Note: Descriptions are shown in the official language in which they were submitted.
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ELECTRICAL CONNECTORS WITH OUTER RETAINER RING
AND INTERNAL UNIDIRECTIONAL CONDUCTOR 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, U.S. Patent 6,935,891 and application Serial No.
11/180,085 filed July 13, 2005, which is a continuation in
part application of Application Serial No. 11/028,373 filed
January 3, 2005, which are incorporated herein by
reference.
More specifically, this application is directed to
further improvements in electrical connector assemblies
having an angular configuration wherein the outlet end is
disposed at an angle relative to the inlet end for
facilitating the connection of a flexible metal conduit and
the electric connector to an electric box or enclosure.
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
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junction box, outlet box, switch box, fuse box, or other
similar type of electric box or panel. Such known
electrical connectors are either of a type that are secured
to an 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.
Also known are 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.
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.
Heretofore, electrical connector assemblies oftentimes
required a connector body having the outlet end disposed at
an angle relative to the inlet end for connecting a
flexible conduit to a knock-out hole of an electric box or
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enclosure. Such known angular connector body had inlet
ends provided with a cover, clamp or screw means for
securing a wire conductor to the inlet end of the connector
body and/or for securing the inlet end to a flexible
conduit. Such known elbow or angular connector bodies
having such securing means generally required the use of
extraneous tools such as screwdrivers, pliers, wrenches or
the like for securing of such known connector bodies or
assemblies to a flexible conduit which was time consuming,
a nuisance, and at times relatively difficult.
Notwithstanding the extensive background relating to
electrical connectors, continuing efforts are being made to
improve, simplify and/or reduce the cost and/or complexity
of the known connectors in an effort to advance the
electrical connector art. The disclosure herein is
directed to such efforts.
SUNIIKARY OF THE INVENTION
An object of this invention is to provide a connector
assembly having a connector body formed with an outlet end
portion angularly disposed relative to an inlet end portion
which is fitted with a unidirectional wire conductor
retainer and which inlet end portion is formed so as to be
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frictionally secured to a flexible conduit without the use
of any extraneous hand tools.
An object of this invention is to provide an
electrical connector with a frustro-conically shaped
external retaining ring having a leading edge and a
trailing edge and integrally formed outwardly sprung
locking tangs that can readily be connected by a snap fit
to a knock-hole of an electric box, panel or enclosure
wherein the trailing edge functions as the electrical
ground between the electrical box and the connector
assembly.
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 for receiving therein a complementary
frustro-conical retaining ring that is readily fitted to
and retained on the outlet end portion of the connector
body, and having an inlet end angularly disposed relative
to the outlet end which is internally fitted with a snap
fit conductor retainer.
Another object is to provide a connector assembly
comprising a connector body having an outlet end free of
any locking ring retaining flange, with an associated
externally circumscribing snap fit retainer ring
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circumscribing the outlet end in a secured manner and an
inlet end angularly disposed relative to the outlet end.
Another object is to provide a retaining ring, adapted
to be fitted onto the outlet end of a connector body having
the outlet end angularly disposed relative to the inlet
end, whereby the retainer ring is frustro-conical in shape
with a first series of tangs for securing the connector
body relative to an electrical box and a trailing edge or
tang for affecting a positive electrical ground with an
associated electrical box.
Another object is to provide an electrical connector
assembly having a connector body with a frustro-conical
outer retainer ring circumscribing the outer surface of the
connector body outlet end and a unidirectional wire
conductor retainer associated with the inlet end of the
connector for securing an electrical wire or conductor
thereto without the need of any extraneous hand tools.
Another object is to provide a 902 electrical
connector assembly that includes a unidirectional wire or
conductor retainer extending internally of the inlet end
thereof for frictionally retaining a wire conductor to the
connector assembly so as to prevent any unintentional
separation of a wire conductor therefrom.
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Another object is to provide a 902 electrical
connector assembly provided with a snap fitting retainer
ring on the outlet end of the connector assembly for
attaching the connector assembly to an electrical box with
a snap fit and having an inner unidirectional wire
conductor retainer extending into the inlet end of the
connector assembly for securing a wire conductor thereto in
a manner to prohibit any unintentional separation of the
wire conductor from the connector assembly and whereby the
inlet end is formed so as to be frictionally secured to a
flexible conduit.
