Note: Descriptions are shown in the official language in which they were submitted.
CA 02463221 2004-04-05
3 02-211-19-4
TECHNICAL FIELD
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.
CA 02463221 2004-04-05
- 2 - 302-211-19-4
BACKGROUND ART
In the field of wiring homes and buildings, whether for new construction
or for improvements or expansion, substantial development and product im-
provements 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.
In any particular installation or location, various cables must be intercon-
netted to each other as well as connected to the priimary power supply in a
suitable power distributing junction box or fuse bo>c. In each of these
instances,
metal sheath cables, within which the electric powE=r carrying wires are con-
tained, must be securely mounted to the housing of the junction box or outlet
box, or connected to appropriate devices, in a protected area.
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 system<.~ all have drawbacks or
difficulties which prevent their universal adoption and use.
CA 02463221 2004-04-05
- 3 - 302-211-19-4
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.
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.
Therefore, it is a principal object of the present invention to provide a
connector for use with metal sheath cables which provides secure, rapid engage-
ment and retention of the cable in the connector.
Another object of the present invention is to provide a cable connector
having the characteristic features described above which is also quickly and
CA 02463221 2004-04-05
- 4 - 302-211-19-4
easily secured to any desired junction box or outlet box in a manner which
assures secure retained engagement therewith.
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.
Another object of the present invention is to provide a cable connector
having the characteristic features described above vvherein the cable
connector
is capable of being produced and assembled quickly and easily, thereby provid-
ing an inexpensive product.
Another object of the present invention is to provide a cable connector
having the characteristic features described above vvherein the cable
connector
automatically provides grounding and/or an electri<:al flow path through the
junction box or outlet box when mounted thereto.
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.
Another object of the present invention is to provide a cable connector
having the characteristic features described above wherein the cable connector
CA 02463221 2004-04-05
- 5 - 302-211-19-4
is rain and/or moisture tight to enable its use outdoors or in other high
moisture
environments without difficulty.
Other and more specific objects will in part be obvious and will in part
appear hereinafter.
CA 02463221 2004-04-05
- 6 - 302-211-19-4
SUMMARY OF THE INVENTION
By employing the present invention, all of the difficulties and drawbacks
of the prior art systems have been overcome, and an efficient, easily manufac-
turgid 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.
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.
Preferably, the outer housing comprises a generally hollow cylindrical
shape constructed with two spaced, co-axial, radially extending flanges formed
CA 02463221 2004-04-05
- 7 - 302-211-19-4
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.
Patents 5,189,258 and 5,342,994, while other rings are taught in Arlington's
U.S. Patents 6,043,432; 6,080,933; and 6,335,488.
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.
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 anguiarly disposed relative to the arm member in at least
one direction and preferably in two directions. Finally, in the preferred
embodi-
ment, each distal end portion is split in two sections and terminates with an
arcuately curved terminating end.
CA 02463221 2004-04-05
- 8 - 302-211-19-4
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 mem-
ber, 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.
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 t:he 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 arrn member. 8y 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.
> ,."....,.x" > ,..M,>",w..,. ;w,d,"a a", >~",,~~~-~.~."~,u..,;,.,..... ..
.M":,"M..." _ _, ,. .,M,. "", ",
,..,~,x,.c,,~"",.",.,.,___.,_.w_.._..,...._.._....., "",y" ",.yK " ~"am
m""."... _ _ _.... _........_
,. . > ~y,,uru.,~ .. .. ~.a.~.x.:.s.~.r>":.. »--,......
CA 02463221 2004-04-05
- 9 - 302-211-19-4
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 andlor 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.
If desired, the two arm members may be formed at different positions
along the axial length of the sleeve member. In thia way, the cable engaging
end
of each arm member interconnects with the metal <.>heath cable at different
longitudinal spaced locations along the length of the cable.
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
CA 02463221 2004-04-05
- 10 - 302-211-19-4
the optimum area of the cable is provided and completely controlled movement-
free securement of the cable by the inner sleeve is achieved.
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
inde-
pendent locking member.
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.
CA 02463221 2004-04-05
- 11 - 302-211-19-4
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 connec-
for 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 andlor 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.
The invention accordingly comprises an article of manufacture possessing
the features, properties, and the relation of element<.> which will be
exemplified
in the article herewith described, and the scope of the invention will be indi-
Gated in the claims.
