Note: Descriptions are shown in the official language in which they were submitted.
CA 02629503 2011-03-03
ADJUSTABLE CONNECTOR FOR ELECTRICAL CABLE
[001]
FIELD OF THE INVENTION
[0021 The present invention relates to fittings for electrical cables. In
particular, the
present invention relates to adjustable connectors that are used to change the
direction of
electrical cables.
BACKGROUND OF INVENTION
[0031 Armored electrical cables can be used in a wide variety of applications.
They are
particularly suited for applications that require the wiring to be isolated
from the
surrounding environment. The construction of the cables permits them to be
used in
environments which are referred to as hazardous locations, as well as in non-
hazardous
locations. Traditionally, wiring runs in hazardous locations use rigid metal
conduit.
However, when permitted by the applicable electrical codes, flexible armored
cable may be
used in place of rigid conduit. In general, rigid conduit is more difficult
and more
expensive to install than armored cable. Therefore, users prefer to use
armored cable
whenever the electrical codes permit.
[0041 Armored cable, typically, includes an electrically conductive flexible
metal casing
which protects the conductors running within from abrasion, impacts and the
like. In
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addition, the metal casing permits the cable to be grounded throughout its
length. An outer
plastic or rubber sheath typically covers the metal casing thereby adding
water proof
protection to the cable, as well as protecting the metal sheathing from
corrosive elements.
Although armored cable is more flexible and easier to install than rigid
conduit, its bend
radius can make it difficult to form tight bends and, hence, installation in
certain locations
requires elbows or other fittings.
[005] In the past, a 90-degree bend in an armored, electrical cable was
accomplished
using either an assembly of different approved fittings (e.g., a pull elbow
connected to a
straight fitting) or a short single 90 degree fitting. Similarly, fittings for
other bend angles
were used and, as a consequence, a user was required to stock fittings for a
variety of
different angles. This was found to be expensive and inconvenient.
[006] Accordingly, there is a need for a fitting for changing the direction of
an armored,
electrical cable, as well as other types of electrical cables, that can be
quickly and easily
installed. There is a further need for an adjustable connector for armored and
other types
of electrical cables that can make bends in an armored, electrical cable over
a range of at
least from 0-90 degrees and preferably from 0-135 degrees.
SUMMARY OF THE INVENTION
[007] In accordance with the present invention, an adjustable connector for
armored and
other types of electrical cables is provided. The adjustable connector
includes a body, a
hub and a coupling nut. The body has a longitudinal axis, opposing ends and an
aperture
extending therebetween. One end is flanged with a scalloped edge and a face
that is
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angularly disposed to the longitudinal axis and the other end is a cable
connecting end.
The hub has a central axis, first and second ends and an opening extending
therebetween.
The first end has a mating surface that is angularly disposed to the central
axis and the
mating surface has a dovetail extending around about one half of the outer
perimeter. The
dovetail can be formed as one continuous dovetail or a plurality of spaced,
individual
dovetails. In a preferred embodiment, the dovetail is formed as two separate
dovetails with
a notch in between. The coupling nut has first and second ends and an opening
extending
therebetween with internal threads. The dovetail on the mating surface of the
hub is
adapted to receive the flanged end of the body and the coupling nut is
threaded onto the
hub to secure the flanged end in the dovetail.
[0081 In preferred embodiments, the face of the flange on one end of the body
is angularly
disposed to the longitudinal axis at an angle of about 45 degrees and the
mating surface on
the first end of the hub is angularly disposed to the central axis at an angle
of about 45
degrees. When the face of the flange is connected to the mating surface, the
body and the
hub can be rotated so that the connector forms various bend angles. The
adjustable
connector can be oriented so that the body is connected to the hub and the
longitudinal axis
is substantially parallel to the central axis or the longitudinal axis is
disposed with respect
to the central axis at an angle of about 45 degrees, about 90 degrees or about
135 degrees,
or any angle in-between.
[0091 In another embodiment, the face of the flange on the end of the body is
angularly
disposed to the longitudinal axis at an angle of from about 30 to 60 degrees
and the mating
surface on the first end of the hub is angularly disposed to the central axis
at an angle of
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from about 30 to 60 degrees. Changing the angular disposition of the flange
and the
mating surface allows the connector to be oriented to provide a bend angle of
from 60
degrees to 120 degrees.
[010] The hub can have an exterior surface that is threaded in the region
adjacent to the
mating surface end for receiving the coupling nut. The coupling nut preferably
contacts the
flanged end at a point opposite the dovetail to lock the flange to the hub.
The cable
connecting end of the body and the second end of the hub opposite the mating
surface can
be threaded and adapted to receive a threaded cable fitting.
[011] Ina preferred embodiment, the flanged end has indicia of the angular
disposition of
the adjustable connector on its surface and the dovetail has a notch near the
center. When
the flanged end is secured in the dovetail and oriented to preferred angles
(e.g., 45, 90, 135
or 180 degrees) the indicia is viewable through the notch. This allows the
user to verify
that the adjustable connector is properly oriented.
[012] In a second embodiment of the adjustable connector, the adjustable
connector
includes a body, a hub and a coupling nut. The body has a longitudinal axis
and includes a
first cable connector end and a first mating end and an aperture extending
therebetween.
The first mating end has a flange with a scalloped edge and a face that is
angularly
disposed to the longitudinal axis. The hub has a central axis and includes a
second cable
connector end and a second mating end and an opening extending therebetween.
