Note: Descriptions are shown in the official language in which they were submitted.
CA 02779248 2013-12-13
ELECTRICAL CONNECTORS AND
METHODS OF MANUFACTURING AND USING SAME
DESCRIPTION
BACKGROUND OF THE INVENTION
[0001] This application claims priority from United States Provisional Patent
Application Serial Number 61/257,827, filed November 3, 2009.
Field of the Invention
[0002] The invention relates generally to electrical connectors that connect
multiple wires together, or that connect one or more wires to other
electrically-conductive
equipment. More specifically, the invention relates to a connector that
comprises an
electrically-conductive spiral for being tightened around conductive, stripped
wire(s),
wherein crimping is not required. In a loosened configuration, the conductive
spiral is
larger in diameter than the diameter of the stripped wire(s) being inserted
into the spiral,
but, after said insertion, the conductive spiral is manually tightened into a
smaller-
diameter configuration that creates electrical contact between said conductive
spiral and
the stripped wire(s). The preferred conductive spiral receives multiple
stripped wires,
and, upon tightening, forces said multiple, stripped wires into electrical
contact with each
1
CA 02779248 2012-04-27
WO 2011/056901
PCT/IJS2010/055337
other and with the spiral. One spiral, or multiple spirals in series, may be
used, and the
wires may enter the spiral(s) from the same direction or from opposite
directions, wherein
the spiral(s) is/are adapted for electrical connection of the wires only to
each other.
Alternatively, the spiral(s) may be adapted for electrical connection of the
wire(s) to a
terminal end, such as an eyelet or a fork, that is integral with the spiral(s)
and that may, in
turn, be connected to another conductive device. Especially-preferred
embodiments
relate to connectors for large-diameter, heavy-duty wire/cable, for example,
for utility
connectors and/or connectors for 4 and 6 wire gauge. Especially-preferred
embodiments
may be used in the place of conventional connectors of the "block style", such
as the
"Polaris BlockTm", and may have additional benefits of being easy to use,
reliable, and
modular. The preferred modularity allows connection of multiple modular units
together
to create connectors with various numbers, and orientations, of wire entry
ports.
Related Art
[0003] Crimp connectors are popular electrical connectors that comprise at
least
one conductive cylindrical portion that is manually crimped (bent, smashed)
against a
wire inserted into the cylindrical portion. See Figures 15 ¨ 17. An
electrically-insulating
sleeve typically surrounds the cylindrical portion. Some crimp connectors,
typically
called "butt splice" crimp connectors, include two, opposing generally
cylindrical ends
that each receive, and is crimped onto, a wire, for electrically connecting
two wires. Said
two generally cylindrical ends are integral parts of the single conductive
member. See,
for example, Figure 14. Other crimp connectors comprise one cylindrical end
for being
crimped and an opposing utility terminal end, such as an eye, a fork, or other
preferably
flat shape for being captured between the head of a screw or bolt and the
surface of said
another conductive device. Or, other shapes may be used, such as a female or
male
quick-connect (and quick-disconnect) connector, including rectangular-tubular
female
(see Figure 17) or cooperating blade male terminal end, and cylindrical or
partial
cylindrical female terminal ends or cooperating male pin terminal ends, and
other utility
terminal ends. In each of these crimp connectors, the only fastening of the
connector to
2
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
the wire is done by crimping the wall of the generally cylindrical end(s) with
a crimping
tool to force portions of the wall against or into the wire. The quality of
the crimping,
that is, the amount and permanence of the contact between the wall and the
wire, varies
greatly depending on the skill of the person doing the crimping. Further, a
crimped
connection between wall and wire comprises, at best, a small surface area of
the wall
abutting and/or gouging into a small surface area of the wire, said small
surface area
being portions or points around a circumferential surface of the wire only
along a very
short axial length of the wire.
[0004] Prior art crimp-connection devices frequently fail because inadequate
pressure is used during crimping. Also, sometimes, the crimping action may
"smash" the
tubular portion of the connector rather than bending the tubular wall inward;
such
smashing tends to open the tubular wall at an axial seam, with at least one
seam edge
moving away from the wire, and, hence, to reduce the integrity and
effectiveness of the
connector. A further problem of such conventional crimp connectors is that is
it not
always easy to determine the quality and permanence of the crimped connection
by
visually inspecting the crimp.
[0005] An alternative conventional electrical connection may be called a
"threaded wire connector," such as is illustrated in Figure 18. Such a device
may be
described as a cap with internal threads tapering from large diameter at an
outer end of
the cap to smaller diameter at an inner end of the cap. As the threaded wire
connector is
pushed and turned onto the end of multiple wires, the threads of generally the
same
diameter as the combined diameter of the multiple wires become screwed around
the
surface of the wires and/or at least grip and compress the wires. Thus, even
though the
wires do not originally have any threads on their surfaces, the threaded wire
connector
enters into a type of threaded engagement with the metal of the wires,
gripping and
electrically connecting the wires. The threaded wire connector may be screwed
off of the
wire in the opposite direction. Only some of the threads of the threaded wire
connector
grip or gouge into the wires. Thus, engagement between the threaded wire
connector and
the wires comprises threads along a short axial distance of the threaded wire
connector
gripping a short axial length of the wires. The larger diameter threads
typically do not
3
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
contact, or at least do not gouge or grip, the wire. The diameters of the
threads of the
threaded wire connector do not change before, during, or after use on the
wire. The
threads of the threaded wire connector do not move relative to each other. For
examples
of threaded wire connectors and/or threaded connectors, see Figure 18 and also
the
following patents: Swanson Patent Number 3497607, issued in 1968; Scott Patent
Number 4104482, issued in 1978; Duve Patent Number 4531016, issued in 1985;
Blaha
Patent Number 4707567, issued in 1987; Blaha Patent Number 4803779, issued in
1989;
Miller, et al, Patent Number 4924035, issued in 1990; Braun, Jr. Patent Number
5260515, issued in 1993; Soni, et al Patent Number 5331113, issued in 1994;
Delalle
Patent Number 5418331, issued in 1995; and Market Patent Number 5975939,
issued in
1999.
[0006] The patent literature also comprises spring connectors that work by a
user
forcing a rigid pin or rod into the center space of a spring that has an
internal diameter
significantly smaller than the diameter of the rigid pin or rod. Said forcing
of the pin/rod
causes the spring to expand its diameter and it is this expansion of the
spring diameter,
and the consequent tight fit, that causes the spring to grip the pin/rod. For
example, see
Fortin Patent No. 1,657,253; Hubbell, et al. Patent No. 2,521,722; Williams
Patent No.
4,632,486, issued in 1986; and Bauer, et al. Patent No. 6,773,312. Many of
these spring
connectors are designed so that rotating the rigid pin/rod may be done to
loosen the
spring's grip on the pin/rod for removal of the pin/rod.
[0007] The patent literature also comprises strain relief devices that
mechanically support and/or reinforce insulation-covered electrical cords, for
example, a
distance from a conventional plug or other convention electrical connection,
to protect the
electrical cord from being damaged. See for example, Burkhardt Patent No.
1,858,816;
Klump, Jr. Patent No. 2,724,736; and Rottmann Patent 3,032,737; and Long
Patent No.
4,632,488. These strain relief devices typically comprise flexible covers or
sleeves that
surround only insulated portions of a wire/cable, and that do not form any
type of
electrical contact or play any role in electrical conduction.
4
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0008] There is still a need for an electrical connector that quickly and
reliably
connects wires to each other, or wires to a terminal end that is then bolted
or screwed to a
conductive surface or to a terminal end that is then quick-connected into
another
conductive member. In view of the millions or billions of such electrical
connections
that must be made every year in the construction, utility, computer and
information
technology (IT), automotive, and other electrician and IT trades, such an
electrical
connector should be economical, compact, and preferably permanent. There is a
need for
a connector, and a need for methods of installing the connector, wherein the
installer may
be certain that a secure and permanent connection with a large electrical
contact surface
area may be made. The present invention meets these and other needs.