CA 02463221 2004-04-05
- 1 ~ - 302-211-19-4
THE DRAWINGS
For a fuller understanding of the nature and c>bjects of the invention,
reference should be had to the following detailed description taken in connec-
tion with the accompanying drawings, in which:
FIGURE 1 is an exploded perspective view oif one embodiment of a fully
assembled electrical cable connector of the present invention;
FIGURES 2 and 3 are perspective views of the fully assembled electrical
cable connector of FIGURE 1;
FIGURE 4 is a side elevation view, partially in cross-section, depicting the
electrical cable connector of FIGURE 1 mounted in a conventional junction box;
FIGURE 5 is a perspective view depicting one preferred embodiment of an
inner sleeve member of the cable connector of the present invention;
FIGURE 6 is a front elevation view of the inner sleeve member of FIGURE
5;
FIGURE 7 is a rear elevation view of the inner sleeve member of FIGURE
5;
FIGURE 8 is a left side elevation view of the inner sleeve member of
FIGURE 5;
CA 02463221 2004-04-05
- 13 - 302-211-19-4
FIGURE 9 is a top plan view of the inner sleeve member of FIGURE 5;
FIGURE 10 is a right side elevation view of the inner sleeve member of
FIGURE 5;
FIGURE 11 is a cross-sectional side elevation view of this embodiment of
the inner sleeve member taken along line 1 1-1 1 of IFIGURE 9;
FIGURE 12 is a cross-sectional side elevation view of this embodiment of
the inner sleeve member taken along line 12-12 of IFiGURE 9;
FIGURES 13 and 14 are perspective views of this embodiment of the fully
assembled electrical cable connector with an electrical cable depicted
therein;
FIGURE 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;
FIGURE 16 is a top plan view of the fully assembled electrical cable
connector of FIGURE 15;
FIGURE 17 is a side elevation view of the fully assembled electrical cable
connector of FIGURE 15;
FIGURE 18 is a perspective view of an altern<~te embodiment of an inner
sleeve member incorporated into the cable connector of the present invention;
CA 02463221 2004-04-05
- 14 - 302-211-19-4
FIGURE 19 is a front elevation view of the inner sleeve member of
FIGURE 18;
FIGURE 20 is a top plan view of the inner sleeve member of FIGURE 18;
FIGURE 21 is a bottom plan view of the inner sleeve member of FIGURE
18;
FIGURE 22 is a side elevation view of the inner sleeve member of FIGURE
18;
FIGURE 23 is a rear elevation view, partially in cross-section, depicting
the inner sleeve member of FIGURE 18 in mounted engagement with the
housing to form this embodiment of the electrical cable connector;
FIGURE 24 is a top plan view of a further altearnate embodiment for the
inner sleeve member of the present invention;
FIGURE 25 is a cross-sectional side elevation view of the inner sleeve
member of FIGURE 24, taken along line 25-25 of FIGURE 24;
FIGURE 26 is an exploded perspective view depicting a still further
alternate embodiment of the cable connector of the present invention;
FIGURE 27 is a perspective view of the fully assembled cable connector of
FIGURE 26;
CA 02463221 2004-04-05
- 15 - 302-211-19-4
FIGURE 28 is a side elevation view, partially in cross-section, depicting
the cable connector of FIGURE 27 mounted in a re<~eiving hole of a conven-
tional j unction box and/or outlet box;
FIGURE 28A is a greatly enlarged, partially broken away, side elevation
view of the cable connector- of FIGURE 28 taken from area "A";
FIGURE 29 is a side elevation view of the housing which forms a compo-
vent of the cable connector of FIGURE 26;
FIGURE 30 is a front end view of the housing of FIGURE 29;
FIGURE 31 is a top plan view of the inner sleeve member which forms a
component of the cable connector of FIGURE 26;
FIGURE 32 is a side view of the inner sleeve member of FIGURE 31;
FIGURE 33 is a front view of the fully assemk>led cable connector of
FIGURE 27;
FIGURE 34 is a cross-sectional side view of the cable connector of
FIGURE 33;
FIGURE 35 is an exploded perspective view .depicting another further
alternate embodiment of the cable connector of the present invention;
CA 02463221 2004-04-05
- 16 - 302-211-19-4
FIGURE 36 is a cross-sectional side elevation view depicting the cable
connector of FIGURE 35 mounted in a receiving hole of a conventional junction
box and/or outlet box;
FIGURE 37 is a rear elevation view of the cable connector of FIGURE 36;
FIGURE 38 is a cross-sectional side elevation view of the inner sleeve
member of FIGURE 36;
FIGURE 39 is a rear elevation view of the inner sleeve member of FIGURE
38;
FIGURE 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
FIGURE 41 is an exploded, cross-sectional side elevation view of the
cable connector of FIGURE 40.
