inner sleeve is achieved.
[0027] In another embodiment of the present invention, the inner sleeve member is constructed with a plurality of radially extending locking tabs formed at one end thereof, with each of the locking tabs constructed for cooperating with and extending through portals formed at the terminating end of the housing. In this way, the fully assembled cable connector is capable of being quickly, easily, and efficiently securely mounted in the receiving hole of any desired junction box or outlet box, with simplicity, while not requiring the use of a separate and independent locking member.
[0028] In a further alternate embodiment, the inner sleeve member incorporates radially extending grounding/conductivity tabs formed at one end thereof, adjacent the radial extending locking tabs. In addition, the grounding/conductivity tabs are constructed to extend from the inner sleeve member through apertures formed in the housing member for being positioned to engage the inside edge of the receiving hole of the junction/outlet box into which the cable connector is mounted. In this way, the cable connector is automatically centered in the receiving hole as well as automatically establishing a grounding path and/or electrical conductivity path for the cable member affixed therein.
[0029] In a further alternate embodiment of the present invention, the cable connector also incorporates a sealing bushing or grommet in addition to the inner sleeve member and the housing member. Furthermore, the cable connector also preferably incorporates a sealing washer for being mounted at one end of the cable connector with a locking nut, while also incorporating a clamping nut for being mounted to the opposed end of the housing in order to assure secure sealing engagement of the bushing/or grommet with the housing and cable. By employing this construction, a rain-tight and/or moisture-tight cable connector is attained, enabling the cable connector to be used in a wide variety of applications where high levels of moisture may exist.
[0030] The invention accordingly comprises an article of manufacture possessing the features, properties, and the relation of elements which will be exemplified in the article herewith described, and the scope of the invention will be indicated in the claims.
The Drawings
[0031] For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which:
[0032] FIG. 1 is an exploded perspective view of one embodiment of a fully assembled electrical cable connector of the present invention;
[0033] FIGS. 2 and 3 are perspective views of the fully assembled electrical cable connector of FIG. 1;
[0034] FIG. 4 is a side elevation view, partially in cross-section, depicting the electrical cable connector of FIG. 1 mounted in a conventional junction box;
[0035] FIG. 5 is a perspective view depicting one preferred embodiment of an inner sleeve member of the cable connector of the present invention;
[0036] FIG. 6 is a front elevation view of the inner sleeve member of FIG. 5;
[0037] FIG. 7 is a rear elevation view of the inner sleeve member of FIG. 5;
[0038] FIG. 8 is a left side elevation view of the inner sleeve member of FIG. 5;
[0039] FIG. 9 is a top plan view of the inner sleeve member of FIG. 5;
[0040] FIG. 10 is a right side elevation view of the inner sleeve member of FIG. 5;
[0041] FIG. 11 is a cross-sectional side elevation view of this embodiment of the inner sleeve member taken along line 11—11 of FIG. 9;
[0042] FIG. 12 is a cross-sectional side elevation view of this embodiment of the inner sleeve member taken along line 12—12 of FIG. 9;
[0043] FIGS. 13 and 14 are perspective views of this embodiment of the fully assembled electrical cable connector with an electrical cable depicted therein;
[0044] FIG. 15 is a perspective view of an alternate embodiment of a fully assembled electrical cable connector of the present invention with the retaining ring removed therefrom;
[0045] FIG. 16 is a top plan view of the fully assembled electrical cable connector of FIG. 15;
[0046] FIG. 17 is a side elevation view of the fully assembled electrical cable connector of FIG. 15;
[0047] FIG. 18 is a perspective view of an alternate embodiment of an inner sleeve member incorporated into the cable connector of the present invention;
[0048] FIG. 19 is a front elevation view of the inner sleeve member of FIG. 18;
[0049] FIG. 20 is a top plan view of the inner sleeve member of FIG. 18;
[0050] FIG. 21 is a bottom plan view of the inner sleeve member of FIG. 18;
[0051] FIG. 22 is a side elevation view of the inner sleeve member of FIG. 18;
[0052] FIG. 23 is a rear elevation view, partially in cross-section, depicting the inner sleeve member of FIG. 18 in mounted engagement with the housing to form this embodiment of the electrical cable connector;
[0053] FIG. 24 is a top plan view of a further alternate embodiment for the inner sleeve member of the present invention;
[0054] FIG. 25 is a cross-sectional side elevation view of the inner sleeve member of FIG. 24, taken along line 25—25 of FIG. 24;
[0055] FIG. 26 is an exploded perspective view depicting a still further alternate embodiment of the cable connector of the present invention;
[0056] FIG. 27 is a perspective view of the fully assembled cable connector of FIG. 26;
[0057] FIG. 28 is a side elevation view, partially in cross-section, depicting the cable connector of FIG. 27 mounted in a receiving hole of a conventional junction box and/or outlet box;
[0058] FIG. 28A is a greatly enlarged, partially broken away, side elevation view of the cable connector of FIG. 28 taken from area “A”;
[0059] FIG. 29 is a side elevation view of the housing which forms a component of the cable connector of FIG. 26;
[0060] FIG. 30 is a front end view of the housing of FIG. 29;
[0061] FIG. 31 is a top plan view of the inner sleeve member which forms a component of the cable connector of FIG. 26;
[0062] FIG. 32A is a cross-sectional side view of the inner sleeve member of FIG. 31;
[0063] FIG. 32B is a side view of the inner sleeve member of FIG. 31;
[0064] FIG. 33 is a front view of the fully assembled cable connector of FIG. 27;
[0065] FIG. 34 is a cross-sectional side view of the cable connector of FIG. 33;
[0066] FIG. 35 is an exploded perspective view depicting another further alternate embodiment of the cable connector of the present invention;
[0067] FIG. 36 is a cross-sectional side elevation view depicting the cable connector of FIG. 35 mounted in a receiving hole of a conventional junction box and/or outlet box;
[0068] FIG. 37 is a rear elevation view of the cable connector of FIG. 36;
[0069] FIG. 38 is a cross-sectional side elevation view of the inner sleeve member of FIG. 36;
[0070] FIG. 39 is a rear elevation view of the inner sleeve member of FIG. 38;
[0071] FIG. 40 is a cross-sectional, side elevation view depicting a still further alternate embodiment of the cable connector of the present invention mounted in a receiving hole of a conventional junction box and/or outlet box with an electrical cable securely mounted in position; and
[0072] FIG. 41 is an exploded, cross-sectional side elevation view of the cable connector of FIG. 40.
Detailed Description
[0073] By referring to FIGS. 1-41, along with the following detailed disclosure, the construction and operation of several alternate embodiments of electrical cable connector 20 of the present inventions can best be understood. As will be evident to one having ordinary skill in this art, numerous alternate constructions may be implemented using the teaching of the present invention in addition to the embodiments shown and described herein. Consequently, it is to be understood, that all of these alternate constructions are intended to be within the scope of the present invention and the embodiments detailed herein are provided for exemplary purposes only.
[0074] As shown in FIGS. 1-4, cable connector 20 of the present invention comprises three separate and independent components, consisting of housing 21, inner sleeve member 22, and locking ring 23. In the preferred construction, housing 21 comprises a substantially hollow cylindrical shape incorporating outer surface 24, and inner surface 25. In addition, a pair of radially extending flanges 26 and 27 are formed on outer surface 24 of housing 21, with flange 27 radially extending outwardly from cylindrical surface 24 a distance greater than flange 26. Furthermore, flanges 26 and 27 are axially spaced away from each other on surface 24 in order to form therebetween a locking ring retaining zone 28.
[0075] By employing this construction, locking ring 23 is quickly and easily secured to housing 21 by positioning locking ring 23 in retaining zone 28, with locking ring 23 retained in this position by flanges 26 and 27, free from axial dislodgement. In addition, as is well-known in the art and as shown in FIG. 4, flange 26 comprises a diameter which enables the passage of flange 26 and locking ring 23 through receiving hole 29 formed in junction box and/or outlet box 30, while flange 27 comprises a diameter greater than the diameter of receiving hole 29. In this way passage of housing 21 through receiving hole 29 of junction box and/or outlet box 30 beyond flange 27 is prevented.
[0076] Furthermore, the construction of locking ring 23 engages in junction/outlet box 30 after passage through receiving hole 29, preventing axial removal of housing 21 from junction/outlet box 30. As a result, secure, locked engagement of housing 21 with junction/outlet box 30 is provided in an easily assembled and quickly installed manner.
[0077] As fully detailed herein and shown in FIGS. 1-14, inner sleeve member 22 of cable connector 20 is constructed in a substantially hollow cylindrical shape which is defined by outer surface 35 and inner surface 36. In the preferred construction, the outer diameter of sleeve member 22, as defined by outer surface 35, is constructed substantially equivalent to the diameter of inner surface 25 of housing 21. In this way, inner sleeve member 22 is securely affixed to housing 21 by a press fit or by frictional engagement between outer surface 35 of sleeve member 22 and inner surface 25 of housing 21. The frictional interengagement established between inner sleeve member 22 and housing 21 is constructed to exceed all force requirements imposed upon cable connectors. In this way, trouble-free, secure engagement of an electrical cable with connector 20 is assured.
[0078] As is well-known in the art, other methods can be employed for providing interengagement of inner sleeve member 22 with housing 21 other than the preferred embodiment of frictional engagement. In this regard, FIGS. 15-24 disclose an alternate embodiment, wherein an alternate engagement system is employed. However, although alternate securement systems or constructions can be employed, as taught in the prior art, the preferred embodiment of the present invention employs frictional interengagement as detailed herein.
[0079] In order to provide secure, locked, movement-free engagement of any desired electrical cable with cable connector 20 of the present invention, inner sleeve member 22 is constructed in a unique manner with a plurality of cable gripping elements integrally associated therewith. By referring to the following detailed discussion, along with FIGS. 1-4, 13 and 14, wherein fully assembled cable connector 20 is disclosed and FIGS. 5-12 wherein inner sleeve member 22 is separately detailed, the construction and operation of the preferred embodiment of cable connector 20 of the present invention, with its uniquely constructed inner sleeve member 22, can best be understood.