The
exterior surface of the hub adjacent to the second mating end is threaded and
adapted to
receive the coupling nut.
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[013] The second mating end of the hub has a flange that is angularly disposed
to the
central axis and a dovetail along the outer perimeter of the flange.
Preferably, the dovetail
extends around about one half of the outer perimeter. The dovetail is adapted
to receive
the flange of the first mating end and the coupling nut is threaded onto the
hub to secure
the flange of the first mating end in the dovetail. Preferably, the dovetail
of the second
mating end rotatably receives the flange of the first mating end. The dovetail
can be
located on the angularly disposed second mating end at a maximal distance from
the
second cable connector end and the coupling nut contacts the flange of the
first mating end
at a point opposite the dovetail. The dovetail can also include an exterior
surface having
one or more finger grips that facilitate the joining of the two mating ends.
The finger grips
are formed by one or more protrusions extending radially from the dovetail or
by one or
more raised members on the dovetail, preferably a plurality of substantially
parallel ribs.
[014] The flange of the first mating end can have indicia of the angular
disposition of the
adjustable connector and the dovetail of the second mating end can have a
notch. The
indicia are viewable through the notch when the flange of the first mating end
is secured in
the dovetail.
[015] The coupling nut has a first end with a perimetrical edge. The scalloped
edge of the
flange of the first mating end has a plurality of recessed portions which are
positioned so
that the perimetrical edge contacts one or more of the recessed portions when
the coupling
nut is tightened. Preferably, the recessed portions are arranged in a
plurality of pairs so that
two points on the perimetrical edge of the coupling nut contact one of the
pairs when the
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body is oriented with respect to the hub at an angle of 45, 90, 135 or 180
degrees.
(016) Ina third embodiment, the adjustable connector includes a body, a hub, a
first
coupler and two coupling nuts. The body and the hub are the same as described
above for
the second embodiment. The first coupler has a longitudinal axis and includes
a first
mating end having a flange with a scalloped edge that is angularly disposed to
the
longitudinal axis, a second mating end having a flange with a dovetail
angularly disposed
to the longitudinal axis and an axial passage extending therebetween. The
first coupling
nut is threaded onto the hub and the second coupling nut is threaded onto the
first coupler.
The dovetail of the hub is adapted to receive the flange of the first coupler
and the first
coupling nut is tightened to secure the flange of the first coupler in the
dovetail of the hub.
The dovetail of the first coupler is adapted to receive the flange of the
first mating end and
the second coupling nut is tightened to secure the flange of the first mating
end in the
dovetail of the first coupler.
10171 The flange on the second mating end has an outer perimeter and the
dovetail
extends around about one half of the outer perimeter. Similarly, the flange on
the first
coupler has an outer perimeter and the dovetail extends around about one half
of the outer
perimeter. The dovetail of the hub rotatably receives the flange of the first
coupler and the
dovetail of the first coupler rotatably receives the flange of the body. The
flange of the
body can have first indicia of the angular disposition of the body in relation
to the first
coupler and the dovetail of the first coupler can have a notch. The first
indicia are
viewable through the notch when the flange of the body is secured in the
dovetail of the
first coupler at predetermined orientations, such as 45, 90, 135 and 180
degrees. Similarly,
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the flange of the first coupler can have second indicia of the angular
disposition of the first
coupler in relation to the hub and the dovetail of the hub can have a notch.
The second
indicia are viewable through the notch when the flange of the first coupler is
secured in the
dovetail of the hub at predetermined orientations, such as 45, 90, 135 and 180
degrees.
[018] The body can be connected to the first coupler and the first coupler can
be
connected to the hub so that the longitudinal axis of the body is
substantially parallel to the
central axis of the hub or the longitudinal axis of the body is disposed with
respect to the
central axis of the hub at an angle of about 45 degrees, about 90 degrees,
about 135 degrees
or about 180 degrees, or various angles from 0 to 180 degrees.
[019] The first coupler can have a stem section that includes the first mating
end and a
stem end and a base section that includes the second mating end and a sleeve
end. The
stem end is inserted through the second coupling nut and rotatably received by
the sleeve
end. The stem section freely rotates with respect to the base section until
the second
coupling nut is tightened.
[020] The adjustable connector can also include a second coupler that is the
same as the
first coupler. The second coupler can be connected to the first coupler and
the body or it
can be connected to the first coupler and the hub.
[020.1] According to one aspect of the present invention there is provided an
adjustable
connector for electrical cables, the adjustable connector comprising a body
having a
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longitudinal axis, opposing ends and an aperture extending therebetween,
wherein one end
is flanged with a scalloped edge and a substantially flat face that is
angularly disposed to
the longitudinal axis and the other end is a cable connecting end; a hub
having a central
axis, first and second ends and an opening extending therebetween, wherein the
first end
has a mating surface that is angularly disposed to the central axis and the
mating surface
has a perimetrical edge and a dovetail extending around about one half of the
perimetrical
edge; and a coupling nut, wherein the scalloped edge of the flanged end is
slidably
received in the dovetail and the coupling nut is threaded onto the hub to
secure the flanged
end in the dovetail.