CA 02463221 2004-04-05
- 17 - 302-211-19-4
DETAILED DESCRIPTION
By referring to FIGURES 1-41, along with the following detailed disclo-
sure, the construction and operation of several alternate embodiments of
electri-
cal 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
construc-
tions 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.
As shown in FIGURES 1-4, cable connector 2:0 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 01~~ 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
CA 02463221 2004-04-05
- 18 - 302-211-19-4
other on surface 24 in order to form therebetween a locking ring retaining
zone
28.
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 ~'.6 and 27, free from
axial
dislodgement. In addition, as is well-known in the .art and as shown in
FIGURE 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.
Furthermore, the construction of locking ring 23 engages in junction/
outlet box 30 after passage through receiving hole ~'.9, preventing axial
removal
of housing 21 from junction/outlet box 30. As a result, secure, locked engage-
ment of housing 21 with junction/outlet box 30 is provided in an easily assem-
bled and quickly installed manner.
As fully detailed herein and shown in FIGURES 1-14, inner sleeve mem-
ber 22 of cable connector 20 is constructed in a substantially hollow
cylindrical
shape which is defined by outer surface 35 and innf~r surface 36. In the pre-
CA 02463221 2004-04-05
- 19 - 302-211-19-4
ferred construction, the outer diameter of sleeve member 22, as defined by
outer
surface 35, is constructed substantially equivalent tc~ 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 eingagement 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 requirf=_ments imposed upon
cable
connectors. In this way, trouble-free, secure engagement of an electrical
cable
with connector 20 is assured.
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, FIGURES 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.
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
CA 02463221 2004-04-05
- 20 - 302-211-19-4
gripping elements integrally associated therewith. E3y referring to the
following
detailed discussion, along with FIGURES 1-4, 13 and 14, wherein fully assem-
bled cable connector 20 is disclosed and FIGURES 5-12 wherein inner sleeve
member 22 is separately detailed, the construction and operation of the pre-
ferred embodiment of cable connector 20 of the present invention, with its
uniquely constructed inner sleeve member 22, can best be understood.
In this preferred embodiment, inner sleeve member 22 comprises, in
addition to its substantially cylindrical shape, two airm members 37 and 38
which extend inwardly from inner surface 36 of sleeve member 22. Preferably,
arm member 37 is constructed with a sloping, inten~nediate section 39 and a
sloping, end section 40. Similarly, arm member 38 comprises a sloping, inter-
mediate section 41 and a sloping, end section 42.
As shown in FIGURE 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 insertf=_d 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
CA 02463221 2004-04-05
- 21 - 302-21 1-19-4
are constructed to maximize engagement with cable 45 and assure secure,
movement-free, locked retention of cable 45 in sleeve member 22.
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 FIGURE 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".
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 prefenred for providing optimum
performance, variations can be made without departing from the scope of this
i nvention.
_. . w__ ..~. . ~ ~,~~~.a.~..y. x ...~.a...~ MR F~~_u ~a_~r~~.~,~,w~.~~n.~ ~ .
_
CA 02463221 2004-04-05
- 22 - 302-211-19-4
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.
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 mem-
ber 38 is also bifurcated into two separate and independent finger portions 54
and 55. As fully detailed herein, and shown throughout the drawings, the
........ .. ,~w. . ~~~ .. ...v~,~~.". ~._T ~~","~~,~: t ~
~wv,.~..,~....____~.. . .. __.r...~".. ~,,..w.~..~___..... .__..~ ~~_~...
CA 02463221 2004-04-05
- 23 - 302-211-19-4
incorporation of two separate and independent finger portions as the
terminating
end section of each arm member 37 and 38 providE=s further enhanced secure,
locked interengagement of arm members 37 and 38 with electrical cable 45. In
order to achieve the desired separation, and offset clistance of about 1/8" is
preferred.
As best seen in FIGURES 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 theoeto. 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 FIGURES 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 nar-
rowed portion thereof.
Similarly, terminating edge 51 of finger portions 54 and 55 of arm mem-
ber 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.
CA 02463221 2004-04-05
- 24 - 302-211-19-4
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
embodi-
meet depicted in FIGURES 8-12, bend lines 58 are formed at a slanting acute
angle relative to the side walls of intermediate secti~~n 39. Similarly,
finger
portions 54 and 55 are bent inward late relative to intermediate section 41
along
bend line 58, which is shown in FIGURES 8-12 as k>eing slanted relative to the
side edges of intermediate section 41 forming an acute angle therewith.