[0080] In this preferred embodiment, inner sleeve member 22 comprises, in addition to its substantially cylindrical shape, two arm members 37 and 38 which extend inwardly from inner surface 36 of sleeve member 22. Preferably, arm member 37 is constructed with a sloping, intermediate section 39 and a sloping, end section 40. Similarly, arm member 38 comprises a sloping, intermediate section 41 and a sloping, end section 42.
[0081] As shown in FIG. 11, arm members 37 and 38 are constructed for securely engaging the outer surface of electrical cable 45, shown in phantom, allowing cable 45 to be easily, telescopically inserted into sleeve member 22 in the direction of arrow 46. By employing this construction, as detailed herein, axial movement of electrical cable 45 in the direction of arrow 46 is easily attained, while axial movement or withdrawal of cable 45 from sleeve member 22 in the opposite direction is prevented. Furthermore, arm members 37 and 38 are constructed to maximize engagement with cable 45 and assure secure, movement-free, locked retention of cable 45 in sleeve member 22.
[0082] One of the features incorporated into arm members 37 and 38 to provide the desired securement to electrical cable 45 is the incorporation of two separate and distinct sloping sections in each arm member. As shown in FIG. 11, intermediate section 39 of arm member 37 slopes inward away from inner surface 36, or outer surface 35, of sleeve member 22 at angle “A”, while end section 40 slopes inwardly from inner surface 36 at angle “B”. Similarly, intermediate section 41 of arm member 38 slopes inwardly from inner surface 36 at angle “A”, while end section 42 slopes inwardly from inner surface 36 at angle “B”.
[0083] In the preferred embodiment, it has been found that angle “A” preferably ranges between about 15° and 30°, while angle “B” preferably ranges between about 45° and 75°. By employing slope angles falling within these parameters, optimum engagement of cable 45 is attained and secure retention thereof is provided. Although these arcuate ranges are preferred for providing optimum performance, variations can be made without departing from the scope of this invention.
[0084] Another feature incorporated into arm members 37 and 38 of sleeve member 22 in order to enhance the secure, locked interengagement of electrical cable 45 in sleeve member 22 is the construction employed for the terminating edge of end sections 40 and 41. As depicted throughout the drawings, end section 40 of arm member 37 comprises an arcuately curved terminating edge 50, while end section 42 of arm member 38 comprises an arcuately curved terminating edge 51. In the preferred construction, terminating edges 50 and 51 comprise a radius of curvature which is substantially equal of the radius of curvature employed in forming the outer surface of electrical cable 45. As a result, terminating edges 50 and 51 are specifically constructed for directly contacting the surface of electrical cable 45 along substantially the entire arcuate length of edges 50 and 51. In this way, engagement of end sections 40 and 42 with electrical cable 45 is further enhanced.
[0085] Another unique and distinctive feature of the present invention which further enhances and optimizes the secure locked retention of electrical cable 45 is the bifurcation of end section 40 of arm member 37 into two separate and independent finger portions 52 and 53. Similarly, end section 42 of arm member 38 is also bifurcated into two separate and independent finger portions 54 and 55. As fully detailed herein, and shown throughout the drawings, the incorporation of two separate and independent finger portions as the terminating end section of each arm member 37 and 38 provides further enhanced secure, locked interengagement of arm members 37 and 38 with electrical cable 45. In order to achieve the desired separation, and offset distance of about ⅛″ is preferred.
[0086] As best seen in FIGS. 11 and 12 in the preferred construction, finger portions 52 and 53 of end section 40 extend from intermediate section 39 at different angles relative thereto. As a result, terminating edge 50 of each finger portion 52 and 53 engages electrical cable 45 at a different location on the outer surface of cable 45. In the preferred embodiment, as depicted in FIGS. 11 and 12, terminating edges 50 of finger portions 52 and 53 are constructed for engaging electrical cable 45 on opposite sides of the minor diameter or narrowed portion thereof.
[0087] Similarly, terminating edge 51 of finger portions 54 and 55 of arm member 38 also extend from intermediate section 41 at different angles relative thereto, engaging the outer surface of electrical cable 45 at different positions directly adjacent the minor diameter or narrowed portion of cable 45. In this way, secure, locked, movement-free interengagement of electrical cable 45 in sleeve member 22 is assured.
[0088] In accordance with the present invention and shown in the drawings, finger portions 52 and 53 of arm member 37 are bent inwardly relative to intermediate section 39 at the desired angles along bend line 58. In the embodiment depicted in FIGS. 8-12, bend lines 58 are formed at a slanting acute angle relative to the side walls of intermediate section 39. Similarly, finger portions 54 and 55 are bent inward late relative to intermediate section 41 along bend line 58, which is shown in FIGS. 8-12 as being slanted relative to the side edges of intermediate section 41 forming an acute angle therewith.
[0089] As is more fully detailed below, bend line 58 may comprise any desired angular relationship relative to the side edges of intermediate sections 39 and 41 without departing from the scope of the present invention. In this regard, although slanted or sloping bend lines are depicted in FIGS. 8-12, a bend line 58 is depicted in FIGS. 21-22 and 24-25, in association with alternate embodiments of the present invention, wherein the bend line is substantially perpendicular to the side edges of the intermediate section.
[0090] By constructing bend line 58 with a slope angle which matches the slope angle of the helical-shaped minor diameter or recessed zone of cable 45, more precise alignment and secure locked engagement of finger portions 52, 53, 54 and 55 with electrical cable 45 is achieved. Consequently, although not required, the incorporation of a bend line 58 which slopes or is angularly disposed relative to the side edges of the intermediate section of the arm member is preferred, with the slope angle preferably matching the slope of the helical recess or minor diameter of electrical cable 45.
[0091] A further feature incorporated into cable connector 20 of the present invention is found in the construction of the axial length of intermediate sections 39 and 41 of arm members 37 and 38 of sleeve member 22. As detailed herein, the axial length of intermediate sections 39 and 41 may be substantially equal, or may be varied relative to each other.
[0092] In the embodiment depicted in FIGS. 8-12, the axial length of intermediate section 39 of arm member 37 is shown substantially longer than the axial length of intermediate section 41 of arm member 38. By employing this construction, and otherwise forming end sections 40 and 42 of each arm member in a substantially identical manner, terminating edges 50 and 51 of arm members 37 and 38 contact electrical cable 45 at separate and distinct positions along the axial length of cable 45. In this way, arm members 37 and 38 are constructed to directly engage the minor diameter or recessed zone of electrical cable 45 at precisely desired locations along the axial length thereof, thereby assuring that both arm members 37 and 38 are each in direct, contacting engagement in the minor diameter or recessed zone of cable 45.
[0093] Alternatively, as shown in FIG. 19, intermediate sections 39 and 41 of arm members 37 and 38 may be constructed with substantially equivalent axial lengths, thereby engaging electrical cable 45 at substantially identical axial locations, substantially diametrically opposed from each other. Depending upon the construction of electrical cable 45, having each arm member 37 and 38 engaging electrical cable 45 at substantially the identical, diametrically opposed position can be desirable and can provide optimum, secure and locked engagement of cable 45. This is particularly true with cable constructions incorporating annular, ring-shaped recessed zones which are substantially parallel to each other.
[0094] As detailed above, the embodiment of cable connector 20 depicted in FIGS. 1-14 is constructed with inner sleeve member 22 comprising an outer diameter defined by outer surface 35 which is configured to assure secure, frictional interengagement between sleeve member 22 and inner surface 25 of housing 21. In this way, as previously discussed, once inner sleeve member 22 is inserted into housing 21, a substantially integral cable connector 20 is formed with sleeve member 22 being securely frictionally engaged and retained in housing 21.
[0095] In order to assist in the positioning and insertion of inner sleeve member 22 in housing 21, sleeve member 22 incorporates a substantially flat or planer surface 60 formed on otherwise cylindrically shaped sleeve member 22. In addition, apertures 61 are also formed on planer surface 60, for assisting in the assembly process. However, the incorporation of apertures 61 as well as in the construction of sleeve member 22 with substantially flat surface 60 may be eliminated, without departing from the scope of this invention.
[0096] In addition to employing the press fit or friction fit engagement of inner sleeve member 22 with housing 21, inner sleeve member 22 may be securely mounted to housing 21 using a plurality of alternate constructions. One such alternate construction is depicted in FIGS. 15-23 wherein the use of locking tabs is employed.
[0097] As is well known to those having ordinary skill in this art, the use of locking tabs to secure a sleeve members with a housing has been employed in a wide variety of alternate constructions. However, as depicted in FIGS. 15-23, the present invention employs a unique construction for producing an easily manufactured and readily installed sleeve member incorporating locking tabs for mounted engagement with a housing.
[0098] As shown in FIGS. 15-17, housing 21 of cable connector 20 is constructed in a manner substantially identical to the construction detailed above, with housing 21 comprising a substantially hollow, cylindrical shape incorporating outer surface 24, inner surface 25, and two, axially spaced, radially extending flanges 26 and 27. In addition, flange 27 radially extends outwardly from cylindrical surface 24 a distance greater than flange 26, defining therebetween locking ring retaining zone 28.
[0099] As detailed above, although not shown in FIGS. 15-17, locking ring 23 depicted in FIGS. 1-4 is employed in the identical manner detailed above, by being positioned in retaining zone 28 for use in securely retaining cable connector 20 in a receiving hole formed in an outlet box or junction box to which cable connector 20 is mounted. In order to avoid redundancy, it should be understood that all of the detailed discussion provided above regarding the locked interengagement between cable connector 20 in any desired outlet box or junction box is equally applicable to this alternate embodiment and this disclosure is incorporated herein by reference.
[0100] The principal variation between this embodiment of housing 21 and the embodiment detailed above is the incorporation of two apertures 63 and 64 formed in housing 21, and extending between outer surface 24 and inner surface 25. As fully detailed herein, apertures 63 and 64 are employed for receiving and securely retaining the locking tabs formed on sleeve member 22.