1020.21 According to a further aspect of the present invention there is
provided an
adjustable connector for electrical cables, the adjustable connector
comprising a body
having a longitudinal axis and comprising a first cable connector end and a
first mating end
and an aperture extending therebetween, wherein the first mating end has a
flange with a
face and a scalloped edge and wherein the face of the flange is angularly
disposed to the
longitudinal axis at an angle of from 30 to 60 degrees; a hub having a central
axis and
comprising a second cable connector end and a second mating end and an opening
extending therebetween, wherein the second mating end has a flange, the flange
having a
face, a perimetrical edge and a dovetail extending along a portion of the
perimetrical edge,
and wherein the face of the flange is angularly disposed to the central axis
at an angle of
from 30 to 60 degrees; and a coupling nut, wherein the scalloped edge on the
flange of the
first mating end slides into and is received by the dovetail and the coupling
nut is threaded
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onto the hub to secure the flange of the first mating end in the dovetail.
[020.3] According to another aspect of present invention there is provided an
adjustable
connector for electrical cables, the adjustable connector comprising a body
having a
longitudinal axis and comprising a first cable connector end and a first
mating end and an
aperture extending therebetween, wherein the first mating end has a flange
with a scalloped
edge angularly disposed to the longitudinal axis; a hub having a central axis
and
comprising a second cable connector end and a second mating end and an opening
extending therebetween, wherein the second mating end has a flange with a
dovetail
angularly disposed to the central axis; a first coupler having a longitudinal
axis and
comprising a first mating end having a flange with a scalloped edge angularly
disposed to
the longitudinal axis, a second mating end having a flange with a dovetail
angularly
disposed to the longitudinal axis and an axial passage extending therebetween;
and a first
coupling nut and a second coupling nut, wherein the first coupling nut is
threaded onto the
hub and the second coupling nut is threaded onto the first coupler, wherein
the dovetail of
the hub is adapted to receive the flange of the first coupler and the first
coupling nut is
tightened to secure the flange of the first coupler in the dovetail of the hub
and wherein the
dovetail of the first coupler is adapted to receive the flange of the first
mating end and the
second coupling nut is tightened to secure the flange of the first mating end
in the dovetail
of the first coupler.
BRIEF DESCRIPTION OF THE FIGURES
[0211 The preferred embodiments of the adjustable cable fitting of the present
invention,
as well as other objects, features and advantages of this invention, will be
apparent from
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the accompanying drawings wherein:
[022] FIGs. 1 A-B are atop view and a sectional view of an embodiment of the
adjustable
connector of the present invention in the unlocked position.
[023] FIG-s. 2A-B are a top view and a sectional view of an embodiment of the
adjustable
connector of the present invention in the locked position.
[024] FIG. 3A is a bottom view of an embodiment of the hub component of the
adjustable
connector of the present invention.
[025] FIG. 3B is a bottom view of an embodiment of the body component of the
adjustable connector of the present invention.
[026] FIG. 4A is a perspective view of an embodiment of the hub component of
the
adjustable connector of the present invention.
[027] FIG. 4B is a perspective view of an embodiment of the body component of
the
adjustable connector of the present invention.
[028] FIG. 5A is a perspective view of an embodiment of the hub and body
components
of the adjustable connector of the present invention with their axes in
parallel relationship.
[029] FIG. 5B is a perspective view of an embodiment of the hub and body
components
of the adjustable connector of the present invention with their axes disposed
at a right
angle.
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[030] FIG. 6A is a perspective view of an embodiment of the hub and body
components
of the adjustable connector of the present invention with their axes in
parallel relationship.
[0311 FIG. 6B is a perspective view of an embodiment of the hub and body
components
of the adjustable connector of the present invention with their axes disposed
at a right
angle.
[032] FIG. 7A is a side view of an embodiment of the hub and body components
of the
adjustable connector of the present invention with their axes in parallel
relationship.
[033] FIG. 7B is a side view of an embodiment of the hub and body components
of the
adjustable connector of the present invention with their axes disposed at a
right angle.
[0341 FIGs. 8A-B are a top view and a sectional view of an embodiment of the
adjustable
connector of the present invention in the unlocked position.
[035] FIG. 9A-B are a top view and a side sectional view of an embodiment of
the
adjustable connector of the present invention with the body and hub disposed
at a right
angle.
[0361 FIGs. 1OA-C area side view, an end view and a sectional view of an
embodiment
of the adjustable connector of the present invention that includes body, hub
and coupler
components disposed coaxially.
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[037] FIGs. 1 IA-C area side view, an end view and a sectional view of an
embodiment
of the adjustable connector of the present invention that includes body, hub
and coupler
components forming a 90-degree bend.
[038] FIGs. 12A-C are a side view, a sectional view and a bottom view of an
embodiment
of the adjustable connector of the present invention that includes body, hub
and coupler
components forming a 45-degree bend.
[039] FIGs. 13A-B are a side view and a perspective view of an embodiment of
the
adjustable connector of the present invention that includes body, hub and two
coupler
components forming a 135-degree bend.
[040] FIGs. 14A-B are detail views of the coupler component shown in FIGs. 1OA-
11B.
[041] FIGs. 15A-B are perspective views illustrating the relationship between
a flanged
end and a coupling of an embodiment of the connector of the present invention.
[042] FIGs. 16A-B are perspective views illustrating the relationship between
a flanged
end and a coupling of an embodiment of the connector of the present invention.
[043] FIGs. 17A-B are perspective views illustrating the relationship between
a flanged
end and a coupling of an embodiment of the connector of the present invention.
[044] FIGs. 18A-C are top, side and perspective views of an embodiment of the
body
section of the adjustable connector with indicia on the top surface of the
flange.
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[045] FIGs. 19A-B are side and perspective views of an embodiment of the hub
section of
the adjustable connector with finger grips on the dovetail.
DETAILED DESCRIPTION OF THE INVENTION
[046] The present invention is an adjustable connector (also referred to
herein as an
"adjustable fitting" or "connector") that is used with armored and other types
of electrical
cables to make bends in a cable run. In general, armored cables are metal clad
and contain
one or more individually insulated conductors. Preferably, the armored,
electrical cable is
a flexible, interlocked aluminum armored cable having an inner PVC jacket over
the
insulated conductors as well as outer PVC jacket over the armor. Such cables
are referred
to herein as "teck cables." However, the invention is not limited to use with
teck or other
types of armored cables and can be used with any electrical cable. As used
herein, the term
"armored electrical cable" means a metal (e.g., steel, aluminum or brass) or
non-metal
(e.g., plastic) conduit or cable having a flexible, corrugated construction
with or without
interlocking helix, whether jacketed or unjacketed or lined or unlined (e.g.,
with a PVC
jacket or liner).
[047] The present invention relates to adjustable fittings or connectors that
are used for
bends in electrical cables. The connectors have two or more components that
have
apertures which extend substantially straight through the components. This
allows the
cables to be easily inserted directly into each of the straight components of
the fitting
without having to bend the cable to conform to the shape of the fitting, which
is typically
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the case with elbow fittings. This eliminates the struggle of pre-bending the
cable and
forcing the wire bundle through a 90 degree elbow.
[048] Traditional rigid 45 or 90-degree fittings need to be disassembled into
separate
components before a prepared cable is inserted and then re-assembled when the
cable is in
place. With regard to armored cables, "prepared cable" means an armored cable
with the
outer protective coating and/or the armored portion removed so that the cable
is compatible
with the connector. The connectors of the present invention can be
disassembled into
separate components and the cable inserted through the separate components or
the
connectors can remain assembled during cable insertion. Prior to running the
cable, the
adjustable connectors can be rotated into a variety of configurations to
facilitate insertion
of the cable by the user. In a preferred configuration, the axes of the two or
more
components that make up the connector are aligned and form an aperture that
goes
substantially straight through the connector without any bends. This "straight-
through"
configuration facilitates the insertion of the cable. After the cable is run
and bends need to
be made, the connector components are rotated (or swiveled) to form the
desired angle and
then locked into position with the coupling nut. The angle formed by the
connector can be
varied from 0 to 90 degrees before the connector is locked in final position.
In some
applications, the user may find it more convenient to adjust the connector to
a specific
angle before inserting the cable. In other applications, the user may choose
not to tighten
the coupling nut so that the cable and connector are not locked into position.
[049] When a bend in an electrical cable is made, the bending of the
conductors occurs
only at a point inside the fitting. This is a significant improvement over the
prior art
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elbows, wherein the entire cable run needed to be pre-bent and forced through
the bending
angle of the elbow. The straight-through configuration of the components of
the adjustable
fitting of the present invention provides openings in the body and hub that
are aligned and
concentric. The angularly disposed flanged end of the body and the angularly
disposed
flanged end of the hub each have elliptically shaped openings with a major
axis (i.e., the
maximum distance between the opposing sides of the opening) and a minor axis
(i.e., the
minimum distance between the opposing sides of the opening). When the body and
hub
are rotated to form different angles for the connector, the minimum opening in
the
connector is at least equal to the minor axis of the body or hub (whichever is
smaller).
[050] The adjustable connector includes a body and a hub rotatably coupled
together so
that each member can be rotated relative to the other between a first
position, wherein the
body and hub extend in longitudinal alignment to provide a straight
connection, and a
second position, wherein the longitudinal axes of the body and hub extend at a
90 degree
angle with respect to the other axis to provide a 90 degree connection. The
body and the
hub can also be connected at any angle between the first and second positions
by rotating
the body and hub to a desired orientation and then tightening the coupling nut
on the hub to
fix the position of the body relative to the hub.
[051] In a first embodiment, the adjustable connector has two sections, the
body and the
hub, and each is provided with a mating flange at their corresponding mating
ends for
connecting the two sections together. The faces of the mating flanges extend
angularly
with respect to the longitudinal axes of the body and hub, preferably at
between 30 and 60
degrees and most preferably about 45 degrees. The face of each flange slidably
and
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rotatably mates with the other one when the body is connected to the hub. One
of the
mating flanges (preferably on the hub) is provided with a dovetail extending
along a
portion of its perimetrical edge that receives the scalloped edge of the other
mating flange
(preferably on the body) in a dovetail relationship. Specifically, the outer
surface of the
edge of the scalloped mating flange slides into and is received by the
dovetail on the
complementary edge of the other mating flange. A coupling nut contacts the
body's mating
flange at a point opposite the dovetail and is tightened to secure the two
mating flanges in
position. Advantageously, the edges of the mating flange received by the
dovetail have
recessed portions (i.e., the edges are beveled) located along the edge of the
mating flange in
a complementary manner with the edge of the coupling nut.
[052] The coupling nut is internally threaded and coaxially mounted around the
hub
proximate the flanged end. After the mating flanges are joined, the coupling
nut is
tightened to secure the body and hub in any desired relative angular position.
In the
tightened position, the coupling nut snugly fits against the scalloped outer
surface at the
perimetrical edge of the flange to lock the body and hub together in the
desired position.
(The engagement or interlocking of the edges of the coupling nut with the
scalloped flange
surface is discussed in more detail below.) Loosening the coupling nut permits
the body
and hub members to be swiveled to any angular orientation relative to one
another. The
slidable faces of the mating flanges allow a continuous 360-degree rotation
until the
coupling nut locks the body and hub in position at a selected angle.