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 FIGURES 8-12, a bend
line 58 is depicted in FIGURES 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.
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. Conser~uently, although not
~m,~.
CA 02463221 2004-04-05
- 25 - 302-211-19-4
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 mem-
ber is preferred, with the slope angle preferably matching the slope of the
helical
recess or minor diameter of electrical cable 45.
A further feature incorporated into cable connector 20 of the present
invention is found in the construction of the axial IE~ngth 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.
In the embodiment depicted in FIGURES 8-12, the axial length of interme-
diate section 39 of arm member 37 is shown substantially longer than the axial
length of intermediate section 41 of arm member 3~S. 8y employing this con-
struction, 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
CA 02463221 2004-04-05
- 26 - 302-211-19-4
both arm members 37 and 38 are each in direct, contacting engagement in the
minor diameter or recessed zone of cable 45.
Alternatively, as shown in FIGURE 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 ideintical, diametrically
opposed
position can be desirable and can provide optimum, secure and locked engage-
ment of cable 45. This is particularly true with cable constructions
incorporating
annular, ring-shaped recessed zones which are substantially parallel to each
other.
As detailed above, the embodiment of cable connector 20 depicted in
FIGURES 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
., r. .... ~. w_.N. ~~..~~~m~z~~,~~.~~~,~r_n ~...~x.~w.~..-~.a:~Ey~:.~.~,~o-
..~.~w.._. . ... ....__~..~. ~...~..~...___.
CA 02463221 2004-04-05
- 27 - 302-211-19-4
with sleeve member 22 being securely fractionally engaged and retained in
housing 21.
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 thi<.~ invention.
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 FIGURES 15-23 wherein the use of locking
tabs is employed.
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 FIGURES 15-
23, the present invention employs a unique construction for producing an
easily
CA 02463221 2004-04-05
- 28 - 302-211-19-4
manufactured and readily installed sleeve member iincorporating locking tabs
for
mounted engagement with a housing.
As shown in FIGURES 15-17, housing 21 of cable connector 20 is con-
structed in a manner substantially identical to the construction detailed
above,
with housing 21 comprising a substantially hollow, cylindrical shape
incorporat-
ing outer surface 24, inner surface 25, and two, axi<~Ily spaced, radially
extend-
ing 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.
As detailed above, although not shown in FIt~URES 15-17, locking ring 23
depicted in FIGURES 1-4 is employed in the identical manner detailed above, by
being positioned in retaining zone 28 for use in securely retaining cable
connec-
for 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.
CA 02463221 2004-04-05
- 29 - 302-211-19-4
The principal variatian 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.
By referring to FIGURES 19-23, along with the following detailed disclo-
sure, the preferred construction of this alternate emlaodiment of sleeve
member
22 can best be understood. In this embodiment, as with the previous err~bodi-
went 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 erase of assembly.
Inner sleeve member 22 also incorporates two diametrically opposed arm
members 37 and 38 which are preferably formed from the substantially c:ylindri-
cally 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 con-
_ ~ .s~ . ~~rx~ r ._~ ... ._x,.~ ~ o..~r ~ 8~~~,~ .~_~._~.~. _ _ __
._~.am..~..c~~,~ ~ ~~..-.r____
CA 02463221 2004-04-05
- 30 - 302-211-19-4
structed preferably comprising sloping, intermediate section 41 and sloping,
end
section 42.
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.
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
FIGURES 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.
CA 02463221 2004-04-05
- 31 - 302-211-19-4
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 FIGURE 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.
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.
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 ~>urface 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
CA 02463221 2004-04-05
- 32 - 302-211-19-4
desired location during the formation and positioning of arm members 37 and
38, ready for securely engaging and lockingly retaining the electrical cable.
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.
In FIGURES 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.
. w ,. .. _, r xm. ~., .,an.~,~rt ,~.~. a~_~M-_ .~. .~ .~~.~r".,w
..".~"~.~,~.~~ h .A.~ _ _...._._~...~.~....~~M .~.__.___. . _.._~.r_,.-
CA 02463221 2004-04-05
- 33 - 302-211-19-4
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 resuilt, sloping end sections 40
and 42 are uniform throughout their width, (ockingly 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
respec-
tive arm members. In this way, substantially horizontal engagement with the
cable member is achieved.
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.