[0101] By referring to FIGS. 19-23, along with the following detailed disclosure, the preferred construction of this alternate embodiment of sleeve member 22 can best be understood. In this embodiment, as with the previous embodiment detailed above, sleeve member 22 comprises a substantially hollow, cylindrical shape which is defined by outer surface 35 and inner surface 36. In addition, in the preferred construction, substantially flat surface 60 and apertures 61 are also incorporated in sleeve member 22 for ease of assembly.
[0102] Inner sleeve member 22 also incorporates two diametrically opposed arm members 37 and 38 which are preferably formed from the substantially cylindrically shaped housing forming sleeve member 22 with arm members 37 and 38 extending inwardly from inner surface 36 of sleeve member 22. As detailed above, arm member 37 is preferably constructed with sloping, intermediate sections 39 and sloping, end sections 40. Similarly, arm member 38 is constructed preferably comprising sloping, intermediate section 41 and sloping, end section 42.
[0103] Although arm members 37 and 38 may be constructed using a variety of alternate methods, the preferred embodiment of inner sleeve member 22 comprises cutting two substantially U-shaped openings 65 in the wall of sleeve member 22 extending from outer surface 35 to inner surface 36 and defining thereby arm members 37 and 38. Then, by bending the resulting arm members 37 and 38 in the appropriate locations, arm member 37 is constructed with sloping intermediate section 39 and sloping end section 40, while arm member 38 is constructed comprising sloping intermediate section 41 and sloping end section 42.
[0104] In order to ease the bending of intermediate sections 39 and 41 of arm members 37 and 38 relative to outer surface 35 of the sleeve member 22, an aperture is formed at the base of intermediate sections 39 and 41 at the juncture with outer wall 35. In the embodiment of inner sleeve member 22 best seen in FIGS. 8 and 10, aperture 66 is formed in outer surface 35 extending through to inner surface 36. Although any configuration may be employed, aperture 66 is depicted as a substantially square shaped aperture.
[0105] In the second, alternate embodiment of inner sleeve member 22, a U-shaped aperture 67 is formed in outer surface 35 of sleeve member 22 extending through to inner surface 36 thereof, as best seen in FIG. 22. By employing a U-shaped aperture in sleeve member 22, extension tab 68 is formed thereby, extending from the proximal end of intermediate section 39 of arm member 37.
[0106] In addition, when intermediate section 39 of arm member 37 is arcuately pivoted inwardly to achieve the desired slope angle relative to inner surface 36, tab 68 arcuately pivots in the opposite direction, extending outwardly from outer surface 35 of sleeve member 22. In this way, tab 68 is quickly and easily constructed, radially extending outwardly from outer surface 35 of sleeve member 22, in a simple, one-step operation which is achieved simultaneously with the formation of inwardly sloping intermediate section 39.
[0107] By employing a substantially identical construction, extending tab 69 is formed at the proximal end of intermediate section 41 of arm member 38, and configured to radially extend outwardly from outer surface 35 of sleeve member 22 simultaneously during the formation of an inwardly sloping intermediate section 41 of arm member 38. As a result of this construction, radially extending locking tabs 68 and 69 are formed and automatically positioned in the precisely desired location during the formation and positioning of arm members 37 and 38, ready for securely engaging and lockingly retaining the electrical cable.
[0108] During the assembly of this embodiment of cable connector 20, inner sleeve member 22 is telescopically inserted into housing 21 until radially extending locking tabs 68 and 69 are brought into engagement in apertures 63 and 64 of housing 21. Once tab 68 and 69 are secured in apertures 63 and 64, sleeve member 22 is retained in housing 21 in a manner which prevents sleeve member 22 from being withdrawn or removed from housing 21. Once in this position, cable connector 20 is fully assembled and ready for use.
[0109] In FIGS. 24 and 25, a further alternate embodiment for inner sleeve member 22 of cable connector 20 is depicted. In this embodiment, inner sleeve member 22 incorporates two diametrically opposed arm members 37 and 38 formed from the substantially cylindrically shaped housing of sleeve member 22, as detailed above, with arm members 37 and 38 extending inwardly from inner surface 36 of sleeve member 22. In addition, as detailed above, arm member 37 is constructed with sloping, intermediate section 39 and sloping end section 40, while arm member 38 is constructed with sloping, intermediate section 41 and sloping, end section 42.
[0110] In this embodiment of the present intervention, sloping end sections 40 and 42 are not bifurcated, as detailed above in connection with alternate embodiments of the present intervention. As a result, sloping end sections 40 and 42 are uniform throughout their width, lockingly engaging a cable member as a single unit, when a cable member is inserted therebetween. Furthermore, bend lines 58 formed between intermediate section 39 and end section 40, as well as intermediate section 41 and end section 42 are preferably constructed, in this embodiment, as substantially perpendicular to the side edges of the respective arm members. In this way, substantially horizontal engagement with the cable member is achieved.
[0111] In order to further enhance the engagement of sloping end sections 40 and 42 with a cable member, end section 40 of arm member 37 comprises an arcuately curved terminating edge 50 constructed for securely engaged the curved surface of the cable member. Similarly, end section 42 of arm member 38 comprises an arcuately curved terminating edge 51 similarly constructed for securely engaging the curved outer surface of the cable member.
[0112] By employing this construction, terminating edges 50 and 51 are constructed for directly contacting the surface of the electrical cable along substantially the entire arcuate length of edges 50 and 51. In this way, engagement of end section 40 and 42 with the electrical cable is enhanced.
[0113] A further feature incorporated into this embodiment of the present invention is rounding of the corners between terminating edges 50 and the side edges of end section 40, while also rounding the corners between terminating edge 51 and the side edges of end section 42. It has been found that this construction provides enhanced ease of assembly of the cable member in sleeve member 22.
[0114] As discussed above, one of the features incorporated into arm members 37 and 38 to provide the desired securement of an electrical cable therewith is the incorporation of two separate and distinct sloping sections in each arm member. In this embodiment, the sloping construction is further enhanced by providing different slope angles for each intermediate section of each arm member, as well as providing different slope angles for each end section of each arm member.
[0115] As clearly depicted in FIGS. 24 and 25, in this embodiment, intermediate section 39 of arm member 37 slopes inwardly from inner surface 36, or outer surface 35, of sleeve member 22 at an angle designated “A2”, while intermediate section 41 of arm member 38 slopes inwardly from surface 36 of sleeve member 22 at an angle designated “A1”. Furthermore, end section 40 of arm member 37 slopes inwardly from inner surface 36 of sleeve member 22 at an angle designated “B2”, while end section 42 of arm member 38 slopes inwardly from inner surface 36 of sleeve member 22 at an angle designated “B1”.
[0116] By employing this construction, arm members 37 and 38 are off-center within sleeve member 22, with arm member 37 being positioned close to inner surface 36 of sleeve member 22, while arm member 38 extends inwardly into sleeve member 22 a substantially greater extent than arm member 37, being substantially spaced away from inner surface 36. As a result, arm member 37 is substantially rigid and inflexible, while arm member 38 is substantially more flexible, and capable of being pivoted through greater arcuate distances. In this way, sleeve member 22 of this embodiment is able to accommodate electrical cables having substantially varied diameters, with the arcuate flexibility of arm member 38 accommodating different cable dimensions while enabling each cable, regardless of its diameter, to be securely mounted in captured engagement with arm members 37 and 38.
[0117] In addition to employing different slope angles for each section of each arm member, this embodiment of the present invention also employs different overall lengths for intermediate sections 39 and 41. As clearly depicted in FIG. 3, intermediate section 41 of arm member 38 comprises a substantially greater length than intermediate section 39 of arm member 37. As a result of this construction, the arcuate pivotabilty of arm member 38 is enhanced while the rigid, generally immovable construction of arm member 37 is further assured.
[0118] By referring to FIGS. 26-34, along with the following detailed disclosure, the construction of a further alternate preferred embodiment of electrical cable connector 20 of the present invention can best be understood. In this alternate embodiment, cable connector 20 of the present invention comprises two separate and independent components, consisting of housing 21 and sleeve member 22. As detailed herein, by employing this embodiment, the necessity of employing locking ring 23, as detailed above, is completely eliminated.
[0119] In the preferred construction of this alternate embodiment, housing 21 comprises a substantially hollow cylindrical shape incorporating outer surface 101, inner surface 102, and wall 103 formed at one end of housing 21. In addition, a single, radially extending flange 104 is formed on outer surface 101 of housing 21, with flange 104 radially extending outwardly from surface 101 a distance greater than the conventional diameter of the knockout plugs or receiving holes formed in conventional junction boxes or outlet boxes.
[0120] Furthermore, in this embodiment, housing 21 incorporates a plurality of apertures or opened zones 105 formed in outer surface 101, peripherally surrounding the portion of housing 21 formed between flange 104 and end wall 103. In the preferred construction, apertures 105 are formed adjacent each other, spaced in substantially equal distances from each other.
[0121] In addition, longitudinally extending channels 106 are formed in housing 21, with each channel 106 being longitudinally aligned with one aperture 105. As is more fully detailed below, by incorporating channels 106 in this aligned position with apertures 105, locking means are capable of being easily inserted into housing 21 and placed in engagement with apertures 105 as detailed below.
[0122] As shown in FIG. 28, housing 21 is quickly and easily inserted into receiving hole 29 formed in a junction box and/or outlet box 30 by constructing the outer diameter of housing 21 adjacent end wall 103 with a diameter which the enables the easy passage of housing 21 through receiving hole 29 as formed in junction box and/or outlet box 30. In addition, since flange 104 comprises a diameter which is greater than the diameter of receiving hole 29, flange 104 abuts the surface of junction box and/or outlet box 30 when end wall 103 and its adjacent section have passed through receiving hole 29. As is more fully detailed below, locking tabs formed on inner sleeve 22 provide the secure locking interengagement of cable connector 20 with junction box and/or outlet box 30.
[0123] In the preferred construction of this embodiment of the present invention, as shown in FIGS. 26-34, inner sleeve member 22 of cable connector 20 is constructed in a substantially hollow cylindrical shape which is defined by outer surface 110, inner surface 111, and terminating ends 112 and 113. In addition, the outer diameter of sleeve member 22, as defined by outer surface 110, is constructed substantially equivalent to the diameter of the inner surface 102 of housing 21. In this way, inner sleeve member 22 is securely affixed to housing 21 by a press fit or by frictional engagement between outer surface 110 of sleeve member 22 and inner surface 102 of housing 21.
[0124] In the preferred construction, the frictional engagement established between inner sleeve member 22 and housing 21 is constructed to exceed all force requirements imposed upon cable connectors. In this way, trouble-free, secure engagement of an electrical cable with connector 20 is assured.
[0125] As is well known in the art, other methods can be employed for providing interengagement of inner sleeve member 22 with housing 21 other than the preferred embodiment of frictional engagement. As shown in FIGS. 15-25, alternate engagement systems have been fully detailed above. If desired, these alternate engagement systems can be employed with equal efficacy.
[0126] In addition, as further detailed below, the present invention also incorporates a locking arrangement integrally formed as part of the overall construction of this embodiment of cable connector 20. In this construction, inner sleeve member 22 is lockingly engaged with housing 21 automatically upon assembly of the components. However, further secure engagement means as detailed above can also be employed.
[0127] In order to provide secure, locking, movement-free engagement of any desired electrical cable with cable connector 20 of the present invention, this embodiment of inner sleeve member 22 is constructed in a strikingly unique manner, incorporating both a plurality of cable gripping elements and locking tabs integral formed thereon. As a result of this construction, a quickly assembled, trouble-free, highly desirable cable connector system is realized. By referring to the following detailed discussion, along with FIGS. 26-34, the construction and operation of this embodiment of cable connector 20 of the present invention can best be understood as well as the construction of the components forming cable connector 20.
[0128] In the preferred construction of this embodiment of the present invention, inner sleeve member 22 comprises, in addition to its substantially cylindrical shape, at least two arm members 114 and 115 which extend inwardly from inner surface 111 of sleeve member 22. Each arm member 114 and 115 may be constructed in a virtually identical manner to any of the alternate constructions detailed above for the arm members formed on the alternate embodiments of the present invention. It is to be understood that the foregoing detailed disclosure, wherein numerous alternate constructions for arm members were clearly depicted and fully discussed, is incorporated herein by reference and is employed in this embodiment of the present invention with equal force and effect. As a result, all of the unique features detailed above in regard to the arm members has equal applicability to the arm members of this embodiment of inner sleeve member 21.
[0129] In FIG. 32A, a further alternate construction for the arm members employed in the sleeve member of the present invention is depicted. In this embodiment, arm member 114 is bifurcated into two substantially separate and independent components 114A and 114B. Preferably, when this embodiment is employed, arm member 115 is constructed in a substantially identical manner.
[0130] It has been found that increased flexibility and locking interengagement is attained by incorporating this embodiment for arm members 114 and 115. However, as discussed above, each of the other alternate embodiments for the construction of the arm members can be employed with substantial equal efficacy. Furthermore, this embodiment of arm members 114 and 115 may also be incorporated in each of the other embodiments detailed above.
[0131] The principal unique and strikingly different feature incorporated into inner sleeve member 22 of this embodiment of the present invention is the formation of a plurality of outwardly extending locking tabs 120 integrally formed on inner sleeve member 22 directly adjacent terminating edge 113. In the preferred embodiment, fully integrated, one-piece sleeve member 22 is achieved with locking fingers 114 and 115 formed therein in combination with a plurality of locking tabs 120 formed peripherally surrounding inner sleeve member 22, with each locking tab 120 being preferably spaced substantially equidistant from each adjacent locking tab 120.
[0132] In addition, in the preferred construction, each locking tab 120 is independently formed on outer surface 110 of sleeve member 22 securely affixed thereto at end 121 of locking tab 120. Furthermore, each locking tab 120 radially extends outwardly from edge 121, with an acute, angular slope, terminating at edge 122. In the preferred construction, each locking tab 120 incorporates a central portion 123 and wing members 124 which are preferably formed along the side edges of central portion 123 and angularly extend therefrom. Finally, in the preferred construction, central portion 123 of each locking tab 120 terminates with a tip 125.
[0133] In the preferred construction, radially extending locking tabs 120 are formed by stamping the desired configuration from the material from which sleeve member 22 is formed, with each locking tab 120 being bent outwardly from the surface of sleeve member 22 into the desired angular relationship. As depicted, and further detailed below, each locking tab 120 angularly extends outwardly away from terminating edge 113 in order to provide the desired locking engagement in apertures 105 of housing 21, as well as the secure locked engagement with the knockout plugs or receiving holes formed in conventional junction boxes or outlet boxes.
[0134] If desired, sleeve member 22 may be constructed using a wide variety of alternate construction methods. However, in the preferred construction method, in order to achieve an easily manufactured and inexpensive product, sleeve member 22 is constructed from a substantially flat metal stamping which is rolled into the desired cylindrical shape. For the reasons detailed below, the use of metal for sleeve member 22 is preferred. In order to assist in achieving the desired diameter, as well as provide locking engagement of abutting edges 126 and 128 of cylindrically shaped sleeve member 22, edge 126 of sleeve member 22 incorporates a plurality of extending tabs or fingers 127 which are configured for mating engagement in receiving cavities 129 of edge 128.
[0135] Once sleeve member 22 is formed in the desired manner, as detailed above, cable connector 20 is assembled by telescopically inserting sleeve member 22 into housing 21. In order to achieve the secure, locked interengagement of sleeve member 22 with housing 21, locking tabs 120 are aligned with longitudinally extending channels 106 of housing 21 and then sleeve member 22 is telescopically advanced into engagement with housing 21.
[0136] During this telescopic assembly, locking tabs 120 are flexed downwardly towards outer surface 110 of sleeve member 22 and slidingly advanced along the channels 106 until locking tabs 120 are brought into alignment with apertures 105 of housing 21. Once locking tabs 120 are advanced into juxtaposed, spaced alignment with apertures 105, the inherent spring force of each locking tab 120 causes locking tab 120 to be flexed outwardly into its original position, causing locking tabs 120 to extend outwardly from apertures 105. When in this position, locking tabs 120 are capable of providing the desired secure, locking engagement with any desired knockout plug or receiving hole 29 formed in conventional junction boxes or outlet boxes 30.
[0137] In order to assure that sleeve member 22 is advanced into axial alignment with housing 21 a sufficient distance which will enable locking tabs 120 to be positioned in alignment with apertures 105, housing 21 incorporates ledge 130, which radially extends inwardly from inner wall 102 at the base of housing 21, directly adjacent end wall 103. By incorporating ledge 130, a positive abutment stop is achieved for terminating end 113 of sleeve member 22. Consequently, when sleeve member 22 is axially inserted into housing 21, with terminating end 113 being brought into contact with ledge 130, assurance is provided that sleeve member 22 is longitudinally inserted into housing 21 to the precisely desired position.
[0138] By employing this embodiment of cable connector 20, a cable connector is attained which is constructed from two components which are quickly and easily assembled into a fully completed, securely locked, interengaged construction. In this embodiment, locking tabs 120 provide sufficient secure engagement of sleeve member 22 with housing 21. However, if desired, frictional engagement may also be employed, as well as any other desired mechanical locking system.
[0139] Whichever fastening system is employed, if any, a cable connector is realized which reduces the number of components typically required for forming an effective cable connector, while also achieving a fully assembled cable connector which is ready for immediate use, without any further subassembly by the user. In addition, the cable connector of the present invention also provides secure locking engagement of the cable member by locking fingers 114 and 115, in order to assure secure mounting and holding engagement of any desired metal clad cable.
[0140] Another feature provided by this embodiment of the present invention is the assurance that electrical continuity or grounding capability is established between the metal clad cable and the junction box and/or outlet box to which cable connector 20 is mounted. With most prior art products, multi-components constructions are employed in order to achieve a viable product. As a result, electrical conductivity must be established between each of these components to assure proper operation of the electrical cable after installation. In many instances, the desired conductivity is not provided.
[0141] By employing the present invention, electrical conductivity is automatically assured by the inherent construction of this embodiment of the cable connector, since the same component engages the metal clad cable and the junction box and/or outlet box. In addition to the benefits detailed above by employing this embodiment of the present invention, this additional feature, which employs a single component for engaging the outer surface of the metal clad cable as well as engaging the metal surfaces of the junction box and/or outlet box, establishes a unique construction which satisfies all industry requirements and achieves substantially improved and enhanced performance capabilities.
[0142] In the present invention, electrical conductivity is assured by employing conductive materials, such as metal, for forming sleeve member 22. In addition, locking tabs 120 are constructed for providing the dual purpose of locking mounting cable connector 20 to any desired junction box or outlet box while also maintaining electrical or conductive contact with the junction box and/or outlet box. This dual function is achieved by the construction employed for locking tabs 120.
[0143] As detailed above and shown in the drawings, each locking tab 120 comprises a central portion 123, wing members 124 formed along the side edges of central portion 123, and angularly extending therefrom, and terminating at its free end with a tip 125. By employing this construction, the secure, locking interengagement of cable connector 20 with any desired junction box and/or outlet box is achieved, as well as assuring that the desired electrical conductivity is established.
[0144] By referring to FIG. 28, along with the following detailed discussion, the engagement of locking tabs 120 in receiving hole 29 of junction box and/or outlet box 30 can best be understood. Whenever cable connector 20 is to be mounted to any desired junction box and/or outlet box 30, cable connector 20 is telescopically inserted through receiving hole 29. By advancing end wall 103 of housing 21 of cable connector 20 through receiving hole 29, cable connector 20 is able to be inserted into hole 29 until flange 104 abuts the surface of the junction box and/or outlet box 30.