[053] The outer surface at the edge of the flange on the body can be
advantageously
provided with scallops (i.e., recessed portions or bevels) which engagingly
receive the edge
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of the coupling nut. Preferably, the scallops are disposed in pairs so that
two points along
the perimetrical edge of the coupling nut engage the scallops. The locking nut
in
combination with the scallops firmly secures the mating flanges together and
provides
protection against vibration.
[054] The adjustable connector is particularly advantageous since it provides
an unbiased
axial alignment of the components. Consequently, there is no offset when the
cable passes
through the two sections of the fitting until the sections are rotated to a
desired orientation.
This provides an initial straight-through connection that is advantageous,
especially for
cables having a large diameter. In addition, the adjustable connector can be
easily
disconnected, even with conductors in the fitting, since the straight-through
connection
facilitates disconnection of the body and the hub.
[055] In a preferred embodiment, the outer surface of the dovetail can be
provided with a
handgrip to facilitate hand installation. The handgrip can be formed by one or
more
protrusions or ribs extending radially from the dovetail or it can be formed
by one or more
slots or depressions in the dovetail. The adjustable connector can be
constructed from a
metal or a plastic material, preferably by a molding process. In addition, the
adjustable
connector can include self draining capabilities through a drain hole in the
hub that allows
draining of the fitting when oriented at any angle.
[056] The apertures in the body and hub can be provided with rounded interior
surfaces to
protect the cable from being cut or frayed by sharp edges. In addition, the
fitting can be
provided with a watertight O-ring for sealing the connection between the two
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flanges. The O-ring can be mounted in a substantially circular recess on the
face of one of
the mating flanges, preferably the hub.
[0571 For larger cables, the angular disposition of the mating flanges with
respect to their
longitudinal axes can be reduced to provide a more gradual bending of the
cable.
Preferably, the fittings for larger cables have flanges with the faces
disposed at 22.5
degrees instead of 45 degrees to provide an increased bend radius. In this
embodiment,
two sets of 45-degree adjustable connectors are used to provide a 90-degree
connection.
Each connector has two mating flanges with the faces of the flanges disposed
at 22.5
degrees from the axis to form the 45-degree connector. Installing the two
connectors in
series provides a 90 degree connection.
[0581 In another embodiment, a coupler is installed between the body and the
hub of the
first embodiment of the adjustable connector. One end of the coupler has a
mating flange
with a scalloped edged similar to the body and the other end of the coupler
has a mating
flange with a dovetail. The scalloped and dovetailed flanges are formed in the
same
manner as the flanges on the body and hub. The scalloped flange of the coupler
mates with
the dovetail flange of the hub and the dovetail flange of the coupler mates
with the
scalloped flange of the body. The coupler can also have two scalloped flanges
that can be
used to connect the coupler to hubs on each end. As will be appreciated by
those skilled in
the art, different combinations of scalloped flanges and dovetail flanges on
the body, hub
and coupler with their faces disposed at various angles from their axes can be
used in order
to provide a universal connection at any angle or a specifically shaped
connection. When
the coupling nut is engaged and secured in the scalloped flange, a three-
member adjustable
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connector assembly (hub, coupling nut and body) locks all three axes of
rotation XYZ of
the adjustable connector and all three linear motions XYZ.
[059] Referring to the drawings, FIGs. IA through 9B show an embodiment of the
connector 10 which includes a body 12 and a hub 30 secured together by a
coupling nut 34.
The body 12 has a cable connection end 22 that has a plurality of threads 20
and a neck 28
that extends from a hex fitting 18 and terminates in a flanged end 26 with a
substantially
flat surface 14 (FIG. 3B) that is angularly disposed to the axis of the neck
28 and has a
scalloped edge 16. A cable (not shown) can be passed through the cable
connection end 22
and through an aperture 24 in the flanged end 26 (FIG. 3B). The hub 30
connects to an
electrical cable (not shown) on one end 42 using threads 40 on the exterior
surface and has
a flanged end 44 that is angularly disposed to the axis of the hub 30 and has
an aperture 38
(FIG. 3A) through which the cable passes. The angular disposition of the
flanged end 44 of
the hub 30 corresponds to the angular disposition of the flanged end 26 of the
body 12.
The flanged end 44 has a dovetail 32 that extends around about one half of the
outer
perimeter and has a number of finger/tool grips 46 on the periphery. The
flanged end 44 of
the hub 30 is joined with the flanged end 26 of the body 12 with the dovetail
32 enclosing a
portion of the scalloped edge 16.
[060] As can be seen in FIGs. 4A, 5A and 6A, the dovetail 32 is separated into
two
segments and has a space or gap 36 between the sections serving as a visual
inspection port
to insure the scalloped edge 16 is fully inserted within the dovetail 32.
[061] Referring to FIGs. IA-B and 2A-B, FIGs. IA-1B show the connector 10 in
the
17
CA 02629503 2008-04-18
unlocked position. The scalloped edge 16 of the flanged end 26 is not engaged
by the
coupling nut 34 and is, therefore, free to swivel or rotate within the
dovetail 32. This
swiveling or rotating allows the user to adjust the angular disposition of the
body 12 in
relation to the hub 30. After the desired angle is achieved, the coupling nut
34 is tightened
and engages the scalloped edge 16 of the flanged end 26, which prevents the
body 12 from
further rotation or swiveling. FIGs. 2A-B show the connector 10 in the locked
position
with the coupling nut 34 engaging the scalloped edge 16 and preventing
movement of the
body 12. Loosening the coupling nut 34 allows the user to rotate and readjust
the
orientation of the body 12.