By employing this construction, terminating edges 50 and 51 are c:on-
structed for directly contacting the surface of the electrical cable along
substan-
... _._ .__ __ w .. ~._r~. ... x~. ..~o.._. , ~A,.r.~..~,.~~~-,~.~m.~~x..... .
. __ ___.~~.-.. ~~..Tr~..~._ ___
CA 02463221 2004-04-05
- 34 - 302-211-19-4
tially 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.
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.
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.
As clearly depicted in FIGURES 24 and 25, in this embodiment, interme-
diate section 39 of arm member 37 slopes inwardly from inner surface 36, or
outer surface 35, of sleeve rnember 22 at an angle clesignated "AZ", while
intermediate section 41 of arm member 38 slopes inwardly from surface 36 of
,...:~,~~~~ .u.ro., ~._.._._ _~~...~~.,~."~ .rt~~..n~--_ _____._--,-
CA 02463221 2004-04-05
- 35 - 302-211-19-4
sleeve member 22 at an angle designated "A,". Furthermore, end section 40 of
arm member 37 slopes inwardly from inner surface 36 of sleeve member 22 at
an angle designated "BZ", while end section 42 of arm member 38 slopes
inwardly from inner surface 36 of sleeve member 22 at an angle designated
"B,".
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. A,s 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 electrica
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 engage-
ment with arm members 37 and 38.
In addition to employing different slope angles for each section of each
arm member, this embodiment of the present invention also employs different
overaPl lengths for intermediate sections 39 and 41. As clearly depicted iin
CA 02463221 2004-04-05
- 36 - 302-211-19-4
FIGURE 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 as-
sured.
By referring to FIGUi2ES 26-34, along with the following detailed disclo-
sure, the construction of a further alternate preferred embodiment of
electrical
cable connector 20 of the present invention can best be understood. (n 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.
In the preferred construction of this alternate embodiment, housing 21
comprises a substantially hollow cylindrical shape iincorporating outer
surface
101, inner surface 102, and wall 103 formed at Onf= 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 t:he knockout plugs or
receiving holes formed in conventional junction boxes or outlet boxes.
CA 02463221 2004-04-05
- 37 - 302-211-19-4
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.
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.
As shown in FIGURE 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
CA 02463221 2004-04-05
- 38 - 302-211-19-4
locking interengagement of cable connector 20 with junction box and/or outlet
box 30.
In the preferred construction of this embodinnent of the present invention,
as shown in FIGURES 26-34, inner sleeve member 22 of cable connector 20 is
constructed in a substantially hollow cylindrical sh<~pe 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.
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.
As is well known in the art, other methods ca.n be employed for providing
interengagement of inner sleeve member 22 with housing 21 other than the
preferred embodiment of frictional engagement. As shown in FIGURES 15-25,
CA 02463221 2004-04-05
- 39 - 302-211-19-4
alternate engagement systems have been fully detailed above. If desired, these
alternate engagement systems can be employed with equal efficacy.
In addition, as further detailed below, the present invention also incorpo-
rates 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 (ockingly engaged with housing 21 automatically upon assembly
of the components. However, further secure engagement means as detailed
above can also be employed.
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 construcaed 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
assem-
bled, trouble-free, highly desirable cable connector system is realized. gy
referring to the following detailed discussion, along, with FIGURES 26-3~, 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.
CA 02463221 2004-04-05
- 40 - 302-21 1-19-4
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 em-
ployed 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
mem-
hers has equal applicability to the arm members of this embodiment of inner
sleeve member 21.
In FIGURE 32, a further alternate constructioin 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 114. Preferably, when this embodiment is
employed, arm member 115 is constructed in a substantially identical manner.
CA 02463221 2004-04-05
- 41 - 302-211-19-4
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.
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 tab120 being preferably spaced substantially
equidistant from each adjacent locking tab 120.
In addition, in the preferred construction, each locking tab 120 is inde-
pendently formed on outer surface 110 of sleeve mE?mber 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, termi-
CA 02463221 2004-04-05
- 42 - 302-211-19-4
nating at edge 122. In the preferred construction, each locking tab 120
incorpo-
rates a central portion 123 and wing members 124 which are preferably formed
along the side edges of central portion 123 and angulariy extend therefrom.
Finally, in the preferred construction, central portion 123 of each locking
tab
120 terminates with a tip 125.
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 Pocking tab 120 anguiarly 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.
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
CA 02463221 2004-04-05
- 43 - 302-211-19-4
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.
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 interengage-
ment 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.