[0145] In addition, as cable connector 20 is telescopically inserted into receiving hole 29, locking tabs 120 flex downwardly, enabling wings 124 of locking tabs 120 to enter receiving hole 29. By properly positioning radially extending flange 104 relative to aperture 105, the telescopic insertion of cable connector 20 is terminated simultaneously with the complete insertion of wings 124 of locking tabs 120, while also assuring that terminating tips 125 of each locking tab 120 remains within the plane defined by receiving hole 29.
[0146] As a result, once wings 124 have entered through receiving hole 29, the inherent spring forces of locking tabs 120 cause locking tabs 120 to return to their original position. As a result of this movement, the terminating edges of wings 124 abut the side wall of cable box and/or junction box 30, while terminating tip 125 is brought into direct contact with the inside diameter forming edge of receiving hole 29.
[0147] As is evident from this construction and operation, axial removal of cable connector 20 from receiving hole 29 is prevented, due to the locking engagement of wings 124 with the side wall of cable box and/or outlet box 30. Furthermore, the desired electrical conductivity is established by contacting engagement of terminating tip 125 with the edge of receiving hole 29.
[0148] In addition, since inner sleeve member 22 comprises a one-piece construction which incorporates both locking tabs 120 and arm members 114 and 115, which are directly engaged with the metal clad cable, any desired electrical conductivity to be established between the electrical cable and outlet box and/or junction box 30 is provided inherently by the construction and mounting of cable connector 20. Furthermore, the engagement of tip 125 with the edge of receiving hole 29 also causes cable connector 20 to be automatically centered in receiving hole 29.
[0149] By referring to FIGS. 35-39, along with the following detailed disclosure, the construction of an alternate embodiment of electrical cable connector 20 of FIGS. 26-34 can best be understood. In this alternate embodiment, as detailed above, cable connector 20 comprises two separate and independent components, consisting of housing 21 and sleeve member 22. As detailed herein, by employing this embodiment, the necessity of employing locking ring 23, detailed above, is completely eliminated.
[0150] In the preferred construction of this alternate embodiment, housing 21 comprises a substantially hollow cylindrical shape incorporating outer surface 101, inner surface 102, and wall 103 formed at one end of housing 21. In addition, a single, radially extending flange 104 is formed on outer surface 101 of housing 21, with flange 104 radially extending outwardly from surface 101 a distance greater than the conventional diameter of the knockout plugs or receiving holes formed in conventional junction boxes or outlet boxes.
[0151] Furthermore, in this embodiment, housing 21 incorporates a plurality of apertures or opened zones 105 and 140 formed in outer surface 101, peripherally surrounding the portion of housing 21 formed between flange 104 and end wall 103. In the preferred construction, apertures 105 and 140 are formed adjacent each other, spaced in substantially equal distances from each other. As shown in FIGS. 36-37, four apertures 105 are formed in housing 21, while two apertures 140 are formed in housing 21. As is evident from this disclosure, any desired number of apertures 105 and 140 may be employed.
[0152] In addition, longitudinally extending channels 106 are formed in housing 21, with each channel 106 being longitudinally aligned with one aperture 105. By incorporating channels 106 in this aligned position with apertures 105, locking means are capable of being easily inserted into housing 21 and placed in engagement with apertures 105 as detailed below.
[0153] In the preferred construction of this embodiment of the present invention, inner sleeve member 22 of cable connector 20 is constructed in a substantially hollow cylindrical shape which is defined by outer surface 110, inner surface 111, and terminating ends 112 and 113. In addition, the outer diameter of sleeve member 22, as defined by outer surface 110, is constructed substantially equivalent to the diameter of the inner surface 102 of housing 21. In this way, inner sleeve member 22 is securely affixed to housing 21 by a press fit or by frictional engagement between outer surface 110 of sleeve member 22 and inner surface 102 of housing 21.
[0154] In the preferred construction, the frictional engagement established between inner sleeve member 22 and housing 21 is constructed to exceed all force requirements imposed upon cable connectors. In this way, trouble-free, secure engagement of an electrical cable with connector 20 is assured.
[0155] As is well known in the art, other methods can be employed for providing interengagement of inner sleeve member 22 with housing 21 other than the preferred embodiment of frictional engagement. As shown in FIGS. 15-25, alternate engagement systems have been fully detailed above. If desired, these alternate engagement systems can be employed with equal efficacy.
[0156] In addition, as discussed above, the present invention also incorporates a locking arrangement integrally formed as part of the overall construction of this embodiment of cable connector 20. In this construction, inner sleeve member 22 is lockingly engaged with housing 21 automatically upon assembly of the components. However, if desired, further secure engagement means can also be employed.
[0157] In order to provide secure, locking, movement-free engagement of any desired electrical cable with cable connector 20 of the present invention and trouble-free mounting of connector 20 in a receiving housing or box, this embodiment of inner sleeve member 22 is constructed in a strikingly unique manner, incorporating (1) a plurality of cable gripping elements, (2) locking tabs, and (3) grounding/conductivity tabs, all of which are integrally formed as a part of sleeve member 22. As a result of this construction, a quickly assembled, trouble-free, highly desirable cable connector system is realized. By referring to the following detailed discussion, along with FIGS. 35-39, the construction and operation of this embodiment of cable connector 20 of the present invention can best be understood as well as the construction of the components forming this embodiment of cable connector 20.
[0158] In the preferred construction of this embodiment of the present invention, inner sleeve member 22 comprises, in addition to its substantially cylindrical shape, at least two arm members 114 and 115 which extend inwardly from inner surface 111 of sleeve member 22. Each arm member 114 and 115 may be constructed in a virtually identical manner to any of the alternate constructions detailed above for the arm members formed on the alternate embodiments of the present invention. It is to be understood that the foregoing detailed disclosure, wherein numerous alternate constructions for arm members were clearly depicted and fully discussed, is incorporated herein by reference and is employed in this embodiment of the present invention with equal force and effect. As a result, all of the unique features detailed above in regard to the arm members has equal applicability to the arm members of this embodiment of inner sleeve member 21.
[0159] In the preferred construction, this embodiment of inner sleeve member 22 incorporates a plurality of outwardly extending locking tabs 120 integrally formed on inner sleeve member 22 directly adjacent terminating edge 113, as detailed above. In addition, in the preferred embodiment, fully integrated, one-piece sleeve member 22 also incorporates a plurality of outwardly extending grounding/conductivity tabs 141 integrally formed on inner sleeve member 22 directly adjacent terminating edge 113, in spaced relationship to locking tabs 120.
[0160] In the embodiment depicted in FIGS. 35-39, sleeve member 22 incorporates two separate and independent grounding/conductivity tabs 141, diametrically mounted thereto, in cooperating relationship with four locking tabs 120 formed in juxtaposed, spaced, cooperating relationship with each other and with grounding/conductivity tabs 141. This embodiment is depicted as an alternate construction to the embodiment detailed above in reference to FIGS. 26-34, where three separate and independent locking tabs 120 are employed.
[0161] If desired, this construction can also be employed in combination with grounding/conductivity tabs 141 in accordance with this embodiment of the present invention. However, if three locking tabs 120 are employed, three separate and independent grounding/conductivity tabs 141 are preferably employed therewith, equally spaced between adjacent locking tabs 120.
[0162] As depicted in FIGS. 35-39, grounding/conductivity tabs 141 are independently formed on outer surface 110 of sleeve member 22 securely affixed thereto at proximal edge 142 of grounding/conductivity tabs 141. Furthermore, each grounding/conductivity tab 141 radially extends outwardly from proximal edge 142 with a smooth, continuous, arcuately curved shaped, terminating with distal edge 143. As is more fully detailed below, each grounding/conductivity tab 141 is specifically constructed for providing secure, contact and engagement with the edge or corner of the receiving hole or portal 29 formed in the junction box and/or outlet box 30 into which connector 20 is mounted. In this way, the required grounding and electrical conductivity of connector 20 with junction box/outlet box 30 is assured.
[0163] In the preferred construction, outwardly extending grounding/conductivity tabs 141 are formed by stamping the desired configuration from the material from which sleeve member 22 is formed, with each grounding/conductivity tab 141 being bent in an outwardly extending curved shape. As depicted, and further detailed below, each grounding/conductivity tab 141 extends outwardly away from terminating edge 113 in order to protrude through apertures 140 of housing 21, while also contacting or engaging the edge of knockout plug or receiving hole formed in junction boxes or outlet boxes 30 to provide grounding of connector 20 therewith.
[0164] Sleeve member 22 may be constructed using a wide variety of alternate construction methods. However, as detailed above, in the preferred construction method, in order to achieve an easily manufactured and inexpensive product, sleeve member 22 is constructed from a substantially flat metal stamping which is rolled into the desired cylindrical shape, with the mating side edge constructed to provide the desired diameter Once sleeve member 22 is formed in the desired manner, as detailed above, cable connector 20 is assembled by telescopically inserting sleeve member 22 into housing 21. In order to achieve the secure, locked interengagement of sleeve member 22 with housing 21, locking tabs 120 are aligned with longitudinally extending channels 106 of housing 21 and then sleeve member 22 is telescopically advanced into engagement with housing 21.
[0165] During this telescopic assembly, locking tabs 120 are flexed downwardly towards outer surface 110 of sleeve member 22 and slidingly advanced along the channels 106 of inside surface 102 until locking tabs 120 are brought into alignment with apertures 105 of housing 21, with grounding/conductivity tabs 141 are aligned with apertures 140. Once locking tabs 120 are advanced into juxtaposed, spaced alignment with apertures 105 and grounding/conductivity tabs 141 are aligned with apertures 140, the inherent spring force of each locking tab 120 and grounding/conductivity tab 141 causes tabs 120 and 141 to be flexed outwardly into their original position, causing locking tabs 120 to extend outwardly from apertures 105, while grounding/conductivity tabs 141 extend outwardly through apertures 140.
[0166] When in this position, locking tabs 120 are capable of providing the desired secure, locking engagement with any desired knockout plug or receiving hole 29 formed in conventional junction boxes or outlet boxes 30, and grounding/conductivity tabs 141 provide the desired frictional contact with the edge of plug/hole 29, providing the desired grounding of connector 20. In addition, grounding/conductivity tabs 141 also provide a pre-loaded, spring-biased engagement of connector 20 in plug/hole 29, maintaining a spring force on the inside surface of junction/outlet box 30, causing flange 104 to be held in contact with the outside surface of junction/outlet box 30.
[0167] By employing this embodiment of cable connector 20, a cable connector is attained which is constructed from two components which are quickly and easily assembled into a fully completed, securely locked, interengaged construction. In this embodiment, locking tabs 120 and grounding/conductivity tabs 141 provide sufficient secure engagement of sleeve member 22 with housing 21. However, if desired, frictional engagement may also be employed, as well as any other desired mechanical locking system.
[0168] Whichever fastening system is employed, if any, a cable connector is realized which reduces the number of components typically required for forming an effective cable connector, while also achieving a fully assembled cable connector which is ready for immediate use, without any further subassembly by the user. In addition, the cable connector of the present invention also provides secure locking engagement of the cable member by locking fingers 114 and 115, in order to assure secure mounting and holding engagement of any desired metal clad cable.
[0169] Another feature provided by this embodiment of the present invention is the assurance that electrical continuity or grounding capability is established between the metal clad cable and the junction box and/or outlet box to which cable connector 20 is mounted. With most prior art products, multi-components constructions are employed in order to achieve a viable product. As a result, electrical conductivity must be established between each of these components to assure proper operation of the electrical cable after installation. In many instances, the desired conductivity is not provided.
[0170] By employing the present invention, electrical conductivity is automatically assured by the inherent construction of this embodiment of the cable connector, since the same component engages the metal clad cable and the junction box and/or outlet box. In addition to the benefits detailed above by employing this embodiment of the present invention, this additional feature, which employs a single component for engaging the outer surface of the metal clad cable as well as engaging the metal surfaces of the junction box and/or outlet box, establishes a unique construction which satisfies all industry requirements and achieves substantially improved and enhanced performance capabilities.
[0171] In the present invention, electrical conductivity is assured by employing conductive materials, such as metal, for forming sleeve member 22. In addition, in this embodiment, grounding/conductivity tabs 141 are employed and are constructed for maintaining electrical or conductive contact with the junction box and/or outlet box automatically upon installation. In addition, as detailed above, locking tabs 120 also assist in providing and establishing electrical conductivity.
[0172] As shown in FIG. 36, housing 21 is quickly and easily inserted into receiving hole 29 formed in a junction box and/or outlet box 30 by constructing the outer diameter of housing 21 adjacent end wall 103 with a diameter which the enables the easy passage of housing 21 through receiving hole 29 as formed in junction box and/or outlet box 30. In addition, since flange 104 comprises a diameter which is greater than the diameter of receiving hole 29, flange 104 abuts the surface of junction box and/or outlet box 30 when end wall 103 and its adjacent section have passed through receiving hole 29. As fully detailed above, locking tabs formed on inner sleeve 22 provide the secure locking interengagement of cable connector 20 with junction box and/or outlet box 30, while grounding/conductivity tabs 141 securely engage the edge of knock-out plug/receiving hole 29 of junction box and/or outlet box 30, assuring electrical conductivity and grounding is established.
[0173] As shown in the drawings, each grounding/conductivity tab 141 extends outwardly from sleeve 22 with a smooth, continuous, arcuately curved shape. By employing this construction, the secure, contacting engagement of grounding/conductivity tab 141 of cable connector 20 with the inside edge of any receiving-hole 29 of any desired junction box and/or outlet box 30 is automatically achieved, assuring that the desired electrical conductivity and/or grounding is established.
[0174] As shown in FIG. 36, whenever cable connector 20 is mounted in receiving hole 29 of any desired junction box and/or outlet box 30, cable connector 20 is telescopically inserted through receiving hole 29. By advancing end wall 103 of housing 21 of cable connector 20 through receiving hole 29, cable connector 20 is able to be inserted into hole 29 until flange 104 abuts the surface of the junction box and/or outlet box 30.
[0175] In addition, as cable connector 20 is telescopically inserted into receiving hole 29, grounding/conductivity tabs 141 flex downwardly, enabling tabs 141 to enter receiving hole 29. By properly positioning outwardly extending tabs 141 relative to aperture 140, the telescopic insertion of cable connector 20 is terminated simultaneously with the complete insertion of tabs 141, while also assuring that the curved surface of each grounding tab 141 directly contacts the edge of receiving hole 29, providing the desired grounding and electrical conductivity.
[0176] Furthermore, once grounding/conductivity tabs 141 are mounted in engagement with the inside edge of receiving holes 29, as shown in FIG. 36, tabs 141 provide a pre-loaded, spring biasing securement of connector 20 to box 30. As detailed above, each grounding/conductivity tab 141 comprises a smooth, continuous, arcuately curved member with a portion of the curved member being maintained in engagement with the inside edge of receiving hole 29 of junction/outlet box 30.
[0177] As a result, grounding/conductivity tabs 141 impart a spring biasing force to connector 20, causing outwardly extending flange 104 of connector 20 to be drawn into secure, abutting engagement with the outside surface of junction/outlet box 30 which peripherally surrounds receiving hole 29, while tabs 141 are maintained in secure contacting engagement-with the inside edge of receiving hole 29. In this way, the secure mounted engagement of connector 20 with any desired junction/outlet box 30 is attained and assured.
[0178] In addition to providing spring biased, secure engagement of connector 20 with any desired junction/outlet box 30, as well as providing the desired grounding and/or electrical conductivity path as detailed above, grounding/conductivity tabs 141 also provide and assure that connector 20 is maintained in an axially aligned, centered position within receiving hole 29. In view of the engagement of grounding/conductivity tabs 141 with the inside edge of receiving hole 29, in combination with the use of at least two grounding/conductivity tabs 141, connector 20 is continuously positioned and maintained in a central, axially aligned position within receiving hole 29.
[0179] As a result, the desired secure mounted engagement of connector 20 with junction/outlet box 30 is effectively provided, along with the establishment and maintenance of the desired grounding and electrical conductivity path. In this way, this embodiment of the present invention clearly provides substantial advances and improvements over prior art constructions.
[0180] By referring to FIGS. 40 and 41, along with the following detailed disclosure, a still further alternate embodiment of the present invention can best be understood. In this embodiment, cable connector 20 is constructed for enabling shielded electrical cable 45 to be securely mounted to any desired electrical box or housing in a manner which provides a moisture tight or rain tight engagement of electrical cable 45 to connector 20 and any desired junction box or housing.
[0181] As is well known in the industry, many installations require shielded electrical cable 45 to be mounted to a desired junction box or housing which is located outdoors, or in an environment where moisture is known to exist. As a result, the embodiment of connector 20 depicted in FIGS. 40 and 41 is constructed in a manner which assures the secure affixation of electrical cable 45 to connector 20 in a completely moisture tight or rain tight manner.
[0182] In the preferred construction of this embodiment, cable connector 20 comprises a housing 21 and an inner sleeve member 22, as is found in the embodiments detailed above, along with locking ring 150, washer 151, gland nut 152, and sealing bushing 153. By employing these components, which are securely interconnected with each other as depicted in FIGS. 40 and 41, a rain/moisture tight connector assembly is realized which is capable of providing all of the benefits detailed above in reference to the connector embodiments of the present invention in a construction which also achieves the desired rain/moisture protection.
[0183] In this embodiment, housing 21 is constructed in a manner which differs from the housing construction detailed above. However, in this embodiment, housing 21 functions in a substantially identical manner, to achieve substantially identical results. In the preferred construction of this embodiment of the present invention, housing 21 comprises a substantially hollow cylindrical shape incorporating outer surface 24 and inner surface 25. In addition, housing 24 incorporates radially extending flange 27 formed on outer surface 24 thereof.
[0184] The principal differences in this embodiment of housing 21, from the construction employed in the connector detailed above, is the incorporation of threaded zones 154 and 155 which are formed on opposite ends of housing 21 in outer surface 24. As depicted, in the preferred embodiment, the diameter of threaded zone 154 is greater than the diameter of threaded zone 155. In addition, threaded zone 154 is constructed for mating threaded engagement with threaded zone 156 of gland nut 152, while threaded zone 155 is constructed for threaded engagement with threads 157 of locking ring 150.
[0185] In this embodiment of the present invention, inner sleeve member 22 of cable connector 20 is constructed in a substantially hollow cylindrical shape which is defined by outer surface 35 and inner surface 36, substantially identically to the constructions detailed above. In addition, in the preferred configuration, the outer diameter of sleeve member 22, as defined by outer surface 35, is constructed substantially equivalent to the diameter of inner surface 25 of housing 21. In this way, inner sleeve member 22 is securely affixed with housing 21 by a press fit or by frictional engagement between outer surface 35 of sleeve member 22 and inner surface 25 of housing 21. The frictional engagement established between inner sleeve member 22 and housing 21 is constructed to exceed all force requirements imposed upon cable connectors. In this way, trouble-free secure engagement of electrical cable 45 with connector 20 is assured.
[0186] As discussed above, although alternate constructions and methods can be employed for providing inter-engagement of inner sleeve member 22 with housing 21, the frictional inter-engagement of sleeve member 22 with housing 21 is preferred. Furthermore, as detailed above, in order to provide secure, locked, movement-free engagement of any desired electrical cable with cable connector 20 of the present invention, inner sleeve member 22 is constructed with a plurality of cable gripping elements integrally associated therewith.
[0187] For exemplary purposes, arm members 37 and 38 are depicted in FIGS. 40 and 41 as representative constructions for cable gripping elements of inner sleeve member 22. However, as is evident from the foregoing detailed discussion, arm members 37 and 38 may be constructed in a wide variety of alternate configurations in accordance with the various embodiments forming a part of the teaching of this present invention, with any of these alternate constructions being employable in this further alternate embodiment of the present invention.
