Note: Descriptions are shown in the official language in which they were submitted.
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SNAP FIT ELECTRICAL CONNECTOR ASSEMBLY
WITH CONICAL OUTER SNAP FIT RETAINER
AND EXTERNALLY MOUNTED INTERNAL WIRE RETAINER
Field of the Invention
This invention is directed to a further advancement in
the field of electrical connector assemblies having a snap
fit retaining ring circumscribing the outlet end of a
connector body for effecting a snap fit connection to an
electrical box of the types described in U.S. Patent
6,860,758, and co-pending application Serial No. 10/790,283
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filed March 1, 2004 for Snap Fitting Electrical Connector;
and in a co-pending Application Serial No. 11/028,373
filed January 3, 2005.
More specifically, this invention relates to a snap
fit electrical connector for facilitating the connection of
an electrical connector and associable cable, wire,
conductors or the like to an electrical box, which is
provided with a readily detachable snap fit outer frustro-
conical member circumscribing the outlet end of a connector
body for simplifying its connection to an electric box and
a unidirectional cable or wire retainer associated with the
inlet end of the connector for positively securing a wire,
cable or conductor to the inlet end of the connector so as
to prohibit any unintentional separation of the wire, cable
or electrical conductor from the connector.
BACKGROUND OF THE INVENTION
Electrical connectors are commonly used for attaching
electrical conductors, cables, wires, electrical metal
tubing (EMT) or the like to an electric box, e.g. a
junction box, outlet box, switch box, fuse box, or other
similar type of electric box. Such known electrical
connectors are either of a type that are secured to an
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electric box by a threaded lock nut or by means of a
circular snap fit retaining ring of the type disclosed in
U.S. Patents 6,860,758; 6,444,907; 5,189,258; 5,266,050;
5,171,164; 2,744,769 and 1,483,218 for example. Reference
is also made to U.S. Patent 6,768,057 which is directed to
a right angle type connector formed of a pair of sheet
metal stampings fitted together and secured to an
electrical box with a snap fit arrangement. Connectors
formed as connector caps which are adapted to be fitted
over the end of a conductor, cable or wires, such as
disclosed in U.S. Patent 4,880,387, are also known.
Various other known efforts to facilitate the connection of
an electrical conductor to an electric box are evidenced by
U.S. Patents 6,043,432; 6,080,933; 6,114,630; 6,133,529;
6,194,661; 6,335,488; 6,352,439; 6,355,884; 6,444,907;
6,555,750; 6,604,400; 6,670,553; 6,737,584; 6,682,355;
6,780,029 and 6,849,803. While such prior known connectors
can be satisfactorily used for their intended purposes,
efforts are constantly being made to improve upon the known
electrical connectors. The disclosure herein comprises but
another effort to advance or improve the manner of forming
and/or securing electrical connectors and/or conductors to
an electric box.
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SUMMARY OF. THE INVENTION
An object of this invention is to provide an
electrical connector with a frustro-conically shaped
retaining ring having integrally formed locking tangs and
electrical grounding tangs.
Another object of this invention is to provide for an
electrical connector assembly that includes an electrical
connector body having an outlet end with a frustro-conical
outer surface having a complementary frustro-conical
retaining ring that is readily fitted to and retained on
the outlet end portion of the connector body.
Another object is to provide a connector assembly
comprising a connector body having an outlet portion free
of any retaining flanges and an associated snap fit
retainer ring circumscribing the outlet end portion.
Another object is to provide a retaining ring having a
face portion with outwardly flaring circumscribing arms or
sides having locking and grounding tangs that are readily
formed out of a surface of the respective arms or side.
Another object is to provide a retaining ring, adapted
to be fitted onto the outlet end of a connector body,
having a frustro-conical shape with a first series of tangs
for securing the connector body relative to an electrical
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box and a second series of tangs for effecting a positive
electrical ground with an associated electrical box.
Another object is to provide a frustro-conically
shaped retaining ring that can be readily formed from a
blank of spring steel.
Another object is to provide an electrical connector
with a frustro-conical outer retainer ring circumscribing
the outer surface of the connector outlet end and a
unidirectional retainer ring or sleeve associated with the
inlet end of the connector for securing an electrical wire
or conductor thereto.
Another object is to provide an electrical connector
with an internal unidirectional sleeve insert for
frictionally retaining a wire conductor to the connector so
as to prevent any unintentional separation of a wire
conductor therefrom.
Another object is to provide an electrical connector
with an outer frustro-conical retainer ring for attaching a
connector to an electrical box with a snap fit and an inner
unidirectional retainer ring or sleeve for securing a wire
conductor thereto in a manner to prohibit any unintentional
separation of the wire conductor from the connector.
Another object is to provide an electrical connector
with an improved wire retainer sleeve or ring whereby the
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wire conductor is positively secured thereto by simply
inserting the wire conductor into the connector whereby
unintentionally separation of the wire conductor from the
connector is prohibited.
Another object of this invention is to provide an
electrical connector with a wire retainer ring whereby a
helical wound wire conductor can be secured upon mere
insertion of the armored conductor wire or by threading the
armored conductor wire into the wire retainer ring so as to
prohibit any unintentional separation of the wire conductor
from the electrical connector.
Another object is to provide or an electrical
connector assembly that is relatively simple to fabricate
and positive in operation.
Another object of this invention is to provide an
electrical connector assembly having an outer frustro
conical retainer ring for positively connecting the
connector assembly to an electrical box and having multiple
inlet ends fitted with an internal wire retainer ring for
unidirectional locking therein a wire conductor in each of
the multiple inlets.