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 aper-
tures 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
CA 02463221 2004-04-05
- 44 - 302-211-19-4
engagement with any desired knockout plug or receiving hole 29 formed in
conventional junction boxes or outlet boxes 30.
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.
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
construc-
Lion. In this embodiment, locking tabs 120 provide sufficient secure
engagement
of sleeve member 22 with housing 21. However, if desired, frictional engage-
ment may also be employed, as well as any other desired mechanical locking
system.
. ,...m _ , ..... . ~",r ~R~,~~ "..~~~.~~ ... ..-.. __....._ .:um b~ ~..~~,..
r#,~."~ ~_ .,.__. _ __ . __~___~.._: ,~,n~~ ~.~.~.______. _ ___~...,-.
~Yr~:~~r3
CA 02463221 2004-04-05
- 45 - 302-211-19-4
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, white 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.
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 cak~le 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 in-
stances, the desired conductivity is not provided.
By employing the present invention, electrical conductivity is automati-
tally assured by the inherent construction of this embodiment of the cable
connector, since the same component engages the metal clad cable and the
0
CA 02463221 2004-04-05
- 46 - 302-211-19-4
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
require-
ments and achieves substantially improved and enhanced performance capabili-
ties.
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.
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 12:3, 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
CA 02463221 2004-04-05
- 47 - 302-211-19-4
and/or outlet box is achieved, as well as assuring that the desired electrical
conductivity is established.
By referring to FIGURE 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.
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.
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
CA 02463221 2004-04-05
- 48 - 302-211-19-4
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 termi-
nating tip 125 is brought into direct contact with this inside diameter
forming
edge of receiving hole 29.
As is evident from this construction and operation, axial removal of cable
connector 20 from receiving hole 29 is prevented, due to the locking engage-
ment of wings 124 with the side wall of cable box and/or outlet box 30.
Further-
more, the desired electrical conductivity is established by contacting engage-
ment of terminating tip 125 with the edge of receiving hole 29.
In addition, since inner sleeve member 22 comprises a one-piece con-
struction 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.
By referring to FIGURES 35-39, along with the following detailed disclo-
sure, the construction of an alternate embodiment of electrical cable
connector
CA 02463221 2004-04-05
- 49 - 302-211-19-4
20 of FIGURES 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.
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 i:he knockout plugs or
receiving holes formed in conventional junction boxes or outlet boxes.
Furthermore, in this embodiment, housing 21 incorporates a plurality of
apertures or opened zones 105 and 140 formed in outer surface 101, peripher-
ally surrounding the portion of housing 21 formed between flange 104 and end
wall 103. In the preferred construction, apertures 105 and 120 are formed
adjacent each other, spaced in substantially equal distances from each other.
As
shown in FIGURES 3fi-37, four apertures 105 are formed in housing 21, while
CA 02463221 2004-04-05
- 50 - 302-211-19-4
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.
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.
in the preferred construction of this embodiment of the present invention,
inner sleeve member 22 of cable connector 20 is c'anstructed 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
substantiaify
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.
In the preferred construction, the frictional engagement established
between inner sleeve member 22 and housing 21 is constructed to exceed all
.....~u..., ... . ~~. u.~~,~.., ~4.~~a~. . ... ._..,. ~~.wr... ~,~ 4:~M,~w
.,..._. .. ..____~.m Rt~~~~ ~.;~,w~.x~.~..___ .__...______~..-
.~. ~~ ~.~ ..
CA 02463221 2004-04-05
- 51 - 302-211-19-4
force requirements imposed upon cable connectors. In this way, trouble-free,
secure engagement of an electrical cable with connector 20 is assured.
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 FIGURES 15-25,
alternate engagement systems have been fully detailed above. If desired, these
alternate engagement systems can be employed with equal efficacy.
In addition, as discussed above, the present invention also incorporates a
locking arrangement integrally formed as part of thc= 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.
fn 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
CA 02463221 2004-04-05
- 52 - 302-211-19-4
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 FIGURES 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.
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 em-
ployed 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
mem-
bers has equal applicability to the arm members of this embodiment of inner
sleeve member 21.
. ," "."..,.. " v ~.,«.x,M,,.rxm ;°,r.. _r ;n r..t:.r .,..n..,..._-
,.,.. ........_. x,...~"H,9r~, e, v....~..".".-.-.....,._.. . _......._.._ ...
._," .,..,.a ,~.-,cue. , ",~,~",-..~.--..- ... ....
tx ."~,.~~,-eq,5~.~' se -..u~&C~s".=gyp:.. ~ »nvv.~,
CA 02463221 2004-04-05
- 53 - 302-211-19-4
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.