[0188] In this embodiment, as with the embodiments detailed above, inner sleeve member 22 is inserted into housing 21 for being securely, frictionally engaged and retained in housing 21. Once in this position, sleeve member 22 is securely retained in housing 21, incapable of being removed with normal forces. Whenever desired, electrical cable 45 is inserted through portal 160, formed directly adjacent threaded zone 154, and advanced into sleeve member 22, a sufficient distance to cause arm members 37 and 38 to engage the outer peripheral surface of cable 45. Once assembled therein, cable 45 is incapable of being withdrawn from sleeve member 22 and is securely affixed to sleeve member 22, housing 21, and, as result, connector 20.
[0189] In this embodiment, in order to provide the desired moisture tight or rain tight engagement of cable 45 with connector 20, cylindrically shaped, sealing bushing 153 and gland nut 152 are mounted on electrical cable 45 prior to inserting cable 45 into sleeve member 22 and housing 21. As shown in. FIG. 40, once cable 45 has been inserted into engagement with arms 37 and 38, sealing bushing 153 is forced through portal 160 of housing 21 with threaded zone 156 of gland nut 152 being threadedly engaged with threaded zone 154 of housing 21.
[0190] With gland nut 152 and sealing bushing 153 securely mounted in place, sealing bushing 153 is compressed into frictional engagement with cable 45, peripherally surrounding cable 45 and effectively sealing the outer peripheral surface of cable 45 with portal 160. As a result, any moisture or rain which would otherwise enter through portal 160 is substantially reduced or effectively eliminated. In this way, the desired moisture tight or rain tight securement of electrical cable 45 with connector 20 is realized.
[0191] In order to assure the sealing engagement of cable 45 with connector 20, sealing bushing 153 is preferably formed from material suitable for providing both deformation, compressibility, and sealing co-operation with cable 45. In this regard, it has been found that nonconductive elastomeric materials such as rubber-based products, or thermoplastic elastomers can be effectively employed to achieve the desired results. As is evident from this disclosure, the actual material employed for sealing bushing 153 may be selected from a wide variety of alternate compositions, with the only limitation being the use of a material which is capable of compressively surrounding cable 45 and cooperating with cable 45 to effectively seal portal zone 160 between cable 45 and housing 21.
[0192] Once cable 45 has been sealingly mounted to connector 20 in the manner detailed above, the assembly is completed by mounting connector 20 to the desired junction box or housing. Typically, each junction box or housing incorporates a plurality of apertures formed therein, or knock-out plugs for aperture selection. When the desired aperture is located, terminating end 161 of connector 20 is axially advanced through the desired aperture.
[0193] With radially extending flange 27 constructed with a diameter greater than the diameter of the aperture of the junction box or housing, flange 27 prevents connector 20 from advancing into the aperture by abutting the side wall of the junction box or housing. In addition, in this embodiment, sealing washer 151 is mounted in threaded zone 155 of housing 21 prior to mounting connector 20 to the junction box or housing. In this way, as shown in FIG. 40, washer 151 abuttingly contacts the outside wall of the junction box or housing instead of flange 27.
[0194] In the preferred embodiment, sealing washer 151 is constructed with soft, compressible material securely affixed or bonded to its side edges. This soft compressible material forms a seal with the side wall of the junction box or housing preventing moisture or rain from entering through the aperture in which connector 20 is mounted. In this way, further protection against rain and moisture is achieved.
[0195] In order to securely affix connector 20 to the desired junction box or housing, locking ring 150 is employed. Once connector 20 is mounted in place, as detailed above, locking ring 150 is threadedly advanced onto threaded zone 150 of housing 21 by engaging threads 157 of ring therewith. Then, ring 150 is advanced into secure engagement with the inside wall of junction box/housing securely mounting connector 20 in the desired location. In addition, by employing the construction detailed above, connector 20 is secured in a manner which provides rain/moisture tight mounting of cable 45.
[0196] It has also been found that any of the embodiments of connector 20 detailed in this disclosure can be employed by preassembling connector 20 with any desired, predetermined length of electrical cable 45. In this construction, a predetermined or desired length of electrical cable 45 is cut and connector 20 is assembled by axially engaging sleeve 22 into housing and 21. In accordance with the teaching of the present invention, any of the embodiments detailed above for housing 21 and sleeve 22 can be employed for this preassembled product, including the use of sealing bushing 153 if so desired.
[0197] Once the precisely desired connector 20 has been assembled and a predetermined length of electrical cable 45 has been determined and cut, one end of electrical cable 45 is trimmed to expose a desired length of the wires contained therein. Then, the end of cable 45 with the exposed wires is axially advanced into the leading end of connector 20, until the wires extend outwardly from the trailing end of connector 20 with the metal clad portion of cable 45 securely mounted in sleeve 21 of connector 20, with the internal engaging arms thereof securely engaged with the outside surface of cable 45.
[0198] Once this process is completed, a pre-manufactured, ready to install assembly of a connector/cable system is attained, ready for sale and/or transportation to any desired location for use. Once this preassembled connector/cable system reaches a desired installation site, the user merely needs to telescopically advance connector 20 into any desired junction/outlet box, in the manner detailed above, securely affixing connector 20 to the junction box. Then, the wires contained in cable 45 are installed in the normal manner and the entire assembly process is quickly, rapidly, and easily completed.
[0199] As is evident from the foregoing detailed disclosures, the present invention is capable of being manufactured in numerous alternate embodiments, with each alternate embodiment incorporating a wide variety of alternate construction details. However, as is clearly evident to one having ordinary skill in this art, the various construction details can be freely employed with any other embodiment, thereby further increasing the possible alternate constructions for the present invention which come within the scope of this discovery. Consequently, it is to be understood that the various embodiments detailed herein, along with the construction details thereof, are all provided for exemplary purposes, and that alternate combinations of features, elements, an arrangement of parts and components can be achieved without departing from the scope of this invention.
[0200] It will thus be seen that the object set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above article without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0201] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
Claims
Having described my invention, what I claim as new and desire to secure by Letters Patent is:
1. An electrical connector for securely engaging and mounting an electrical cable to a receiving box or plate having a receiving hole formed therein, said electrical connector comprising:
whereby an electrical connector is achieved which is quickly and easily assembled and securely mounted to any desired box or plate, providing electrical conductivity and grounding.
A. a housing having
a. a generally hollow cylindrical shape defined by an outer wall, an inner wall, and two terminating ends,
b. at least one flange mounted about the outer wall of the housing, radially extending outwardly therefrom, and comprising a diameter greater than the diameter of the receiving hole formed in the receiving box/plate, and
c. a plurality of apertures formed in the housing in peripherally surrounding, juxtaposed, spaced relationship to each other, positioned between the flange and the adjacent terminating end; and
B. an inner sleeve member comprising
a. a substantially hollow, substantially cylindrical shape, having an inner surface, an outer surface, and two terminating ends, dimensioned for mating, engagement within the inner wall of the housing to form a substantially integral construction therewith,
b. a pair of arm members extending inwardly from the inner surface of the sleeve member and positioned for mating engagement and securement with an electrical cable when inserted therein, and
c. a plurality of grounding/conductivity tabs formed about the outer surface of the sleeve member in peripherally surrounding, juxtaposed, spaced relationship to each other, positioned directly adjacent one of said two terminating ends of said inner sleeve member and angularly extending outwardly from the outer surface of the sleeve member and positioned for extending through the apertures formed in the housing;
2. An electrical connector for securely engaging and mounting an electrical cable to a receiving box or plate having a receiving hole formed therein, said electrical connector comprising:
whereby an electrical connector is achieved which is quickly and easily assembled and securely mounted to any desired box or plate, providing secure, mating, locked engagement with an electrical cable mounted therewith while also assuring electrical conductivity and/or grounding.
A. a housing having
a. a generally hollow cylindrical shape defined by an outer wall, an inner wall, and two terminating ends,
b. at least one flange mounted about the outer wall of the housing, radially extending outwardly therefrom, and comprising a diameter greater than the diameter of the receiving hole formed in the receiving box/plate, and
c. a plurality of apertures formed in the housing in peripherally surrounding, juxtaposed, spaced relationship to each other, positioned between the flange and the adjacent terminating end; and
B. an inner sleeve member comprising
a. a substantially hollow, substantially cylindrical shape, having an inner surface, an outer surface, and two terminating ends, dimensioned for mating, engagement within the inner wall of the housing to form a substantially integral construction therewith,
b. a pair of arm members extending inwardly from the inner surface of the sleeve member and positioned for mating engagement and securement with an electrical cable when inserted therein,
c. a plurality of locking tabs formed about the outer surface of the sleeve member in peripherally surrounding, juxtaposed, spaced relationship to each other, positioned directly adjacent one of said two terminating ends of said inner sleeve member, and angularly extending outwardly from the outer surface of the sleeve member, and positioned for extending through the apertures formed in the housing, and
d. a plurality of grounding/conductivity tabs formed about the outer surface of the sleeve member in peripherally surrounding, juxtaposed, spaced relationship to each other, positioned directly adjacent one terminating end thereof, and angularly extending outwardly from the outer surface of the sleeve member and positioned for extending through the apertures formed in the housing;
3. The electrical connector defined in claim 2, wherein at least six apertures are formed in the housing and at least three locking tabs and at least three grounding tabs are formed on the inner sleeve member and positioned for cooperating alignment with the apertures of the housing for extending through the apertures.
4. The electrical connector defined in claim 3, wherein said apertures are formed in the housing substantially equidistant from each other and said locking tabs and grounding tabs are formed on the sleeve member substantially equidistant from each other.
5. The electrical connector defined in claim 2, wherein each of said grounding/conductivity tabs is constructed for
A. flexible movement relative to the outer surface of the sleeve member for enabling telescopic insertion of the sleeve member into the housing and telescopic insertion into the receiving hole of the receiving box or plate, and
B. return to its original position, for providing secure, contacting engagement of the tabs with the edge of the receiving hole of the box or plate.