Another object of this invention is to provide an
improved multiple connector assembly that is relatively
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simple in structure, easy to assemble and having a minimum
of component parts.
Another object is to provide a connector assembly
having multiple inlet ends, each inlet end being fitted
with internal spring steel internal retaining ring arranged
to maximize electrical conductivity or grounding.
Another object is to provide an electrical connector
having an outer frustro-conical retainer ring forming a
snap fit attachment to an electric box or panel and having
an improved unidirectional wire conductor retainer in the
form of a retaining finger projecting into the inlet end of
a connector body so as to provide a snap fit wire retention
device which prohibits any unintentional separation of the
wire conductor form the connector.
Another object is to provide a relatively simple and
positive acting snap fit wire conductor retaining device
for securing and retaining a wire conductor to an
electrical connector in a manner to prohibit any
unintentional separation of a wire conductor from the
connector.
Another object is to provide a snap fit wire retainer
that extends inwardly of an electrical connector body
constructed so that the wire retainer is externally secured
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to the exterior of the connector body so as to facilitate
the assembly of the connector and associated wire retainer.
Another object is to provide an electrical connector
having a wire retainer arranged to be externally secured to
the connector in a fixed relationship relative to the
connector so that the free end thereof extends in the inlet
end portion of the connector whereby a wire conductor may
be snap fitted thereto.
The foregoing objects and other features and
advantages are attained by an electrical connector assembly
that includes a connector body having an inlet end portion
for receiving an electrical conductor and an outlet portion
which is adapted to be inserted through a knockout hole of
an electrical panel or electric box, e.g. an electric
outlet box or the like. A radially outwardly extending
flange circumscribes an intermediate portion of the
connector body to function as a stop to limit the insertion
of the outlet end portion of the connector body through the
knockout hole of an electric box. The outlet end portion
may be provided with an outer surface that converges or
tapers inwardly toward the outlet opening thereof. Formed
on the surface of the outlet end portion are one or more
retaining lugs, which may be circumferentially spaced about
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the outlet end portion. A frustro-conically shaped snap
ring is fitted onto the outlet end portion.
In accordance with this invention, the outer retaining
ring is initially formed from a blank of sheet material,
e.g. spring steel, having a cruciform shape that includes a
face portion with a central opening wherein the radiating
arms of the cruciform blank are disposed about the face
portion to define a frustro-conical ring or cup. The ring
so formed is provided with blanked out or die cut tangs to
define locking tangs and grounding tangs. The frustro-
conical ring so formed also has a slot adapted to receive
the retaining lug when the retaining ring is fitted onto
the outlet end portion of the connector body so that the
free or trailing ends of the ring or grounding tangs engage
the inner periphery of the knockout hole of an electric box
for effecting positive electrical continuity and grounding.
To form the retaining ring, the cruciform arms are
arranged to be folded relative to the front or face forming
portion of the blank, which is provided with a central
opening, to define a unitary frustro-conically shaped cup-
like member to compliment or be fitted to the outlet end
portion of the connector body. The retaining ring thus
formed is fitted over or onto the outlet end portion
whereby the retaining slot formed in the ring is adapted to
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receive the complementary retaining lug formed on the
surface of the outlet end portion for retaining the ring on
the outlet end portion of the connector body.
With the construction described, the connector
assembly can be readily inserted through the knockout
opening of an electric box wherein the locking tangs will
spring outwardly to lock the connector assembly to the
electric box with the grounding tangs or free ends of the
arms being biased or urged against the internal periphery
of the knockout hole to effect a positive electric ground,
due to the inherent resiliency of the respective tangs and
the material from which they are formed.
This invention further contemplates providing the
inlet end of the connector with an inner or internal
retainer ring which is uniquely formed for positively
securing thereto a wire conductor by merely inserting the
wire conductor into the inner retainer ring, and whereby
the wire conductor is prohibited from being unintentionally
separated therefrom. The inner retainer ring is preferably
formed of a blank of spring metal material which is rolled
to form a cylinder or sleeve having an outer diameter which
can be frictionally retained within the inlet end of a
connector, e.g. by a press or friction fit.
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A further embodiment of the disclosed invention
utilizes a simplified clamping arrangement for securing the
wire conductor to the inlet end of the connector by a mere
insertion. In the event the wire conductor has a helical
wound armored shield, e.g. a BX wire conductor, such
armored wire conductor may be alternatively secured to the
wire retainer ring or sleeve by threading the armored
conductor to the wire retainer ring or sleeve.
A further embodiment of the invention utilizes a
connector body having complementary housing or body
sections which can be mated together and secured by a
fastener. One of the body sections is formed wih a leading
end that is provided with an outer frustro conical surface
and a trailing end having multiple chambers interconnected
to the leading end by a transition section. The other body
section defines a trailing end complementing the trailing
end portion of the other housing section. An outer frustro
conical retainer ring circumscribes the leading end to
provide a snap fit connection of the assembled connector
body to a knockout hole of an electric box. The respective
chambers, defined by the mated complementary trailing ends,
are each fitted with a spring steel retainer sleeve to
provide a snap fit connection between a wire conductor and
its corresponding inlet end of the assembled connector body
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section. The arrangement is such that the respective wire
retainer is securely clamped between the respective body
section to provide a very positive surface to surface
contact between the wire retainer and the associated body
sections to enhance the electrical continuity between the
assembled connector body sections and the wire retainer
clamped therebetween. -
A still further embodiment of the invention utilizes a
modified connector body provided with a frustro conical
outlet end having a frustro conical shaped external snap
fit retaining ring by which the connector assembly can be
readily attached to an electrical panel or electrical box
by a snap fit, and having a uniquely formed wire retainer
device that clips onto the inlet end of the connector body
and is externally secured to the connector body for
enhancing ease of assembly while providing the wire
retainer to extend into the inlet end of the connector body
with sufficient flexibility and range of movement for
retaining a wire conductor or conductor sheath within the
connector body in a manner to prohibit any unintentional
separation of the wire conductor or sheath from the
connector body.