Another object of this invention is to provide a 902
electrical connector with a wire retainer whereby a helical
wound wire conductor can be secured thereto by merely
inserting the armored conductor wire into the inlet end of
the electrical connector to secure the wire conductor
thereto, so as to prohibit any unintentional separation of
the wire conductor from the electrical connector and
whereby a flexible conduit may be frictionally fitted to
the inlet end.
Another object is to provide or a 902 electrical
connector assembly that is relatively simple to fabricate,
positive in operation, and economical to produce and sell.
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The foregoing objects and other features and
advantages are attained by an electrical connector assembly
that includes a connector body having an outlet end adapted
to be secured to a knock-out hole of an electric box or
panel, and an inlet end angularly disposed relative to the
outlet end, the inlet end being adapted to receive an
electric or wire conductor. A radially outwardly extending
flange circumscribes the outlet end 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 of the
connector body is also 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 the outlet end portion. A
frustro-conically shaped snap ring is fitted onto the
outlet end portion.
The outer retaining ring is initially formed from a
blank of sheet material, e.g. spring steel or the like,
having a cruciform shape that includes a face portion or
simply a central opening wherein the radiating arms of the
cruciform blank are disposed about the face portion or
central opening to define a frustro-conical ring or cup.
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The ring or cup so formed is provided with blanked out or
die cut tangs to define outwardly bent locking tangs. The
trailing edge of the frustro-conical ring provides for
electrical grounding. 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 of the
connector body so that the free or trailing edges of the
ring define a grounding edge or tang that engages 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 central opening or
face forming portion that circumscribes the central
opening, to define a unitary frustro-conically shaped cup-
like member or ring to compliment or be fitted onto 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 receive the complementary retaining lug formed
on the surface of the outlet end portion for retaining or
securing 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 hole
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of an electric box wherein the locking tangs will initially
be flexed inwardly to pass through the knock-out hole of an
electric box, and then spring outwardly to lock the
connector assembly to the electric box with the trailing or
grounding edge or tang of the retaining ring being
inherently biased so as to be urged against the internal
periphery of the knockout hole due to the conical
configuration of the retaining ring to effect a positive
electric ground as a result of the inherent resiliency of
the respective grounding edge or tangs and the material
from which they are formed.
This invention further contemplates providing the
inlet end of the connector to be angularly disposed
relative the outlet end. A wire or conductor retainer is
positioned within the inlet end portion for positively
securing thereto a wire conductor by merely inserting the
wire conductor into the inlet end of a connector. The
inlet end portion is further formed so that it can be
readily friction fitted to the end of a flexible conduit to
effect the connection of the flexible conduit to an
electric box.
IN THE DRAWINGS
Fig. 1 is an exploded perspective view of the
electrical connector assembly.
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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 of Fig. 3.
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 909.
Fig. 10 is a fragmentary front view of the connector
assembly secured to an electric box as viewed from the
electrical box.
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.
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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.
Fig. 23 is a sectional view taken along line 23-23 on
Fig. 22.
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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.
Fig. 36 is a side view of the blank of Figs. 34 and 35
as formed to define wire retainer.
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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 of Fig. 33.
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. 39.
Fig. 42 is a right end view of Fig. 39.
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.
Fig. 45 is an exploded perspective of another modified
form of the invention.
Fig. 46 is a perspective view similar to Fig. 45
illustrated in the assembled position.
Fig. 47 is a side view of Fig. 46.
Fig. 48 is a side view of the connector assembly of
Fig. 47 in engagement with a pulling tool of the present
invention.
Fig. 49 is a bottom plan view of Fig. 48.
Fig. 50 is a side elevation view illustrating the
initial insertion of the connector assembly of Fig. 45 into
a knockout hole of an electric box.
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Fig. 51 is a side elevation view similar to Fig. 50
illustrating the connector assembly fully seated and locked
in the knockout hole of an electric box which is affected
by the lever action of the operating tool.