In the embodiment depicted in FIGURES 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 FIG-
URES 26-34, where three separate and independent locking tabs 120 are
employed.
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
. ,."_, m,rv. .rm...-. s-xm"c.-,~,~.rms ~,~ r-fi..=.~.,~. , -...._ ,.w,.,.m "R-
~;".a~aoa..nsrt7_.,~r,5sec: ~rw.~,~...~--m...... ..~........ _. _,_ -..,.,~.w-
.~,=n,~»._.R,~..""~....,.,..,.._rv.._ _...~__..
CA 02463221 2004-04-05
- 54 - 302-211-19-4
separate and independent grounding/conductivity tabs 141 are preferably
employed therewith, equally spaced between adjacent locking tabs 120.
As depicted in FIGURES 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 iradially extends outwardly
from proximal edge 142 with a smooth, continuous, arcuately curved shaped,
terminating with distal edge 143. As is more fully cletailed below, each
ground-
ing/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 2U is
mounted. In this way, the required grounding and electrical conductivity of
connector 20 with junction box/outlet box 30 is assured.
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
~.~~~.x~.r._mf
CA 02463221 2004-04-05
- 55 - 302-21 1-19-4
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.
Sleeve member 22 may be constructed using a wide variety of alternate
construction methods. However, as detailed above, in the preferred construc-
tion method, in order to achieve an easily manufacitured and inexpensive
product, sleeve member 22 is constructed from a substantially flat metal stamp-
ing 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 interengage-
ment 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.
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 groundinglconductivity tabs
4 _...m ~.5 _ _ .~. . .,aa,~ ~. . ~~~ ,~ ,~ ~,.. ~ . ._ . ...._ ~ .m __~, , ~~-
a. . ~_ _. _ . . _ ____ m .. ~,~~ -_.w~~..__._ _ _
CA 02463221 2004-04-05
- 56 - 302-211-19-4
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.
When in this position, locking tabs 120 are capable of providing the
desired secure, locking engagement with any desirE~d knockout plug or
receiving
hole 29 formed in conventional junction boxes or outlet boxes 30, and ground-
ing/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.
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
construc-
~...~_._..~ _,~u~.~,~~..~, . . ~ ~-.. ~~. ._ . _ .... ..... m~.. ~~.:. ~~~n.~M
.~._r_._ . __..._ ._. ~.._. _. _.~ -. ~ ..~~~~.. ___ ._.. _... . ._... _..._.
~~- ~~~ o
CA 02463221 2004-04-05
- 57 - 302-211-19-4
tion. In this embodiment, locking tabs 120 and grounding/conductivity tabs 141
provide sufficient secure engagement of sleeve mernber 22 with housing 21.
However, if desired, frictional engagement may also be employed, as well as
any other desired mechanical locking system.
Whichever fastening system is employed, if amy, 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 far immediate use, without any further subassembly by
the user. In addition, the cable connector of the prcasent 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 meta
clad cable.
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
.:T.w~k
CA 02463221 2004-04-05
- 58 - 302-211-19-4
assure proper operation of the electrical cable after installation. In many in-
stances, the desired conductivity is not provided.
By employing the present invention, electrical conductivity is automati-
cally 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
require-
ments and achieves substantially improved and enhanced performance capabili-
ties.
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 1~t1 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.
CA 02463221 2004-04-05
- 59 - 302-211-19-4
As shown in FIGURE 36, housing 21 is quick:ly 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 receiiving 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 interengage-
ment 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.
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, contactiing engagement of ground-
ing/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 automati-
CA 02463221 2004-04-05
- 60 - 302-211-19-4
cally achieved, assuring that the desired electrical conductivity and/or
grounding
is established.
As shown in FIGURE 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 :?9 until flange 104 abuts
the
surface of the junction box and/or outlet box 30.
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.
Furthermore, once grounding/conductivity tabs 141 are mounted in
engagement with the inside edge of receiving holes 29, as shown in FIGURE 36,
tabs 141 provide a pre-loaded, spring biasing securement of connector 20 to
box
CA 02463221 2004-04-05
- 61 - 302-211-19-4
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.
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 wiith the inside edge of receiv-
ing hole 29. In this way, the secure mounted engagement of connector .20 with
any desired junction/outlet box 30 is attained and assured.