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IN THE DRAWINGS
Fig. 1 is an exploded perspective view of the
electrical connector assembly.
Fig. 2 is a plan view of the blank from which the
outer retaining ring of the present invention is formed.
Fig. 3 is a detail front view of the outer retainer
ring.
Fig. 4 is a detail top plan view of the outer retainer
ring.
Fig. 5 is a detail end view of Fig. 4.
Fig. 6 is a sectional view of the outer retainer ring
taken along line 6-6 on Fig. 3.
Fig. 7 is a side view of the connector assembly
illustrating the alignment thereof relative to the knockout
opening of an electric box.
Fig. 8 is a section side view illustrating the
connector assembly secured to an electric box, taken along
line 8-8 on Fig. 10.
Fig. 9 is a sectional side view taken along line 9-9
on Fig. 10 and rotated 900.
Fig. 10 is a fragmentary front view of the connector
assembly secured to an electric box as viewed from the
inside of the electrical box.
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Fig. 11 is an exploded perspective view of a modified
form of the invention.
Fig. 12 is a sectional side view of the modified form
of the invention of Fig. 11.
Fig. 13 is a top plan view of the blank from which the
internal wire conductor retainer is formed.
Fig. 14 is a fragmentary top view of a portion of the
blank forming the inner retainer sleeve or ring.
Fig. 15 is an end view of the inner wire conductor
retainer ring or sleeve.
Fig. 16 is a top view of the inner retainer ring or
sleeve of Fig. 15.
Fig. 17 is a section view taken along 17-17 on Fig.
16.
Fig. 18 is a side view of the inner retainer ring or
sleeve.
Fig. 19 is a sectional side view of still another
embodiment.
Fig. 20 is a perspective view of a further embodiment
of the invention.
Fig. 21 is an exploded perspective view of the
embodiment of Fig. 20.
Fig. 22 is a top plan view of the embodiment of Fig.
20 having parts thereof broken away.
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Fig. 23 is a sectional view taken along line 23-23 on
Fig. 22.
Fig. 24 is the interior plan view of one section of
the connector housing of the embodiment illustrated in Fig.
20.
Fig. 25 is an outer end view of Fig. 24.
Fig. 26 is an end view of the connector housing
section of Fig. 24.
Fig. 27 is a sectional view of the housing section
taken along line 27-27 on Fig. 26.
Fig. 28 is an inside plan view of the complementary
housing section of the embodiment illustrated by Fig. 20.
Fig. 29 is an end view of Fig. 28.
Fig. 30 is an inlet end view of Fig. 28.
Fig. 31 is a sectional view taken on line 31-31 on
Fig. 30.
Fig. 32 is a sectional view taken on line 32-32 on
Fig. 28.
Fig. 33 is a perspective exploded view of a further
embodiment of the invention.
Fig. 34 is a top plan view of the blank from which the
wire retainer device is formed.
Fig. 35 is a side view of the blank of Fig. 34.
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Fig. 36 is a side view of the blank of Figs. 34 and 35
as formed to define wire retainer.
Fig. 37 is a top view of a slightly modified form of a
wire retainer.
Fig. 38 is a perspective view of the connector body
embodying the invention.
Fig. 39 is a side view of Fig. 38.
Fig. 40 is a top plan view of Fig. 39.
Fig. 41 is a left end view of Fig. 38.
Fig. 42 is a right end view of Fig. 38.
Fig. 43 is a perspective view of the assembled
connector embodiment shown in Fig. 33.
Fig. 44 is a side sectional view of the connector
assembly of Fig. 43.
DETAILED DESCRIPTION
Referring to the drawings, there is shown in Fig. 1 an
electrical connector assembly 10. The connector assembly
includes a connector body 11, which is usually formed of
metal casting, e.g. zinc or other suitable metallic alloy.
The connector body 11 is formed with an inlet end portion
11A and an outlet end portion 11B and having a bore 12
extending therethrough. Intermediate the connector body 11
or between the inlet end portion 11A and outlet end portion
11B there is provided a radially outwardly extending flange
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13 which functions as a stop to limit the amount that the
connector body 11 may be inserted through the knockout hole
14 of an electric box 15, as noted in Fig. 8.
As shown in Figs. 1 and 8, the outer surface S of the
outlet end portion 11B slopes, tapers or converges toward
the outlet opening 16 whereby the outer surface S of the
outlet end portion 11B has a generally frustro-conical
configuration. Formed on the surface S of the outlet end
portion 11B is an outwardly projecting retainer lug 17. In
the illustrated embodiment, two such lugs 17 are shown
disposed 1800 apart about the outer circumference of the
outlet end portion 11B.
The connector assembly 10 also includes a snap fit
retaining ring 18. In accordance with this invention, the
retaining ring 18 is integrally formed from a blank 19 of
spring steel material. As best seen in Fig. 2, the blank
19 is initially formed or stamped to define a generally
cruciform shape. The cruciform shape is provided with a
face portion 20 having central opening or hole 20A and
having four generally radially extending arms defining two
pairs of oppositely disposed arms AA and BB.
As illustrated in Fig. 2, the opposed pair of arms AA
are each provided with a retaining slot 21. The opposed
pair of arms BB, as best seen in Fig. 8, are blanked or
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formed to define a locking tang 22 and to either side
thereof an electrical grounding tang 23, 23. As shown, the
locking tang 22 is slightly shorter than the adjacent
grounding tangs 23, 23. The arrangement is such that the
free end of the locking tangs 22 are formed so as to engage
the inside surface of the electric box 15 in the assembled
portion, as best seen in Fig. 9, to secure the connector
assembly 10 to the electric box 15 and prohibit any
unintentional withdrawal of the connector assembly 10 from
the electrical box 15, whereas the free ends of the
grounding tangs 23 are biased in engagement with the
internal periphery of the knockout hole 14. Also, the free
ends 24, 24 of arms AA in the assembled position will also
function as electrical grounding tangs, as noted in Fig. 8.
In forming the retaining ring 18 from blank 19, the
respective arms AA and BB are subjected to a series of
progressive bending dies which will gradually bend the
respective arms about a foldline f, which defines the face
or front portion 20, whereby arms AA and BB form a cup
having circumscribing frustro-conical or outwardly flaring
sides to define a frustro conical ring 18 which complements
the conical surface S of the leading or outlet end portion
11B, as seen in Fig. 1. In doing so, the locking tangs 22
are outwardly and cantileverly bent or displaced relative
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to the surface of the ring at a slightly greater outwardly
angle or slope than the adjacent grounding tangs 23 and the
slope of arms AA. With the retaining ring 18 so formed, it
can be readily fitted onto the outlet end portion 11B
whereby the inherent resiliency of the arms AA will cause
the retainer slots 22 to snap fit onto the retaining lug 17
when slots 21 are placed in alignment with lugs 17. The
arrangement is such that the retainer ring 18 will be
firmly and positively secured to the outlet end portion 11B
as seen in Fig. 8. Yet, due to the inherent resiliency of
the material of the retaining ring 18, it can be easily
detached from the outlet end portion 11B when removal is
desired, without destroying the ring 18 by lifting arms AA
free of the retaining lugs 17.
With the retainer ring 18 properly secured to the
outlet end 11B of the connector body 11, the connector
assembly 10 can be readily secured to an electric box 10 by
simply aligning the assembly 10 with a knockout hole 14, as
best seen in Fig. 7, and inserting the leading or outlet
end portion into the knockout hole 14 until the flange 13
engages the outer side of the electric box 15. In doing
so, the tangs 22, 23 and the free ends 24 of arms AA,
respectively, will depress inwardly to permit insertion of
the assembly 10. When the assembly is fully seated in the
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knockout hole 14, the locking tangs 22 will normally spring
outwardly to secure the assembly 10 to the electric box 15,
as noted in Fig. 9. The inherent resiliency of the
grounding tangs 23, 23 and the free end 24 of arms AA are
normally biased in engagement with the internal periphery
of the knockout hole 14 to ensure a positive electrical
ground with the electric box 15. The engagement of the
free ends 24 of arms AA against the inner periphery of the
knockout hole 14, as noted in Fig. 8, further ensures the
firm securing of the retaining slot 21 with the retaining
lugs 17, so as to prohibit any disengagement of the outer
retaining ring 18 from the connector body 11.
It will be understood that the wire conductor 25 may
be secured to the connector assembly 10 either before or
after the assembly 10 has been secured to the electric box
15. In the illustrated embodiment, the conductor wire 25
is simply inserted into the inlet end portion 11A and
secured in position by a suitable securing means. In the
illustrated embodiment of Fig. 1, the securing means is
illustrated as a set screw 26. However, it will be
understood that other conventional forms of securing means
may be used, than the set screw 26 illustrated.
From the foregoing, it will be apparent that the
disclosed connector assembly is quite novel and simple in
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construction. The snap fit retaining ring 18 can be simply
formed from a cruciform shaped blank 19 whereby the opposed
radially extending arms AA and BB can be readily formed
into a cup having a generally frustro-conically shaped
sidewalls complementing the slope of the outlet end portion
11A, and whereby the outer retainer ring 18 can be readily
secured to the connector body simply by the inter-
engagement of slots 21 with its complementary lugs 17.
In the assembled position, the outer retainer ring 18
is positively secured to the connector body in a manner to
prohibit any unintentional separation. Also the tangs 22
and 23, which are formed integral with ring 18, are shaped
and formed so that the locking tangs 22 secure the assembly
to an electric box 15 while the grounding tangs 23
ensure a positive electrical ground of the assembly 10 with
the associated electric box 15.
Fig. 11 illustrates a perspective view of a modified
form of the invention. As illustrated in Fig. 11, the
connector assembly 30 includes a connector body 31 which
may be formed as a casting form of a suitable metal or
alloy, e.g. zinc and the like, as hereinbefore described.
The connector body 31 includes a conically shaped outlet
end 31A similar to that described with respect to Fig. 1,
and a cylindrical inlet end 31B. A circumscribing internal
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shoulder 31C is formed intermediate the opposed ends of the
connector body 31. As shown in Fig. 12, the internal
shoulder 31C defines the demarcation between the bore 32A
defining the outlet end 31 and the bore 32B defining the
bore of the inlet end. Circumscribing the connector body
31 about the exterior thereof is a radially outwardly
extending stop flange 33.
The outlet end 31A of the connector body 30 is
provided with opposed retaining lugs 37 adjacent the outlet
opening 36. Circumscribing the sloping or conical surface
S of the outlet end 31A is the outer retaining ring 38,
similar to that hereinbefore described with respect to
Figs. 1 to 10.
In the embodiment illustrated in Fig. 11, the
connector assembly 30 includes an internal wire retainer 39
in the form of a ring, cylinder or sleeve which is fitted
to the bore 32B of the connector body 31, and which
retainer 39 functions as a unidirectional retainer means
arranged to permit a wire conductor to be readily inserted
and secured thereinto, and which will resist any applied
force imparted to the wire conductor =in the opposite
direction to prohibit any unintentional separation of the
wire conductor from the connector body 31. Wire conductor,
as used herein, means any wire, cable, helical wound metal
22
=
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covering or sheath (BX) wire, plastic sheath wire conductor
and the like.
Referring to Figs. 13 to 15, the internal retainer 39
is preferably formed from an elongated blank 40 of spring
steel. The retainer blank 40, as best seen in Fig. 13,
comprises an elongated generally rectangular blank having a
longitudinal leading edge 40A, a trailing edge 40B and
opposed end edges 40C and 40D. End edge 40C is provided
with a pair of spaced apart notches 41, 41 and a projecting
tongue 42. The other end edge 40D of blank 40 is provided
with a pair of projecting tongues 43, 43 arranged to
complement notches 41, 41 and a complementary notch 44 for
receiving tongue 42 in the formed or rolled position of the
retainer sleeve 39, as shown in Fig. 18.
Blanked, lanced, cut or stamped out of the plane of
blank 40 are one or more tangs 45. In the form of the
invention as shown in Fig. 13, tangs 45 are formed out of
the plane of the blank. The respective tangs 45 are
bifurcated to define a pair of finger tangs 45A, 45A
longitudinally spaced along the longitudinal axis of the
blank 40 at a distance, which, when the blank 40 is rolled
to form the retainer sleeve 39, the respective pairs of
finger tangs 45A are oppositely disposed, as best seen in
Fig. 15.
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As shown in Figs. 15 and 18, the respective finger
tangs 45A, 45A are inwardly bent out of the plane of the
retainer sleeve 39. In the illustrated embodiment, the
respective finger tangs are provided with a pair of
intermediate transverse fold lines F1 and F2 whereby the free
end of the respective finger tangs is directed toward the
longitudinal axis of the sleeve 39, as shown in Fig. 18.
Referring to Fig. 15, it will be noted that the
retainer sleeve is provided with a flattened portion 46 on
one side thereof.
The connector body of Figs. 11 and 12 may be formed
with an internal complementary flat surface along a portion
of the inner circumference thereof. The arrangement is
such that the retainer sleeve 39, when inserted into the
inlet end 31B of the connector body, is oriented so that
the flattened surface 46 of the sleeve 39 complements the
internal flattened surface 47 of the connector body. The
orientation is such that the opposed finger tangs 45A are
oppositely disposed to firmly grip the wire conductors,
e.g. an armored conductor or other covered conductor.
The outer circumference of the inner retainer sleeve
or ring 39 is proportioned so that it can be press fitted
or frictionally fitted into the inlet end 31B of the
connector body 31 by a force sufficient to firmly secure
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the inner retainer ring or sleeve 39 within the inlet end
so as to prohibit any separation of the retainer ring or
sleeve 39 from the inlet end of the connector body. The
complementary flattened surfaces 46 of the internal sleeve
39 and 47 of the inlet end of the connector body insures
proper orientation of the internal sleeve 39 within the
inlet end of the connector body.
Fig. 14 illustrates a fragmentary portion of the blank
40 to show an intermediate step in forming the tang fingers
45A, 45A so that when the formed blank 40 is rolled to form
the internal retaining sleeve, the tang fingers will be
disposed in parallel as seen in Figs. 15 and 16. This is
attained by fold line F3 which is disposed at an angle, as
noted in Fig. 14, so that when the blank is rolled to form
the internal retaining sleeve 39, the tang fingers 45A, 45A
will be disposed in parallel. The free ends 45B of the
respective fingers 45A are angularly offset to engage the
grooves of an armored conductor, as noted in Fig. 12 or
other covering sheath of a wire conductor that will resist
a force attempting to effect separation of the conductor
from the connector assembly. The respective free ends 45B
may also be laterally offset so that an armored conductor
may be threadedly connected to the internal sleeve 39, as
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well as by simply inserting the armored covered conductor
into the retainer sleeve to effect a snap fit connection.
Fig. 19 illustrates a further embodiment of the
invention. The embodiment of Fig. 19 is directed to a
connector assembly 50 which is generally similar to that
disclosed in Figs. 1 to 10. The embodiment of Fig. 19
differs from that disclosed in Figs. 1 to 10 and Figs. 11
to 18 in that the connector body 51 is provided with a
slotted opening 52 in the inlet end 51A thereof positioned
adjacent to the radially outwardly extending flange 53.
Intermediate between the inlet end 51A and the flange 53,
the inlet end is provided with a tapped or threaded hole 54
for receiving a set screw 55.
In this form of the invention, the wire retainer means
comprises an inverted U shape clamp 56 having opposed leg
portions 56A, 56B and an interconnected web 560. The web
56C is provided with an aperture or hole 57 arranged to be
disposed in alignment with the tapped or threaded hole 57.
The web 56C is sufficiently wide so that one leg, e.g. leg
56B, is extended through the slotted opening 52 and the
other leg 56A extends over the inlet opening 58 to the
inlet end portion 51A. The retaining clamp 56 is
adjustably secured to the connector body 51 by the set
screw 55 extending through the aligned tapped hole or screw
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hole 52. By having one leg 56B extending through the
slotted opening 52 and the other leg 56A extending over the
inlet opening 58, the clamp 56 can be readily adjusted
relative to the connector body by turning the set screw 18
in one direction or the other. The arrangement is such
that as the set screw 55 is tightened, the opposed and
spaced apart free ends of the respective clamp legs 56A,
56B will exert a bearing force on the wire conductor sheath
to positively secure a wire conductor to the inlet end of
the connector assembly. In all other respects, the
connector assembly of Fig. 19 is similar to that disclosed
in Figs. 1 to 10, and need not be repeated.
Figs. 20 to 32 are directed to a further modification
of the disclosed invention. As best seen in Figs. 20 and
21, the connector assembly 60 includes a housing or
connector body formed of a pair of complementary sections
or members 61 and 62. The respective complementary
sections or members 61 and 62 are preferably formed as
casting of any suitable metal or alloy material, e.g. zinc,
aluminum and the like.
As best seen in Fig. 21, one of the housing
complementary members, e.g. 61, is provided with a
projecting leading or outlet end 61A, which is adapted to
be inserted through a knockout hole 14 of an electric box
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CA 02537073 2006-02-21
or panel 15. The leading or outlet end 61A is formed with
an annular configuration to define an outlet opening 63,
through which the conductor leads or wires 80A may extend
=
as noted in Fig. 20. The outer surface S of the leading
end 61A slopes or tapers downward toward the central axis
of the connector assembly to define a frustro conical outer
surface S on the leading end 61A.
The complementary member 61 also includes a trailing
or inlet end 64. As shown in Fig. 21, the trailing or
inlet end 64 is formed as a pair of semi-cylindrical
chambers 64A, 64B disposed in parallel side by side
arrangement separated by an intermediate wall or division
65. The opposed ends of the respective chambers 64A, 64B
are defined between an inturned lip 66A circumscribing the
inlet opening 66 to the respective chambers 64A, 64B and a
transverse web 67. A transition section 68 connects the
respective chambers 64A-64B to leading or outlet end 61A.
Extending through the intermediate wall 65 is a tapped
hole 68B having internal threads. Also formed on the wall
65 is an aligning depression or recess 69. Circumscribing
the leading or outlet end61A is a radially outwardly
extending flange 70 which functions as a stop to limit the
distance the connector assembly 60 can be inserted through
a knockout opening 14 of an electric box or panel 15.
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CA 02537073 2006-02-21
The complementary housing section or member 62 is
formed with a pair of semi-cylindrical chambers 64A:, 64B'
disposed in parallel relationship and arranged to
complement chambers 64A, 64B in the assembled position of
the respective housing members 61, 62, as best noted in
Figs. 20 and 31. Housing member 62 is provided with a hole
71 extending therethrough which is arranged to be disposed
in alignment with the tapped hole 68B whereby the
respective housing sections 61, 62 can be secured in the
assembled position by a threaded fastening screw 72
inserted through hole 71 and threaded into the tapped hole
68 of the other housing member 61. Housing member 62 is
also provided with a transition section 68A that
complements transition section 68 of the other housing
member or section 61.
To facilitate the alignment of the two housing
sections 61 and 62 in assembling the sections 61, 62, there
are provided complementary aligning means. In the
illustrated embodiment, the aligning means comprises a
notch 73 formed at the leading end of the housing member 62
which is arranged to mate with a complementary projection
or lug 74 formed on the outlet end portion of the housing
member 61. Another alignment means includes a recess or
depression 69 formed in the dividing wall 65 of housing
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CA 02537073 2006-02-21
member 61 arranged to be disposed in alignment with the
projection or dimple 69A formed on the dividing wall 65A of
housing member 62.
In this form of the invention, the outlet or leading
end 61A is provided with retainer lug 75 projecting
outwardly from the conical surface S of the outlet end 61A.
In the illustrated embodiment, two such retaining lugs 75
are oppositely disposed. Disposed about the outer sloping
or tapered surface S of the outlet end 61A is a frustro-
conical retainer ring 76. The conical retaining ring 76 is
formed and constructed in the manner hereinbefore described
with respect to Figs. 2 to 4 and need not be repeated. As
seen in Figs. 20 and 21, the frustro conical external
retainer ring 76 can be readily slipped onto the outlet end
61A so that upon engagement of the retainer lugs 75 with
the complementary slots 76A formed on the retainer ring 76,
the retainer ring 76 is maintained in position on the
external surface S of the leading or outlet end 61A as
hereinbefore described.
In this form of the invention, a wire conductor
retainer ring or sleeve 77 is arranged to be disposed and
clamped between the complementary chambers defined by the
respective housing sections or members 61, 62 when
assembled. The respective wire retainer rings or sleeves
CA 02537073 2006-02-21
77 are similar in construction and function to that
described with respect to Figs. 13 to 16, which need not be
repeated. It will be noted that dividing wall 65, 65A of
the respective housing members 61, 62 are arranged to
engage the flat area 77A of the respective wire retainer
sleeves 77 thereby functioning as a means for effecting
proper orientation of the respective wire retainer sleeves
77 within their respective chambers in the assembled
position of the housing sections or members 61, 62.
To assemble the connector 60 of Figs. 20, 21, a formed
conductor wire retainer ring 77 as hereinbefore described,
is position in each semi-cylindrical chamber defined in one
of the housing sections, e.g., as illustrated in Figs. 21
or 22; noting that the flat portion 77A of the respective
wire conductor retainer sleeves 77 are positioned against
the adjacent opposing surfaces 65B of the dividing wall 65,
as best seen in Fig. 23. In this position, the opposite
ends of the respective sleeves 77 abut the interior lip 66A
adjacent the inlet opening and the transverse web 67. With
the wire retainer rings 77 thus positioned within their
respective chamber, the other housing member, e.g. member
62, is fitted to housing member 61 whereby the respective
housing sections clamp the respective wire retaining
sleeves 77 therebetween as the fastening screw 72 is
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CA 02537073 2006-02-21
rotated to secure the two housing sections together as
shown in Figs. 20 and 23. It will be noted that the outer
diameter (OD) of the wire retainer sleeves 77 are
substantially equal to or slightly greater than the
internal diameter of the respective chambers in the
assembly position of the housing sections 61, 62, as noted
in Figs. 20 and 23. The arrangement is such that the
respective retainer sleeves 77 are firmly secured within
their respective chamber, when assembled, so that the wire
retainer sleeves are prohibited from being separated from
the connector body or housing. With the housing members
61, 62 thus secured, the external retainer ring 76 can be
readily fitted onto the leading end 61A of the connector
body or housing, as hereinbefore described.
With the connector body of Fig. 20 thus assembled, it
will be noted that the connector assembly 60 can be readily
secured to an electric box or panel simply by inserting the
leading or outlet end 61A through a knockout hole of a
panel or electrical box so as to be readily secured thereto
with a snap fit as hereinbefore described. Also with the
arrangement described, a wire conductor or cable can be
readily attached to the trailing end of the connector
assembly 60 with a simple snap fit.
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CA 02537073 2006-02-21
Fig. 20 illustrates a wire conductor having an
external helically wound sheath or outer covering 80 which
can be readily inserted through the inlet opening of one of
the respective chambers formed in the trailing end whereby
the gripping tangs 78 formed in the wire retainer sleeves
77, as hereinbefore described, securely grips the armored
cable or wire conductors with a snap fit, the arrangement
being such that the wire so secured is prohibited from
becoming accidentally separated from the connector body, as
hereinbefore described. While a conventional armored type
conductor 80 is illustrated in Fig. 20, it will be
understood that the described connector assembly herein can
be suitable for use with other types of wire conductors,
e.g. conductors having an external plastic or fabric like
sheath.
By simply removing the single fastening 72, the entire
assembly can be readily taken apart to effect the
separation of the wire conductor if so desired. If
desired, the transition portions 68, 68A of the respective
housing sections 61, 62 may be provided with peep holes 70
to view the individual conductor wires 80A arranged within
the connector body to facilitate an electrical
installation.
33
CA 02537073 2006-02-21
From the foregoing, it will be noted that the
connector assemblies disclosed herein utilize a frustro
conically shaped outer retainer ring which is uniquely
secured to the leading end of a connector body, with
securing tangs and grounding tangs arranged to effect both
a positive securement of the connector assembly to a
knockout hole of an electric box or panel and a positive
electrical ground. In association with an external frustro
conical retaining ring, other disclosed embodiments include
a trailing end constructed to receive one or more wire
conductors and retaining the same to the connector body
with a simple snap fit motion. While the embodiment of
Fig. 20 has been illustrated and described as having a
duplex trailing end portion, it will be understood that the
subject matter described can be utilized with one or more
chambers formed in the trailing end of the connector body
described herein, depending upon the number of wire
conductors one may wish to connect to a single connector
body.
With respect to the embodiment of Figs. 20 to 32, the
arrangement is such that the connector body, being formed
of two component housing sections, and secured together
with a fastener as described imparts a clamping force onto
the spring steel wire retaining ring or sleeve with a
34
CA 02537073 2006-02-21
surface to surface contact to enhance electrical
conductivity or grounding between the component housing
sections, and the wire retaining sleeves clamped
therebetween.
Figs. 33 to 44 illustrate a further modification of
the invention. In this embodiment, the connector assembly
80 includes a connector body 81, an outer frustro conical
external snap-fit retainer ring 82, a wire retainer device
83, and an optional plastic electrical insulating end ring
insert 84.
As shown, the connector body 81 includes an inlet
portion 81A and an outlet portion 81B, formed as a casting
of a suitable metal, e.g. zinc or other suitable metal
alloy. The inlet portion 81A, for the greater portion
thereof, is defined by a cylindrical body having a
circumference which is greater than 180 , and preferably
about 320 plus or minus a few degrees. The open portion
of the cylindrical body defining the inlet end portion 81A,
as viewed in Figs. 33 and 43, is provided with a flat
closure 85 which is integrally connected to the opposed
edges of the cylindrical body by interconnecting opposed
side walls 85A and 85B. Projecting outwardly of the flat
closure 85 is an anchoring pin or boss 86.
CA 02537073 2006-02-21
The outlet portion 81B comprises a frustro conical end
similar to that hereinbefore described with respect to the
embodiments of Figs. 1, 11, 19 and 21. Also, the external
snap fit ring 82 adapted to be disposed about the outlet
end portion 81B is structurally and functionally similar to
that hereinbefore described, and need not be repeated.
In the embodiment of Figs. 33 and 44, a wire retainer
or device 83 is arranged to extend into the inlet portion
81A, whereby a wire conductor 90, adapted to be inserted
into the inlet portion 81A, is retained therein merely by
inserting the wire conductor into the inlet end portion
81A. The arrangement is such that the wire conductor 90,
once inserted into the inlet portion 81A and past the free
end 83C of the wire retainer 83, positively retains the
wire conductor 90 so as to prohibit any unintentional
separation of the wire conductor 90 from the connector body
81, as best seen in Fig. 44.
The wire or conductor retainer 83 is formed from an
elongated rectangular blank 87, preferably a blank of
spring steel. The blank 87 is provided with a plurality of
longitudinally spaced apart transverse foldlines F1 to F6/
whereby the blank 87 can be readily formed to define the
spring steel retainer 83.
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CA 02537073 2006-02-21
As shown, the elongated blank 87, intermediate the
length thereof and adjacent the longitudinal edges 87A,
87B, is provided with die cut or slit 87C to form opposed
projecting prongs 88 that are bent out or project beyond
the plane of the blank 87. The right end of the blank 81,
as seen in Fig. 35, is reversely bent or folded about
foldlines F1 and F2 so as to overlie the projecting prongs
88, as best seen in Fig. 36, whereby the reversely bent end
83A is spaced above the projecting prongs 88. Formed in
the bent end 83A is an aperture or hole 89 which is
positioned to receive anchor pin or boss 86 in the
assembled position. The portion of the blank 87 to the
left of the prongs 88 are bent about transverse foldlines
F3, Fg, F5 and F6 at longitudinally spaced intervals to
configure the blank 87 with a series of angular bends, as
shown in Fig. 36. The angle of respective bends about the
respective foldlines F3 to F6 is not critical and may vary
depending upon the internal diameter of the inlet end 81A.
As shown in Fig. 44, the retainer device .83 may be
angularly bent so that the free end 83B extends to a
position sufficient to engage the wire conductor or the
wire covering or sheath 90, as noted in Fig. 44.
In the illustrated embodiment, the wire conductor, as
shown, includes a typical helically wound metallic sheath
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CA 02537073 2006-02-21
or covering 90 that houses the conducting insulated wires
90A. To facilitate the retention of the sheath 90, the
free end of the retainer device 83 may terminate in a
curvilinear arc 83B to complement the circumference of the
sheath 90 disposed between the adjacent helical ridges as
best seen in Fig. 44.
To assemble the wire retainer 83 to the inlet portion
81A of the connector body 81, the reversely bent end
portion is fitted to or clipped onto the end of the flat
closure or top 85, as best seen in Figs. 43 and 44 so that
the anchoring pin 86 is received in the hole 89. To secure
the retainer device 83 to the connector body 80, the top of
the anchor pin is swedged so as to deform the end of the
anchor pin 86, whereby the deformation of the anchor pin 86
firmly and fixedly secures the retainer device 83 to the
connector body. In the swedging operation, the prongs 88
formed in the blank 87 are caused to "bite" into the under
surface of the flat closure or top 85, as best seen in Fig.
44, to enhance the attachment of the retainer device 83 to
the connector body 81. To complete the assembly of the
connector assembly, the frustro conical external ring 82 is
snap fitted onto the conically formed outer end portion 81B
as hereinbefore described. While the means for securing
the wire retainer 83 to the connector body portion 81A is
38
CA 02537073 2006-02-21
described by means of a swedged pin, it will be understood
that other suitable fastening means may be used, e.g.
screws, bolts, welding, solder and the like.
As will be best noted in Fig. 44, the retainer device
is so formed that the free end 83B is arranged to extend
into the inlet portion 81A of the connector body 81 and is
angularly disposed so as to enable a wire conductor or
sheathing 90 to be unidirectionally inserted into the inlet
end portion 81A so as to be retained by the free end 83A of
the retaining device 83 in a manner whereby the wire
conductor 90 is prohibited from being unintentionally
separated from the connector body.
To effect the release of the wire conductor, one need
only to insert an appropriate tool to effect displacement
of the retainer device away form the wire conductor or
covering sheath 90, to effect the withdrawal of the
conductor sheath 90.
Fig. 37 illustrates a slightly modified wire retainer
device 91. The modified wire retainer device 91 is similar
to that the wire retainer 83, herein described, with the
exception that the free end of the blank 91A is provided
with an end notch 92 to define a pair of finger portions 93
for engaging and retaining a wire conductor, as
hereinbefore described. In all other respects, the
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CA 02537073 2006-02-21
structure of embodiment Fig. 37 is similar to the wire
retainer 83 as described.
To complete the connector assembly 80, an end ring
insert 84 may be provided to protect the wire conductors
90A that extend beyond the outlet end 81B, as noted in Fig.
44. The illustrated ring inset 84 preferably formed of a
suitable plastic, comprises a ring body 84A having an
outwardly radially extending flange 84B. Blanked out of
the plane of the ring body are opposed tangs 84C which are
outwardly bent. The outer diameter of the ring body 84A is
slightly smaller than the diameter of the opening 82A
formed in the face portion of the external retainer ring
82. The arrangement is such that the ring insert 84 can be
readily snap fitted to the opening 82A of the external
retainer ring 82 and the outlet opening of the outlet end
portion 81B. The insert body tangs 84C function to enable
the ring insert 84 to be readily snap fitted to the outlet
end portion 81A, so that the ring insert 84 is prohibited
from being unintentionally separated therefrom.
Intermediate the opposed opening of the connector
body, there is provided a radially outwardly projecting
stop flange 95, which functions to limit the insertion of
the connector assembly through a knock-out hole of an
electric panel or electric box, as hereinbefore described.
CA 02537073 2006-02-21
While the present invention has been described with
respect to several embodiments, it will be understood that
various modifications may be made without departing from
the spirit or scope of the invention.
41