Fig. 52 is a perspective view of the operating tool
embodiment for facilitating the locking of an electrical
connector to an electric box.
Fig. 53 is a plan view of the tool of Fig. 52.
Fig. 54 is an edge view of Fig. 53.
Fig. 55 is a bottom plan view of Fig. 54.
Fig. 56 is a left end view of Fig. 55.
Fig. 57 is a perspective view of a slightly modified
tool.
Fig. 58 is a left end view of Fig. 57.
Fig. 59 is a perspective view of still another
modified operating tool.
Fig. 60 is an exploded perspective view of another
modified form of the invention.
Fig. 61 is a section side view of the embodiment of
Fig. 60 illustrating the manner for effecting the
connection of the modified embodiment of Fig. 60 to a
knock-out hole of an electric box.
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Fig. 62 is a section side view similar to Fig. 61
illustrating the connector assembly of Fig. 61 in locked
position relative to an electric box.
Fig. 63 is an assembled view of Fig. 1 connector
Fig. 64 is a front end view of the frustro-conical
retainer ring of the embodiment illustrated in Fig. 60.
Fig. 65 is a fragmentary detail sectional side view of
a modified auxiliary tang construction.
Fig. 66 is a plan view of a modified blank for forming
a frustro-conical snap fit retaining ring.
Fig. 67 is an exploded perspective view of still
another modification of the invention.
Fig. 68 is a top plan view of the embodiment of Fig.
67.
Fig. 69 is a right end view of Fig. 68.
Fig. 70 is a sectional view taken along line 70-70 on
Fig. 69.
Fig. 71 is a perspective of a partially exploded view
of another embodiment of the disclosed invention.
Fig. 72 is a perspective view of another modified form
of the disclosed invention illustrated without the outer
retainer ring.
Fig. 73 is a perspective exploded view of a further
embodiment of the invention.
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Fig. 74 is a side assembled view of Fig. 73.
Fig. 75 is a side sectional view taken essentially
along line 75-75 of Fig. 74.
Fig. 76 is a right end view of Fig. 74.
Fig. 77 is a perspective exploded view of a modified
form of the invention.
Fig. 78 is a perspective view of another embodiment of
the invention.
Fig. 79 is a cross sectional view of Fig. 78.
Fig. 80 is a perspective view of another modified
embodiment.
Fig. 81 is a cross sectional view of Fig. 80.
Fig. 82 is a perspective view of another modified
embodiment.
Fig. 83 is a cross sectional view of Fig. 82.
Fig. 84 is a perspective view of a further
modification of the invention.
Fig. 85 is an exploded perspective view of the
connector assembly of Fig. 88.
Fig. 86 is a detail side elevation view of the
connector body of Fig. 84.
Fig. 87 is a bottom view of Fig. 86.
Fig. 88 is a front elevation view of the connector
body of Fig. 86 as connected to a flexible conduit.
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Fig. 89 is a sectional view of the connector assembly
taken along line 89-89 on Fig. 84 as connected to a
flexible conduit.
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
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
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disposed 1809 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
formed to define a locking tang 22 and to either side
thereof the trailing edge defines 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 sprung outwardly and 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
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the electrical box 15, whereas the free ends or trailing
edges of the frustro-conical ring define the grounding
tangs 23 that are biased in engagement with the internal
periphery of the knockout hole 14. Also, the free edges or
ends 24, 24 of arms A,A 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 A,A and B,B 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 A,A and B,B 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 cantileverly and outwardly bent or displaced relative
to the surface of the frustro-conical ring at a slightly
greater outwardly angle or slope than the adjacent
grounding edge or tangs 23 and the slope of arms A,A. 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 A,A 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
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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 A,A free of the
retaining lugs 17.
It will be understood that, if desired, the opening
20A may be enlarged to the diameter of the foldline f, in
which case the arms A,A and B,B may be gradually bent about
the periphery of the enlarged opening, thereby eliminating
the face portion 20.