In addition to providing spring biased, secure engagement of connector 20
with any desired junction/outlet box 30, as well as providing the desired
ground-
ing 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,
CA 02463221 2004-04-05
- 62 - 302-211-19-4
connector 20 is continuously positioned and maintained in a central, axially
aligned position within receiving hole 23.
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.
By referring to FIGURES 40 and 41, along wiith 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.
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 FIGURES 40 and 41 is
CA 02463221 2004-04-05
- 63 - 302-211-19-4
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.
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 FIGURES 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.
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. Ln addition, housing 24
incorporates radially extending flange 27 formed on outer surface 24 thereof.
..«,...~~.."~ :.x -_..~._........
x~~~~H~. r
CA 02463221 2004-04-05
- 64 - 302-211-19-4
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 engagerr~ent
with
threaded zone 156 of gland nut i52, while threaded zone 155 is constructed for
threaded engagement with threads 157 of locking ring 150.
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
identi-
tally to the constructions detailed above. In addition, in the preferred
configura-
tion, 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 engage-
ment established between inner sleeve member 22 and housing 21 is con-
strutted to exceed all force requirements imposed upon cable connectors. In
....~.w,.-. , .ur AF»..Wf,::i;w. aM~'t2r:.~R~..nvn ..,.w"". .,...,...."....
.",~."A,y.~,., k,,>,.,~,~,,~ym,~a..,."~..~,~ ...._._,....... , ..._-
....,..~."m, ~~.,.~_.. ......... ...
CA 02463221 2004-04-05
- 65 - 302-211-19-4
this way, trouble-free secure engagement of electrical cable 45 with connector
20 is assured.
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.
For exemplary purposes, arm members 37 and 38 are depicted in FlG-
URES 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
con-
structions being employable in this further alternate embodiment of the
present
invention.
In this embodiment, as with the embodiments detailed above, inner sleeve
member 22 is inserted into housing 21 for being securely, frictionally engaged
CA 02463221 2004-04-05
- 66 - 302-211-19-4
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 periph-
eral 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.
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 FIGURE
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.
With gland nut 152 and sealing bushing 153 securely mounted in place,
sealing bushing 153 is compressed into frictiona) engagement with cable 45,
peripherally surrounding cable 45 and effectively sealing the outer peripheral
CA 02463221 2004-04-05
- 67 - 302-211-19-4
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.
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 el'astomeric 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 k~eing 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.
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
CA 02463221 2004-04-05
- 6g - 302-211-19-4
aperture selection. When the desired aperture is located, terminating end 161
of
connector 20 is axially advanced through the desired aperture.
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 FIGURE 40, washer 151
abuttingly contacts the outside wail of the junction box or housing instead of
flange 27.
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.
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
__ _____ .g .~...~x.~~__..__._ .__..._.__ _. ~ ~ _ ~~~.~~.,~_.~_~.~...__,~ ~..
___. __
CA 02463221 2004-04-05
- 69 - 302-211-19-4
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 employ-
ing the construction detailed above, connector 20 is secured in a manner which
provides rain/moisture tight mounting of cable 45.
It has also been found that any of the embodiments of connector 20
detailed in this disclosure can be employed by prea~ssembling connector 20
with
any desired, predetermined length of electrical cablle 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 ii= so desired.
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 metalclad portion of cable 45
. .. . _ _. . . ~ M ~ . . ,M. m.. a, ... b..,. ~~R~ .~. ..,~A. ~"a~,M"rcr , ~
_ _._..... . . _....~_ ~. ~. -" w., _
CA 02463221 2004-04-05
- 70 - 302-211-19-4
securely mounted in sleeve 21 of connector 20, with the internal engaging arms
thereof securely engaged with the outside surface of cable 45.
Once this process is completed, a pre-manufactured, ready to install
assembly of a connector/cable system is attained, ready for sale and/or
transpor-
tation 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 juncaion 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.
As is evident from the foregoing detailed dis<:losures, the present inven-
tion 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 al! provided for exE~mplary purposes, and
that
... ___ _ _.. __ ..,. . . M_ . .~.r... . . , ~ . . a ~ p ", . .~...
~.axry~~~~"~ .~ . . ~~,.-m .S a.M __ .. .. _ _ _~. ~.~ ~r~~p.,~ ~.a- .~ . _ _
CA 02463221 2004-04-05
- 71 - 302-211-19-4
alternate combinations of features, elements, an arrangement of parts and
components can be achieved without departing froim the scope of this
invention.
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.
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.
Having described my invention, what I claim as new and desire to secure
by Letters Patent is:
