Note: Descriptions are shown in the official language in which they were submitted.
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Modified Electrical Cable Connector Assembly
Field of the Invention
This invention relates generally to electrical cable connectors, and more
particularly, to a protective modification to be used in conjunction with a
plug and
socket, electrical cable connector.
Background of the Invention
Various wire connectors are known in the prior art. One particular type of
connector utilizes a plug and socket approach for preparing the connector, and
is
described in, for example, US Patent No. 5637010. In these connectors, the
various
wires from an electrical cable are connected to either a male or female
contact insert
attachment. Once connected, the two contact inserts are "snapped" into two
separate
back shells, or housings, which hold the separate contact inserts. To
establish an
electrical connection, the male and female contact inserts are brought into
operative
engagement with one another. The components are typically held together by a
bayonet
and socket assembly. In this approach, a spring-loaded, or flexibly resilient,
bayonet
projection on one section of the connector is inserted into a corresponding
recess in a
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socket section on the opposite connector, where it "clips" into position and
locks the two
components of the connector, together.
The dimensions of the inside and outside parts of the connector components are
usually matched to one another, and the connectors can be used for various low
voltage
and higher voltage applications.
While this type of connection can be done for a single wire in a cable, more
typically, the connector is a multi-pole connector having a plurality of wires
within a
cable, to be connected through the connector. Further, while the connector
components
can be used to connect one end of a cable to a second end of a corresponding
cable, the
connector can also be used to attach a cable directly to a socket assembly on
an electrical
device.
Often, the electrical connector arrangement further comprises a sealing means
such that the electrical cable connection is protected from the weather once
the bayonet
and socket system has been fully engaged.
Commonly, the cable assemblies are pre-assembled so as to be easily connected
andJor installed on the job site, as required.
For most routine operations, this arrangement provides a rapid and normally
secure means for attachment of electrical cables, and these types of
electrical cable
connectors are widely used. For example, one supplier of these types of
devices is
Wieland Electric GmbH, of Germany.
However, occasionally, a more secure method of joining the electrical cable
connector components is desired. For example, in an oil-sand production
facility, the
cable connectors must be more securely fastened to ensure that they do not
become
disconnected under the rough conditions and weather typically encountered. For
example, cold weather can cause the bayonet section to become brittle and more
easily
broken, and the rough handling and other conditions can cause the connector
components to be either exposed to the weather by failure of the sealing
means, or in a
worse case scenario, to become disconnected one from the other.
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While stronger connectors of the bayonet and socket approach can be designed
and built, this would require production and stocking of additional "stronger"
devices
having an increased cost. If the "weaker" devices were already stocked, it
would be
necessary to replace them and/or stock additional components by the cable
manufacturer
in order to prepare cables having improved resistance to this type of
premature failure.
As such, it would be desirable to provide a more robust method of securing
these
types of plug and socket electrical cable connector assemblies, and in
particular, a more
robust method of securing those connectors which are held together by bayonet
and
socket assemblies.
Further, it would be desirable to provide a method for such providing improved
securement capability in a manner which can be easily accomplished by a user,
under
harsh weather conditions; - preferably without having to remove the user's
gloves or the
like.
Still further, it would be desirable to provide an arrangement wherein the
existing
plug and socket electrical cable connectors could be modified to provide
additional
strength properties, and which could be easily added to the cable assembly
during
production.
Summary of the Invention
An exemplary implementation of an enhanced plug and socket electrical cable
connector is provided herein wherein mated coupling rings are attached to each
end of
the cable connector assembly. These coupling rings are positioned on the ends
of the
mated connector components, but are sized so as to be connectable once the
connector
bayonet and socket arrangement has been engaged. The coupling rings are
preferably
threaded so as to allow an additional, and protective, locking means to be
engaged once
the cable connector components have connected.
The coupling rings are preferably mated, one to the other. Normally, coupling
rings will also have a male and female engagement relationship, and this can
be directly
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or indirectly related to the male/female engagement relationship of the
electrical
connector. For example, each male connector component might be associated with
a
male coupling ring, as will be seen hereinbelow.
Each portion of the coupling rings is sized so as to fit around at least part
of the
electrical connector assembly. At an end of the coupling ring, an aperture is
provided
through which the electrical cable can be fed. The aperture is sized so as to
allow the
cable to free pass through the coupling ring, but the aperture is small enough
that the
coupling ring preferably engages at least part of the back shell, or housing
component.
Prior to installation, the coupling ring can be free to move along the cable,
or can be held
adjacent to the connector component.
An exemplary implementation of the device includes a threaded coupling ring
fitted to the cable connector at one end of a cable, and a second,
correspondingly
threaded coupling ring fitted to the matched connector at the end of a second
cable, or on
the contact insert and assembly, fitted directly to an electrical device. In
this manner, the
mated coupling rings can be connected one to the other after the electrical
connector has
been operatively connected.
In a further exemplary implementation, a plurality of cable connectors can be
connected together using a multi-part connector assembly, such as a T-shaped
apparatus,
wherein each connector on the apparatus is fitted with a coupling ring which
is adapted
to be mated to a corresponding coupling ring on a connector affixed to the end
of an
electrical cable.
The advantages set out hereinabove, as well as other objects and goals
inherent
thereto, are at least partially or fully provided by the modified cable
connector of the
present invention, as set out herein below.
Accordingly, in one aspect, the present invention provides an enhanced
electrical
connector comprising:
at least two mated contact inserts connected to the ends of two electrical
wires or
cables and which form the ends of two connector assemblies, wherein said
contact
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inserts are adapted to be connected together in order to form an electrical
connection, and
wherein said contact inserts have first locking elements adapted to hold the
contact
inserts in an operative connection; and
two mated coupling rings, separately attached to said contact inserts, which
coupling rings can be brought into operative engagement as second locking
elements,
when said contact inserts have been connected together.
Brief Description of the Drawings
Embodiments of the invention will now be described by way of example only, in
association with the accompanying drawings in which:
Figure 1 is an exploded side view of a prior art plug and socket electrical
connector;
Figure 2 is an exploded side view of an enhanced plug and socket electrical
connector of the present invention;
Figure 3 is a perspective view of the two ends of the retainer nuts used as
coupling rings, in the present embodiment;
Figure 4A is a side view of the assembled components of the enhanced plug and
socket electrical connector of the present invention, which are ready to be
connected;
Figure 4B is a side view of part of the connector assemblies from Figure 4A;
Figure 4C is a side view of the completely assembled connector of this
embodiment of the present invention;
Figure 5 is an exploded view of an embodiment of the enhanced connector of the
present invention, wherein a cable is being attached to an electrical device;
and
Figure 6 is an exploded view of an embodiment of the enhanced connector of the
present invention, which is being used in an multi-part connection apparatus.
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Detailed Description of the Preferred Embodiments
The novel features which are believed to be characteristic of the present
invention, as to its structure, organization, use and method of operation,
together with
further objectives and advantages thereof, will be better understood from the
following
drawings in which a presently preferred embodiment of the invention will now
be
illustrated by way of example only. In the drawings, like reference numerals
depict like
elements. Further, unless otherwise specifically noted, all of the features
described herein
may be combined with each other, in any combination.
It is expressly understood, however, that the drawings are for the purpose of
illustration and description only and are not intended as a definition of the
limits of the
invention.
Referring to Figure 1, a prior art plug and socket electrical cable connector
apparatus 10 is shown having a female contact insert 12 to which the various
wires 14A
from electrical cable 16A have been attached. Female contact insert 12 is
adapted to be
snap-fitted into back shell 18A, which includes a threaded strain relief nut
20A which
can be tightened so as to engage cable 16A.
Similarly, male contact insert 22 is connected to wires 14B which are
contained
within cable 16B, and is adapted to be snap-fitted within a second back shell
18B. Again,
strain relief nut 20B is tightened so as to engage cable 16B.
A flexibly resilient plastic bayonet 23 having a barb 24 is provided on female
contact insert 12, which is adapted to be fitted within a corresponding socket
26 on male
contact insert 22. When male contact insert 22 is inserted into female contact
insert 12,
wires 14A and 14B are brought into operative connection. Simultaneously,
bayonet 23 is
inserted into recess 26 wherein barb 24 engages a stop located within recess
26. As
bayonet 23 is inserted, it is deformed, but springs back into shape when fully
inserted.
Barb 24 is then engaged within recess 26, and holds male contact insert 22 in
contact
with female contact insert 12.
The components of prior art apparatus 10 are known within the industry. As
will
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be known, while only one bayonet and barb have been shown, typically, a
plurality of
resilient bayonets with barbs can be used. Preferably, however, two bayonet
with barbs,
are used, and these are located opposite one another across the one connector
component. The bayonet can be located on either the male or female contact
insert.
The corresponding connector section on the mating connector, has a
corresponding number of recesses for receiving the bayonets and barbs. For the
locking
process, the barbs 24 are preferably blocked against a radial deflection by a
sleeve that
surrounds the outside part coaxially. For disconnection of the electrical
connector, the
barbs can be pushed inwards to disengage the locking mechanism, and the
connector
components released from one another.
Under sufficient strain on the cable, however, barbs 24 can break, or can
deform.
Either situation can result in accidental disconnection of the cable wires,
and it is this
disadvantage of the prior art, that the present invention seeks to address.
The construction materials of the various components of the prior art device
shown in Figure 1, are all known within the industry, and are outside of the
scope of the
present invention. Further, providing a sealing means, such as an 0-ring or
the like on
the contact inserts, and/or on the back shells, is also known within the
industry, so as to
prevent water, or the like, from reaching the exposed ends of wires 14. Again,
though,
the prior art sealing means and methods are outside of the scope of the
present invention.
In Figure 2, an exploded view of an enhanced electrical cable connector
apparatus 30, in accordance with the present invention, is shown. Apparatus 30
includes
the components described and shown in Figure 1, but additionally includes a
female
retainer nut 32A located near back shell 18A, and a male retainer nut 32B
located near
back shell 18B. Matching threads 34B on the male retainer nut 32B, and 34A
(Figure 3)
on female retainer nut 32A, are provided.
During assembly of the components, the ends of cables 16A and 16B are
removed to expose the wires 14A and 14B contained therein. The ends are then
passed
through an aperture 33A or 33B (Figure 3) in retainer nut 32A or 32B, and then
through
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back shells 18A and 18B. The wires can then be connected to contact inserts 12
and 22.
When this is complete, contact inserts 12 and 22 are snap fitted into back
shells
18A and 18B, respectively. Once in place, strain relief nuts 20A and 20B are
tightened to
engage cables 16A and 16B. The cable is now ready to be shipped and/or used,
and the
assembled components can be seen in Figure 4A.
In use, the male contact insert 22 of connector 30 is inserted into the female
contact insert 12 so that an electrical connection is established between
wires 14A and
14B. As a consequence of the insertion of male contact insert 22 into female
contact
insert 12, bayonets 23 is inserted and locked into recess 26. This can be seen
in Figure
4B. Male and female retainer nuts (32B and 32A), as coupling rings, can then
be brought
into contact with one another, and threaded together using the threads 34A and
34B.
Retainer nuts 32A and 32B tighten against a shoulder 21A and 21B on back
shells 18A
and 18B respectively. The resultant, assembled enhanced electrical connector,
as seen in
Figure 4C, is now complete, and the retainer nuts completely surround the area
where the
electrical connection is made, and are tightened against the back shoulders 21
A and 21 B
of back shells 18A and 18B. This not only protects contact inserts 12 and 22,
it also
assists in maintaining the electrical contact between inserts 12 and 22 in
conjunction
with the bayonet 23 and recess 26 connection.
Retainer nuts 32A and 32B thus act as a simple, reliable coupling ring
mechanisms to protect the entire connector 30 from damage, and act to prevent
the
premature or accidental disconnection of the electrical cables. Further,
retainer nuts 32A
and 32B can be sized so as to be easily threaded together even by an operator
wearing
gloves, or the like.
Retainer nuts 32A and 32B can be made from any suitable material including
metal or plastics, for example. However, preferred materials include impact
resistant
polymers including polyethylene, polypropylene, impact modified styrene or
ABS, or the
like. Again, for cold environments, plastic components are preferred to avoid
contact by
the user with cold metal.
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Retainer nuts 32A and 32B, when assembled, are not typically used for
protection
of the connector from the weather and/or water, since this function is already
provided
within connector 30. However, retainer nuts 32A and 32B can be modified to
provide
this function, if required.
In Figure 5, an exploded side view is shown of a connector 30A which is
adapted
to be fitted directly to an electrical device. In this case, the electrical
device is a light
assembly 40, and connector 30A is a modified connector; one end of which has
been
modified so as to be adapted to be attached to light assembly 40. As a result,
Wires 14B
extend from cable 16B within the light assembly 40, where they can be
connected to the
electrical connections for light assembly 40. Back shell 18B has been replaced
with a
modified, threaded back shell 42 which does not include a strain relief nut
20B, but has
modified thread 41 adapted to be threaded into the inside of modified retainer
nut 43.
Modified retainer nut 43 also includes an additional threaded section 44,
which section
44 is inserted through a rubber gasket 46, a suitably sized opening in light
assembly 40, a
equalization plate 48. A lock nut 50 is threaded onto threaded section 44 in
order to hold
retainer nut 43, back shell 42 and contact insert 22, on to light assembly 40.
In use, contact inserts 12 and 22 are snapped into back shells 18A and 42,
respectively. Contact insert 12 is inserted into contact insert 22, as
previously described,
and the bayonet and recess arrangement provides a locked electrical
connection. Retainer
nut 32A is then threaded onto the end of modified retainer nut 43 to provide
an enhanced
electrical connector.
In Figure 6, an exploded side view of a multi-part cable connector 60 having a
central connector apparatus 62 is shown having a T-shape, and thus having
three separate
legs 64. The cables and wires have been omitted for this embodiment.
Connected to each leg 64 is an adaptor 66 which is inserted into leg 64 and
held
in place by a clip lock, or some other device. Adapter 66 has an internal,
female thread
section (not shown) which is adapted to receive the male threaded section 41
from
modified back shel142. Male and female contact inserts (12, 22) are inserted
into back
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shells 42. Male and female retainer rings (32A and 32B) are provided at the
end of each
back shell 42, and are adapted to be connected to the corresponding retainer
rings from
the individual cables and connectors (not shown) that are to be attached to
connector 60.
In use, the ends of three cables can be attached to connector 60, in the
manner
previously described.
Thus, it is apparent that there has been provided, in accordance with the
present
invention, a modified and enhanced electrical cable connector, which fully
satisfies the
goals, objects, and advantages set forth hereinbefore. Therefore, having
described
specific embodiments of the present invention, it will be understood that
alternatives,
modifications and variations thereof may be suggested to those skilled in the
art, and that
it is intended that the present specification embrace all such alternatives,
modifications
and variations as fall within the scope of the appended claims.
Additionally, for clarity and unless otherwise stated, the word "comprise" and
variations of the word such as "comprising" and "comprises", when used in the
description and claims of the present specification, is not intended to
exclude other
additives, components, integers or steps.
Moreover, the words "substantially" or "essentially", when used with an
adjective
or adverb is intended to enhance the scope of the particular characteristic;
e.g.,
substantially planar is intended to mean planar, nearly planar and/or
exhibiting
characteristics associated with a planar element.
Further, use of the terms "he", "him", or "his", is not intended to be
specifically
directed to persons of the masculine gender, and could easily be read as
"she", "her", or
"hers", respectively.
Also, while this discussion has addressed prior art known to the inventor, it
is not
an admission that all art discussed is citable against the present
application.
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