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 A,A,
respectively, will depress inwardly to permit insertion of
the assembly 10. When the assembly is fully seated in the
knockout hole 14, the locking tangs 22 will normally spring
outwardly to secure the assembly 10 to the electric box 15,
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as noted in Fig. 9. The inherent resiliency of the
grounding tangs 23, 23 and the free ends or edges 24 of
arms A,A 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 A,A and grounding
tangs 23, 23 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 forms of securing means, including
some of the securing wire conductor retaining means
disclosed herein, may be used in lieu of a screw.
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 of spring metal
whereby the opposed radially extending arms A,A and B,B 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.
Figs. 11 to 19 illustrate various views of a modified
form of the invention which are described in application
S.N. 11/100,250 filed April 6, 2005 for Snap In Electrical
Connector Assembly With Unidirectional Wire Conductor Ring,
which is incorporated by reference herein.
In the embodiment illustrated in Fig. 11, the
connector assembly 30 includes an internal wire retainer 39
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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
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.
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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.
As shown in Figs. 15 and 18, the respective finger
tangs 45A, 45A are inwardly bent from 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 or may be 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
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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
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
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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
well as by simply inserting the armored covered conductor
into the retainer sleeve to effect a snap fit connection.
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 61 having an outlet end 61A and an inlet end
64 connected to the outlet end 61A by a transition section
68, 68A, preferably formed as casting of any suitable metal
or alloy material, e.g. zinc, aluminum and the like. While
the inlet end 64 of the connector body 61 is illustrated as
a duplex inlet end, it will be understood that the inlet
end may be formed to accommodate more than two separate
wire conductors, cables or the like.
The outlet end 61A and the external frustro-conical
ring 76 circumscribing the outlet end 61A are similar in
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CA 02605681 2007-10-04
structure hereinbefore described with respect to Figs. 1 to
10. A more detailed description of the embodiments
disclosed in Figs. 20 to 32 is set forth in application
S.N. 11/100,250 filed April 6, 2005 for Snap In Electrical
Connector Assembly With Unidirectional Wire Conductor
Retaining Ring, which is incorporated herein by reference.
With the connector body of Fig. 20 illustrated, 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. With the
arrangement described, the respective wire conductors or
cables 80 can be readily attached to the trailing or inlet
end of the connector assembly 60 with a simple snap fit, as
described in application S.N. 11/100,250 filed April 6,
2005, which is also incorporated by reference herein.
From the foregoing, it will be noted that the
connector assemblies disclosed in Figs. 1 to 32 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
e
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CA 02605681 2007-10-04
electrical ground. In association with an external frustro
conical retaining ring, the disclosed embodiments include a
trailing or inlet end constructed to receive an associated
wire or conductor retainer in each inlet end for securing a
wire conductor thereto by a snap fit inlet end of the
connector body. It will be understood that the described
electrical connector bodies may include one or more wire
receiving chambers formed in the inlet end thereof,
depending upon the number of wire conductors one may wish
to connect to the inlet end of a connector body.
Figs. 33 to 44 illustrate a further modification of
the invention. In this embodiment, the connector assembly
81 includes a connector body 81A having 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. The outlet end 81B of the connector
body 81A and the external frustro-conical retainer ring is
similar in structure and function as hereinbefore
described. A more detailed description of the embodiments
33 to 44 are set forth in application S.N. 11/151,374 filed
June 13, 2005, which is incorporated herein by reference.
Figs. 45 to 51 illustrate another embodiment of the
invention. The embodiment of Figs. 45 to 51 is directed to
a snap-fit electrical connector assembly 100 which is
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CA 02605681 2007-10-04
particularly suitable for attaching an electric cable or
conductor 101 to an electric box 102 which is disposed in a
finish wall structure 103, and which is rendered the
subject matter of an application S.N. 11/258,990 filed
October 26, 2005, which is incorporated herein by
reference.
It is frequently necessary to upgrade, repair, or add
new electric conductors or circuits to existing electric
boxes concealed within the wall of an existing structure.
In such instances, the installer is generally unable to
access a snap-fit connector so as to apply the necessary
pulling or pushing force necessary to insert and lock a
snap-fit connector assembly, e.g. 100, in a knockout
opening of the electric box 102. Heretofore, in such
situations, the installer generally utilized a connector
having a threaded outlet end which could be readily passed
through a knockout hole of an electric box, which could
then be secured by threading thereon a lock nut from within
the box opening, which is both difficult and time
consuming.
The connector assembly 100, as illustrated, includes a
connector body 104 having a leading end or outlet end 105
and a trailing or inlet end 106. The connector body may be
formed as a metal casting of a suitable material, e.g. a
0
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CA 02605681 2007-10-04
zinc alloy, having a bore 107 extending therethrough.
Circumscribing the connector body 104 between the outlet
end 105 and the inlet end 106 is a radially outwardly
extending stop flange 108. As hereinbefore described, the
outer surface S of the outlet end 105 tapers or converges
inwardly toward the central axis of the connector body 104
and the outlet opening 109.
Complementing the slope or taper of the outer surface
S of the outlet end 105 is a frustro-conical snap-fit
retainer ring 110 which is similar in structure
hereinbefore described with respect to Figs. 1 to 4, except
that the width of the retaining slot 111 adapted to receive
the retaining lug 112 is enlarged, as compared to the width
of retaining slot 21 as hereinbefore described. As best
seen in Figs. 47 and 48, the retaining slot 111 has a width
which is greater than the width of the retainer lug 112
adapted to be received in slot 111 in the assembled
position, as best illustrated in Figs. 46 and 47. In all
other respects, the structure of the retainer ring 110 is
similar to the construction of retainer ring 18
hereinbefore described with respect to the embodiments
illustrated, for example in Figs. 1 to 4, and which need
not be repeated. A more detailed description of Figs. 45
to 51 is set forth in application S.N. 11/258,990 filed
CA 02605681 2007-10-04
October 26, 2005, which is incorporated herein by
reference.
Figs. 60 to 66 illustrate a further embodiment of the
invention. As best seen in Figs. 61 and 62, the connector
assembly 200 comprises a connector body 201 and a modified
outer frustro-conical retainer ring 202 as described in a
co-pending application S.N. 11/364,435 filed February 28,
2006, for Snap Fit Electrical Connector Assembly For
Facilitating The Electric Connector Assembly To An Electric
Box, which is incorporated by reference herein.
While the embodiment of the connector assembly 200 of
Figs. 60-66 is illustrated without any electrical conductor
retaining means associated with the inlet end portion 201A
of the connector body 201, it will be understood that the
inlet end portion 201A may be fitted with any of the wire
conductor retainer means as are described and illustrated
herein, the descriptions of which need not be repeated.
Figs. 67 to 70 illustrate a further embodiment of the
invention. The connector assembly 300, as illustrated in
Figs. 67 and 68, includes a connector body 301 formed as a
unitary casting of any suitable metal or alloy, e.g. zinc
and the like. The form of the casting is somewhat similar
to that shown in Fig. 20. The embodiment of Fig. 67
differs from that of Fig. 20 in that connector body 301 is
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CA 02605681 2007-10-04
formed as a unitary casting rather than as separable parts
as illustrated in Fig. 20. A more detailed description of
the embodiment of Figs. 67 to 70 is set forth in
application S.N. 11/403,009 filed April 12, 2006, for Snap
Fit Electrical Connector Assembly With Frustro-Conical
Retainer Ring And Internal Unidirectional Snap Fit Wire
Conductor Retainer, which is incorporated by reference
herein.
Figs. 71-83 illustrate further modified embodiments of
the invention which is disclosed in the co-pending
application Serial No. 11/501,131 filed August 8, 2006 for
Electrical Connector With Outer Retainer Ring And
Unidirectional Conductor Retainer, which is also
incorporated by reference herein, and need not be repeated
herein.
Figs. 84 to 89 illustrate a further embodiment of the
invention. The electrical connector assembly 500 disclosed
in Figs. 84 to 89 are particularly useful in connecting
flexible conduits that shield or direct wire conductors,
cables and the like to an electric box or enclosures 501.
As shown, the electrical connector assembly 500 includes a
connector body 502, which may be described as an elbow
having an outlet end portion 502A and an inlet end portion
502B that are angularly disposed relative to one another
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CA 02605681 2007-10-04
and having a bore B extending therethrough. In the
illustrated embodiment, the outlet end portion 502A and the
inlet end portion 502B are disposed at a 902 angle relative
to one another. However, it will be understood that the
angle formed by the axises of the outlet end portion and
inlet end portion is not crucial. The angle between the
outlet and inlet end portions may define any other suitable
angles such as 452 angle, 602 angle, or other suitable
angular standard as practiced in the electrical arts. The
connector body 502 is preferably formed as a metal casting
which may comprise zinc, aluminum or such other material
that would satisfy any code requirements as practiced
within the electrical industry.
Circumscribing the outlet end portion 502A is a
radially outwardly extending flange 503 to function as a
stop to limit the amount that the connector body may be
inserted through a knock-out hole of an electric box or
enclosure 501. The inlet end portion 502B is also provided
with a stop flange 505 that limits the amount of the
connector body that may be inserted into a flexible conduit
506, as will be hereinafter described.
As hereinbefore described, the outer surface "S" of
the outlet portion 502A slopes downwardly toward the outlet
opening 507 defined by the outlet end portion 502A. Formed
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CA 02605681 2007-10-04
on the sloping surface S are opposed retaining lugs 504,
similar to that hereinbefore described. Circumscribing the
outlet end portion 502A is a frustro-conical retainer ring
508, which is similar in structure to that described with
respect to Figs. 2 to 6, which need not be repeated herein.
The inlet end portion 502B has a generally circular
outer surface provided with one or more circumferentially
spaced, longitudinally extending external ribs,
protrusions, or slightly raised linear surface 509. Press-
fitted or frictionally-fitted in the inlet end portion 502B
is a wire or electrical conductor retainer 510. The wire
or conductor retainer 510 is in the form of a sleeve 511
formed of spring metal and having a generally circular
surface, a portion of which comprises a flattened portion
511A, similar to that hereinbefore described. Blanked out
of the surface of the retaining sleeve 511 are oppositely
disposed wire retaining tangs 512. In all other respects,
the wire retainer sleeve 511 is constructed similar to that
hereinbefore described with respect to Figs. 13 to 18, and
which need not be repeated. The arrangement is such that
the wire retainer sleeve 511 is force fitted or press
fitted to the interior surface of the inlet end portion
502B. The frustro-conical wire retainer ring 508 is fitted
onto the outer sloping surface S of the outlet end portion
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CA 02605681 2007-10-04
502A and is retained thereon by the inter-engaging of the
retaining lugs 504 within the slots 513 of the external
frustro-conical retainer ring 508, similar to that
hereinbefore described.
In operation, the external frustro-conical retaining
or locking ring 508 is readily snap fitted onto the sloping
complementary surface S of the outlet end portion 502A, and
is retained thereon by the inter-engagement of the retainer
lugs 504 engaging the retaining slots 513 of the external
frustro-conical retaining ring 508. The wire retainer
sleeve 511 is pressed or force fitted in the inlet end
portion 502B. The arrangement is such that the inlet end
portion 502B can readily be secured to a flexible conduit
506 as noted in Figs. 88, 89 with a frictional fit so that
the conductors, wires or cables directed through the
flexible conduit 506 can be unidirected from the inlet end
portion and through the outlet end portion 502A in a manner
whereby the wire conductor or cable cannot be
unintentionally separated form the inlet end portion 502B.
The arrangement is such that the outlet end portion 502B
can be readily snap fitted to a knock-out hole simply by a
snap fit, and without the use of any hand tools. The
electrical connector assembly 500 as described herein
simplifies the fabrication of the connector body by
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CA 02605681 2007-10-04
eliminating the requirement of a cover plate or other
clamping means for securing a cable or conductor to the
inlet end portion and/or to a flexible conduit, as was
hereinbefore customary.
From the foregoing, it will be apparent that the
principle components described herein, viz. the external
frustro-conical retainer rings, the connector bodies and
the differently described wire conductor retainers, are
rendered readily interchangeable with respect to the
complementary components of the other embodiments described
herein.
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.
36