6. The electrical connector defined in claim 2, wherein each of said grounding/conductivity tabs comprises an elongated, continuous, arcuately curved finger portion affixed at a first end thereof to the inner sleeve member and extending therefrom to a second and terminating free end whereby said grounding/conductivity tab construction is attained which enables said finger portion to continuously contact the edge of the receiving hole providing a grounding/conductivity path while also providing a biased, pre-loaded engagement of the flange with the box/plate.
7. The electrical connector defined in claim 6, wherein said housing further comprises a ledge formed about the inner wall of the housing, radially extending inwardly and positioned between the apertures and the end wall, providing a positive abutment stop for the inner sleeve member when telescopically inserted into the housing.
8. The electrical connector defined in claim 2, wherein the pair of arm members extending inwardly from the inner surface of the sleeve member are each further defined as comprising a first, intermediate, sloping section extending from the sleeve member and a second, sloping, end section extending from the intermediate section at an angle relative thereto, positioned for mating engagement and securement with an electrical cable when inserted therein.
9. The electrical connector defined in claim 8, wherein said electrical cable comprises a curved outer surface and the end section of each of said arm members is further defined as comprising a curved terminating edge constructed for mating, engaged relationship with the surface of the electrical cable.
10. The electrical connector defined in claim 9, wherein the end section of each arm member is further defined as being bifurcated to create two separate and independent finger members formed therein.
11. The electrical connector defined in claim 8, wherein the intermediate section of each arm member of the inner sleeve member is further defined as comprising different axial lengths, whereby said pair of arm members engage the electrical cable at different axial positions thereof.
12. The electrical connector defined in claim 8, wherein the intermediate section of each arm member of the inner sleeve member is further defined as comprising substantially equivalent axial lengths, whereby said arm members engage the electrical cable at substantially equivalent, diametrically opposed positions.
13. An electrical connector for securely engaging and mounting an electrical cable to a receiving box or plate having a receiving hole formed therein, said electrical connector comprising:
whereby an electrical connector is achieved which is quickly and easily assembled and securely mounted to any desired box or plate, providing electrical conductivity/grounding of said connector with said box/plate and secure, mating, locked engagement with an electrical cable mounted therewith.
A. a housing having
a. a generally hollow cylindrical shape defined by an outer wall, an inner wall, and two terminating ends,
b. at least one flange mounted about the outer wall of the housing, radially extending outwardly therefrom, and comprising a diameter greater than the diameter of the receiving hole formed en the receiving box/plate,
c. a plurality of apertures formed in the housing in peripherally surrounding, juxtaposed, spaced relationship to each other, positioned between the flange and the adjacent terminating end;
d. an end wall formed on the terminating end directly adjacent the aperture, said end wall incorporating an enlarged portal hole formed therein, and
e. a ledge, formed about the inner wall of the housing, radially extending inwardly and positioned between the apertures and the end wall; and
B. an inner sleeve member comprising
a. a substantially hollow, substantially cylindrical shape, having an inner surface, an outer surface, and two terminating ends, dimensioned for mating, engagement within the inner wall of the housing to form a substantially integral construction therewith,
b. a pair of arm members extending inwardly from the inner surface of the sleeve member and positioned for mating engagement and securement with an electrical cable when inserted therein, and
c. a plurality of grounding/conductivity tabs
A. formed about the outer surface of the sleeve member in peripherally surrounding, juxtaposed, spaced relationship to each other,
B. positioned directly adjacent one of said two terminating ends of said inner sleeve member,
C. angularly extending outwardly from the outer surface of the sleeve member,
D. affixed at a first end to the inner sleeve member and extending therefrom to a second and terminating free end, and
E. positioned for providing contacting engagement with an edge of the receiving hole of the receiving box/plate,
14. The electrical connector defined in claim 13, wherein the inner sleeve member further comprises:
d. a plurality of locking tabs
1. formed about the outer surface of the sleeve member in peripherally surrounding, juxtaposed, spaced relationship to each other,
2. positioned directly adjacent one of said two terminating ends of said inner sleeve member.
3. angularly extending outwardly from the outer surface of the sleeve member, and
4. affixed at a first end to the inner sleeve member and extending therefrom to a second, terminating free end.
15. The electrical connector defined in claim 14, wherein said ledge is positioned for providing an abutment stop for the inner sleeve member, thereby assuring precise positioning of the sleeve member in said housing.
16. The electrical connector defined in claim 14, wherein the terminating end section of each arm member is further defined as comprising a curved terminating edge constructed for mating, engaged relationship with the outer surface of the electrical cable.
17. An electrical connector for securely engaging and mounting an electrical cable to a receiving box or plate having an aperture formed therein, said connector comprising:
whereby said electrical connector member is achieved which is quickly and easily mounted to any desired box or plate and provides secure, mating, locked and sealed engagement with an electrical cable member when mounted therewith, thereby providing a rain/moisture-tight engagement.
A. a housing having
a. a generally hollow cylindrical shape defined by an outer wall, an inner wall, and a first end and a second end,
b. at least one flange mounted about the outer wall of the housing, radially extending outwardly therefrom in spaced relationship to the first end, and comprising a diameter greater than the diameter of the aperture formed in the receiving box/plate, and
c. a first threaded zone formed in a portion of the outer wall adjacent the second end;
B. a clamping nut constructed for peripherally surrounding the second end of the housing and being threadedly engaged with the threaded zone formed therein;
C. a locking member mounted to the outer wall of the housing in cooperating engagement with the radially extending flange thereof for securing the housing in the aperture of the box/plate;
D. a sealing washer mounted to the outer wall of the housing between the radially extending flange and the locking member, positioned for sealingly engaging the receiving box/plate adjacent the aperture formed therein;
E. an inner sleeve member comprising:
a. a substantially hollow, substantially cylindrical shape, having any inner surface and an outer surface, dimensioned for mating, frictional engagement with the inner wall of the housing to form a substantially integral construction therewith, and
b. a pair of arm members extending inwardly from the inner surface of the sleeve member, with each of said arm members comprising a first, sloping section extending from the sleeve member and a second, sloping, end section angularly extending from the first section at an angle relative thereto and positioned for mating engagement and securement with the electrical cable when inserted therein; and
F. a sealing bushing comprising a generally hollow cylindrical shape, constructed for being inserted into the second end of the housing in contacting, sealing engagement with a portion of the inner wall of the housing, peripherally surrounding and sealingly engaging an electrical cable mounted therein;
18. The electrical connector defined in claim 17, wherein said electrical cable comprises a curved outer surface and the end section of each arm member is further defined as comprising a curved terminating edge constructed for mating, engaged relationship with the surface of the electrical cable and said clamping nut applies a compressive force to the sealing grommet for assuring sealed contact with the outer surface of the cable.
19. The electrical connector defined in claim 18, wherein the end section of each arm member is further defined as being bifurcated to create two separate and independent finger members formed therein.
20. The electrical connector defined in claim 19, wherein each of said separate and independent finger members formed on the end section of each arm member comprises different angular relationships relative to the intermediate section.
21. The electrical connector defined in claim 17, wherein a second threaded zone formed in a portion of the outer wall adjacent the first end, and the locking member comprises a lock nut threadedly mounted to the second threaded zone for being advanced therein into engagement with the wall of the box/plate when the connector is positioned in a receiving hole therein.
22. The electrical connector defined in claim 21, wherein said sealing ring and lock nut are mounted to the second threaded tone after insertion of the connector into the receiving hole and said lock nut is threadedly advanced into engagement with the sealing ring for securely engaging the sealing ring with the wall of the junction/outlet box thereby enhancing the moisture/rain-tight engagement of the connector.
23. A method for fabricating pre-assembled, ready to install connector/cable systems, said method comprising the steps of:
A. forming a plurality of connectors, each comprising:
a. a housing having
1. a generally hollow cylindrical shape defined by an outer wall, an inner wall, and two terminating ends,
2. at least one flange mounted about the outer wail of the housing, radially extending outwardly therefrom, and comprising a diameter greater than the diameter of the receiving hole formed in the receiving box/plate, and
3. a plurality of apertures formed in the housing in peripherally surrounding, juxtaposed, spaced relationship to each other, positioned between the flange and the adjacent terminating end; and
b. an inner sleeve member comprising
1. a substantially hollow, substantially cylindrical shape, having an inner surface, an outer surface, and two terminating ends, dimensioned for mating, engagement within the inner wall of the housing to form a substantially integral construction therewith,
2. a pair of arm members extending inwardly from the inner surface of the sleeve member and positioned for mating engagement and securement with an electrical cable when inserted therein,
3. a plurality of locking tabs formed about the outer surface of the sleeve member in peripherally surrounding, juxtaposed, spaced relationship to each other, positioned directly adjacent one of said two terminating ends of said inner sleeve member, and angularly extending outwardly from the outer surface of the sleeve member, and positioned for extending through the apertures formed in the housing, and
4. a plurality of grounding/conductivity tabs formed about the outer surface of the sleeve member in peripherally surrounding, juxtaposed, spaced relationship to each other, positioned directly adjacent one terminating end thereof, and angularly extending outwardly from the outer surface of the sleeve member and positioned for extending through the apertures formed in the housing;
B. telescopically inserting the sleeve member of each connector into the housing for secure mounted engagement therein;
C. cutting an electrical cable to a plurality of cable members having a desired length;
D. trimming a first end of one cable member to reveal a length of the wires contained therein;
E. telescopically inserting and advancing the first end of said cable member into the receiving end of one of the connectors until the wire extends through the connector and the cable is securely engaged with the holding fingers of the sleeve member forming a fully assembled connector/cable system ready for use;
F. repeating steps D and E until all cable length and connectors are assembled; and
G. transporting the pre-assembled connector/cable system to a desired site for use.
24. The method for fabricating pre-assembled, ready to install connector/cable systems defined in claim 23 comprising the additional steps of:
H. telescopically advancing the connector into a desired junction box or outlet box;
I. securing the connector in position in the desired junction box or outlet box; and
J. completing the installation by connecting the wires in the cable to the desired locations.