(062] The coupling nut 34 is designed to overlap one side of the flanged end
26 and force
the other side of the flanged end 26 into the dovetail 32. The coupling nut 34
can be
completely removed from the body 12, but it only has to be rotated one or two
turns to
disengage the flanged end 26 from the dovetail 32 and separate the body 12
from the
hub 30. Loosening the coupling nut 34 frees the flanged end 26 so that it can
be
repositioned in the dovetail 32 to adjust the angle of the connector 10. At
the same time,
the coupling nut 34 retains the flanged end 26 in the dovetail 32 so that the
hub 30 does not
completely separate from the body 12. FIGs. 1B and 2B show a circular rib 48
on the
hub 30, near the coupling nut 34. This rib 48 is for aesthetic purposes and
does not form a
stop for the nut 34. However, when the connector 10 is oriented in certain
positions, the
circular rib 48 deflects water away from the nut 34. FIGs. lB and 2B are cross-
sectional
views of the hub 30 and show the inner diameter of the hub 30 decreasing in
stages from
the end 42 where the electrical cable (not shown) is connected to form three
separate
18
CA 02629503 2008-04-18
chambers 43, 45, 47. When an armored cable is used with the connector 10, the
first
chamber 43 receives the electrical cable, the second chamber 45 receives the
portion of the
electrical cable that has the outer protective coating removed and the third
chamber 47
receives the electrical cable with the outer protective coating and armored
layer removed.
When an unarmored cable is used with the connector 10, the first chamber 43
and second
chamber 45 receives the portion of the electrical cable and the third chamber
47 receives
the electrical cable with the outer protective coating removed.
[0631 FIGs. 3A and 4A show a groove 50 at the flanged end 44 of the hub 30
that contacts
the flat surface 14 of the flanged end 26 of the body 12 when the connector 10
is
assembled. An O-ring (not shown) can be inserted in this groove 50 so that
when the body
12 is connected to the hub 30, the O-ring seals out dust and moisture. While
the groove 50
is shown in the flanged end 44, it can also be located in the flat surface 14
of body 12, if
desired. FIG. 4B shows the flat surface 14 of the flanged end 26 of the body
12 that is
sealed by the O-ring. The threads 20 on the cable connection end 22 can be
used to
connect the body 12 to a cable or an enclosure.
10641 FIGs. 5A and 6A show the adjustable connector 10 with the body 12 and
the hub 30
oriented so that, when they are joined, they form a "straight through"
connector. This
configuration is preferred when the cable (not shown) is initially installed
in the
connector 10. After the cable is pulled through the connector 10, the body 12
and hub 30
can be rotated as shown in FIGs. 5B and 6B to form a 90-degree angle. The
coupling nut
34 is then threaded onto the hub 30 and tightened to secure the connector 10
in the desired
19
CA 02629503 2008-04-18
orientation.
[065] Referring now to FIG. 7A, the threads 52 for the coupling nut 34 in this
embodiment are not cut into the surface of a round tube, but instead the
threads 52 are cut
into the flats 54 in the hub 30. Accordingly, the threads 52 effectively
disappear at points
that correspond to the mid-point of the flats 54. The flattened threads 52 can
also be seen
in FIGs. 3A, 4A and 5A. The coupling nut 34 is placed on the hub 30 before the
cable (not
shown) is installed but the coupling nut 34 is not tightened until the
adjustable connector
is oriented in the desired position. FIG. 7B shows the connector 10 oriented
to provide
a 90-degree angle.
10 [066] FIGs. 8A and 8B show the adjustable connector 10 in a straight
through or 180
degree angle configuration. The apertures in the body 12 and the hub 30 are
aligned so that
a cable (not shown) enters the cable connector end 42 of the hub 30 (i.e., the
end of the
hub 30 with the threads 40) and passes straight through to the cable connector
end 22 of the
body 12.
[067] FIGs. 9A and 9B show the adjustable connector 10 oriented so that the
axes of the
body 12 and the hub 30 form a 90 degree angle. A cable (not shown) entering
the cable
connector end 42 of the hub 30 bends 90 degrees as it passes through the
aperture 24 in the
body 12 and exits the cable connector end 22. FIG. 9B shows how the shoulder
31 on the
hub 30 and the shoulder 13 on the body 12 are rounded to minimize any damage
to the
cable.
[068] FIGs. I OA-C and 11 A-C show another embodiment of the present invention
in
CA 02629503 2008-04-18
which the connector 110 has three components, a body, 112, a hub 130 and in
between
them a coupler 160. The finger grips 146, 170 shown on the exterior surface of
the
dovetails 132, 162 in FIGs. 1 OA-C are raised members or ribs, which are
different from the
finger grips 46 shown in FIGs. 1 A-9B, but they can be the same. The
connectors 110, 210,
310 shown in FIGs. 1OA-13B are for larger diameter cables that do not bend
easily and,
hence, have a greater bend radius, which require connectors 110, 210, 310,
with larger
bend radii. Referring to FIGs. 1 OA-C and 11 A-C, the body 112 has a hex
fitting 118, a
neck 128 and a flanged end 126 with a scalloped edge 116. The coupler 160 has
a dovetail
162 on one end, a coupling nut 164 a neck 166 and a flanged end 168 with a
scalloped edge
172, which connects to the hub 130. The hub 130 has a dovetail 132 with hand
grips 146
and a lock nut 134 for engaging the flanged end 168 of the coupling 160.
[0691 FIGs. IOA-C show an adjustable connector 110 configured so that the
aperture 111
through the connector 110 is substantially straight. When a cable (not shown)
is inserted
into the connector 110, it easily passes through until the connector 110
reaches the desired
location along the cable run. The connector 110 can then be oriented to
provide the desired
bend angle before the coupling nuts 134, 164 are tightened to lock the
connector 110 in
place. FIGs. 1 IA-C show how the components (i.e., the body 112, coupler 160
and hub
130) of the connector 110 are reconfigured by rotating the coupler 160 and the
hub 130 to
form a 90-degree bend. After the connector 110 is configured for a 90-degree
bend, or any
other desired angle, the coupling nuts 134, 164 are tightened to secure the
flanged ends
126, 168 at a fixed position. When the connector 110 in FIG. 11B is compared
to the
connector 10 in FIG. 9B, it is readily apparent that the coupler 160 provides
a larger bend
21
CA 02629503 2008-04-18
radius for the cable (not shown) inside the connector 110.
[070] FIGs. 12A-C show a connector 210 used for larger cables, which is a
larger version
of the connector in FIGs. lA-9B. The connector 210 has the same principal of
operation,
wherein the flanged end 226 of the body 212 rotates in the dovetail 232 of the
hub 230
until a desired orientation is achieved. The connector 210 is then maintained
at that angle
by tightening the coupling nut 234. The connector 210 includes a body 212 that
has a hex
fitting 218, a neck 228 and a flanged end 226 with a scalloped edge 216, and a
hub 230 that
has a dovetail 232 and coupling nut 234.
[071] FIGs. 13A-B show another embodiment of the present invention, wherein
the
connector 310 has four components, a body 312 and a hub 330 and two couplers
360, 380
disposed between them. This embodiment is similar to the embodiment shown in
FIGs.
l0A-C and 11A-C except a second coupler 380 is included. The second coupler
380
provides greater flexibility so that the connector 310 can have additional
configurations.
Moreover, the second coupler 380 also provides a larger bend radius which is
needed for
large diameter cables. The body 312 has a hex fitting 318, a neck 328 and a
flanged end
326 and the hub 330 that has a dovetail 332 and coupling nut 334. The first
coupler 360
has a dovetail 362 on one end, a coupling nut 364 a neck 366 and a flanged end
368 with a
scalloped edge 372, which connects to the hub 330. The second coupler 380 has
a dovetail
382 on one end that connects to the flanged end 326 of the body 312, a
coupling nut 384, a
neck 386 and a flanged end 388 with a scalloped edge 392, which connects to
the dovetail
362 of the first coupler 360. Although FIGs. 13A-B show a connector 310 with
two
couplers 360, 380, the invention is not limited to two couplers 360, 380 and
additional
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CA 02629503 2008-04-18
couplers can be added.
[072] FIGs. 14-A-B show a detail of the coupler 160 that is used in the
connector 110
shown in FIGs. l0A-C and 11 A-C. The coupler 160 in FIG. 14A-B is
substantially the
same as the couplers 360, 380 shown in FIGs. 13A-B. The coupler 160 has two
sections, a
stem 166 and a base 174, wherein the first end of the stem 166 is slidably
received by the
first end of the base 174. The second end of the stem 166 is a flanged end 168
with a
scalloped edge 172, which is disposed at an angle to the axis of the stem 166.
The second
end of the base 174 has a dovetail 162. After the coupling nut 164 (FIGs. 1 lA-
C) is placed
over the stem 166, the stem 166 is inserted into the base 174 and can be set
in a fixed
orientation by tightening the coupling nut 164 onto the threaded end 176 of
the base 174 so
that the flanged end 168 of the stem 166 and the dovetail 162 of the base 174
are in a fixed
relationship. However, in another embodiment, after the stem 166 is inserted
into the
base 174, the stem 166 is not set in a fixed position and is left to freely
rotate over 360-
degrees so that the angularly disposed flanged end 168 can connect to another
component
of the connector 110 at a variety of angles. Once the coupler 160 is set to
the desired
orientation, the stem 166 is locked into position by tightening the coupling
nut 164 so that
it can no longer rotate.
[073] Referring now to the scalloped edges or scallops 16 on the flanged end
26 of the
body 12 (FIG. 4B) and the scallops 172 on the flanged end 168 of the coupler
160 (FIG.
14B), while these scallops 16, 172 may serve as finger grips to help rotate
the body 12 or
the coupler 160, they also have a wholly separate purpose which can be better
explained by
referring to the line drawings shown in Figs 15-17. These scallops are located
for select
23
CA 02629503 2008-04-18
pre-set angles such as 22.5, 45, 90 and/or 180 (or zero) degrees. Not all
angles need be
accommodated on a single connector and a connector can be manufactured with
the
position of these scallops 16, 172 moved or changed so as to accommodate other
pre-set
degrees desired by the user.
[0741 FIGs. 15A-17B illustrate the rotating/swivel operation of the connectors
of the
present invention. FIGs. 15A-B show a coupling nut represented by a cylinder
434 and a
flanged end represented by a conical section 426, wherein the flanged
end/conical section
426 is unlocked from the coupling nut/cylinder 434, but still held in place by
the coupling
nut/cylinder 434. The edge 416 (the scalloped portion is not shown) of the
flanged
end/conical section 426 is represented by the larger end of the flanged
end/conical section
426. In the unlocked position shown in FIGs. 15A-B, contact is made between
the edge
416 of the flanged end/conical section 426 and the coupling nut/cylinder 434
at two points
490, 492 (FIG. 15A) and a small portion 494 of the edge 416 extends inside the
coupling
nut/cylinder 434 (FIG. 15B). The two points 490, 492 of contact between the
edge 416 and
the coupling nut 434 are separated by a sufficient distance to permit the
coupling
nut/cylinder 434 and the flanged end/conical section 426 to independently
rotate.
[0751 FIGs. 16A-B illustrates the operation of the scalloped edge 516 of the
flanged
end/conical section 526 and the coupling nut/cylinder 534. As the coupling
nut/cylinder
534 is tightened, it moves closer to, or encroaches more upon, the flanged
end/conical
section 526. FIGs. 16A-B show only a single indentation for the scalloped edge
516, but it
is only representative and it is understood that the scalloped edge 516
consists of a plurality
of indentations. Accordingly, as the coupling nut/cylinder 534 is rotated and
tightened, it
24
CA 02629503 2008-04-18
"rides up" the flanged end 526 (illustrated in FIGs. 16A-B as the larger end
of the conical
section) and begins to engage the indentations of the scalloped edge 516 at
one or more
points 590, 592. The second point 592 is on the far side of the conical
section and,
therefore, not clearly visible in FIGs. 16A-B. The coupling nut/cylinder 534
extends
further over the flanged end/conical section 526 as it is tightened and,
consequently, the
separation between the two contact points 590, 592 decreases. FIGs. 16A-B show
that the
coupling nut/cylinder 534 contacts only at point 590 on one side of the
scallop and that the
opposite side is not yet engaged by the coupling nut/cylinder 534.
10761 FIGs. 17A-B shows the coupling nut/cylinder 534 in the fully locked
position with
the angular relationship between the coupling nut/cylinder 534 and the flanged
end/conical
section 526 in a fixed position. The coupling nut 534/cylinder continues to
"ride up" the
larger end of the conical section that represents the flanged end/conical
section 526 further
than shown in FIGs. 16A-B and contacts the indentation in the scalloped edge
516 at two
points 590, 591 (i.e., the opposite sides of the same indentation). The second
point 591 of
contact abuts or "digs into" the edge of the coupling nut/cylinder 534 and
provides
significant frictional force that increases as the coupling nut/cylinder 534
is tightened.
These frictional or biasing forces and the scallop edge 516 (i.e.,
indentations engaged by
the coupling nut/cylinder 534) on both sides of the centerline of the flanged
end 526
prevent the flanged end/conical section 526 from any further rotation with
respect to the
coupling nut/cylinder 534. The flanged end/conical section 526 cannot rotate
because a
portion of the flanged end 526 extends underneath the coupling nut/cylinder
534.
Accordingly, the contact points 590, 591, 592, 593 on the sides of the
indentations of the
CA 02629503 2008-04-18
scalloped edge 516 lock the flanged end/conical section 526 in place and
prevent it from
any further movement.
[0771 The indentations on the scallop edge 516 can be configured for
engagement by the
coupling nut/cylinder 534 at pre-set angles. If the flanged end/conical
section 526 is
positioned at any angle other than the configured angle (e.g., 30 degrees
instead of 45
degrees), the flanged end/conical section 526 does not completely engage or
dig-into the
coupling nut/cylinder 534 and the relationship between the flanged end/conical
section 526
and the coupling nut/cylinder 534 is more like that shown in FIGs. 16A-B (or
even FIGs.
15A-B). The flanged end/conical section 526 is engaged by the coupling
nut/cylinder 534,
but it's not locked in place since the flanged end/conical section 526 is only
held in place
by friction and the indentations on the scallop edge 516 are not engaged. The
position of
the coupling nut/cylinder 534 in FIGs. 15A-16B does not physically restrain
the flanged
end/conical section 526 from further movement, as is the case when the
coupling nut is
fully tightened as shown in FIGs. 17A-B.
[0781 FIGs. 18A-C show an embodiment of the body 712 of the adjustable
connector 710
with a cable connector end 722 and a flanged end 726 connected by a neck 728
with a
hexed fitting 718. The connector end 722 has threads 720 for connecting the
body 712 to a
cable or enclosure (not shown) and the flanged end 726 has a plurality of
scallops 716
along the perimetrical edge and a substantially flat face 714. In addition,
the top surface of
the flanged end 726 has indicia 725, 727 which provide visual verification for
the user that
26
CA 02629503 2008-04-18
the body 712 is oriented at designated angles with respect to the either a hub
or a coupler
(not shown)..
[079] FIGs. 19A-B show an embodiment of the hub 630 having a cable connector
end
642 with threads 640 on the exterior surface and a flanged end 644 with a
dovetail 632
extending along a portion of the perimetrical edge. The dovetail 632 has a
notch 636 near
its middle which allows the user to view the edge of a flange (not shown)
inserted into the
dovetail 632. The dovetail 632 also has a plurality of raised members (or
ribs) 646
extending from its radial surface. These raised members 646 are used as finger
grips and
facilitate rotation of the mating flange (not shown) into the dovetail 632.
[0801] Thus, while there have been described the preferred embodiments of the
present
invention, those skilled in the art will realize that other embodiments can be
made without
departing from the spirit of the invention, and it is intended to include all
such further
modifications and changes as come within the true scope of the claims set
forth herein.
27