SUMMARY OF THE INVENTION
[0009] The present invention comprises an electrical connector that comprises
a
conductive spiral that is moveable from at least one relatively large diameter
configuration, into which stripped wire(s), cable(s), or other elongated
conductive
elements may be inserted, to at least one relatively smaller, or reduced,
diameter
configuration that grips said stripped wire(s), cable(s), or other elongated
elements. The
engagement of the conductive spiral against the stripped wire(s) or other un-
insulated
conductive element(s) forms an electrical connection between the conductive
spiral and
the wire(s) or element(s) and, in the case wherein multiple stripped/un-
insulated
wires/elements are inserted into the conductive spiral, the spiral also forces
the
wires/elements together into electrical contact with each other. The
conductive spiral is
preferably sized in diameter so that, in the large-diameter configuration, the
inner
diameter of the spiral is larger than the combined diameter of the
wire(s)/element(s) that
are to be inserted, so that little if any resistance to insertion of the
wire(s)/element(s) is
created by the spiral.
[0010] Conductive spirals according to a first group of embodiments of the
invention may comprise a conductive terminal end, wherein the terminal end may
protrude from the coiled portion of the spiral, so that stripped
wire(s)/element(s) inside
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
the conductive spiral are also in electrical connection with said terminal
end. The utility
terminal end is preferably an eyelet, fork, or other substantially flat member
for being
bolted or screwed to a conductive surface, or a female or male quick-
connect/disconnect
piece that relies on cylindrical or rectangular-tubular mating members for
example.
Preferably, the terminal end is directly attached to, or integral with, the
coiled portion of
the spiral so that the coils and terminal end form a single unitary piece with
no break or
interruption in the electrical conductivity of said single unitary piece.
[0011] Conductive spirals according to a second group of embodiments of the
invention electrically connect together stripped multiple wires/elements from
separate
cables by compression of said stripped multiple wires/elements together in a
bundle.
Such conductive spirals preferably have no protruding terminal end. Said
stripped
multiple wires/elements may enter the conductive spiral(s) from the same
direction.
Alternatively, said stripped multiple wires/elements may enter the conductive
spiral(s)
from opposite directions, for example, wherein a conductive spiral comprises
spiral
portions at two opposite ends of the spiral unit, for insertion of
wire(s)/element(s) toward
each other from opposite directions.
[0012] Conductive spirals according to a third group of embodiments of the
invention may comprise a conductive protruding elongated member, such as a
dowel, bar,
or tube, that is electrically connected to a spiral or spirals, and that
protrudes to
electrically connect to another spiral or spirals. For example, this third
group may
comprise a modular system, wherein each of a plurality of modules has a spiral
or spirals,
and at least one dowel or other elongated member electrically is connected to
the spiral(s)
and protrudes at an angle to the longitudinal axis of the spiral(s) to
electrically connect to
the spiral(s) of an adjacent module. Further, the protruding elongated member
may be
one or the only means of mechanically connecting the module to said adjacent
module.
Preferred embodiments of such a modular system, for example, include modules
that: 1)
receive wire(s) in a single port from a single direction; 2) receive wire(s)
in multiple ports
extending in the same direction from the main body of the module, so that the
wire(s)
enter the ports from the same direction; and/or 3) receive wire(s) into
multiple ports
extending in different directions from the main body of the module.
6
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0013] In each of the preferred embodiment groups, the conductive spiral(s)
are
sized to be, when relaxed in the larger-diameter configuration, significantly
larger than
the combined diameter of the wire(s)/element(s) being inserted into the
conductive spiral.
Only upon twisting of one end of the conductive spiral(s) relative to their
other end(s)
will the spiral(s) reduce in diameter to an extent that the spiral(s) will
exert substantial
force on the wire(s)/element(s) inside the spiral(s) to create a reliable and
secure electrical
connection between the spiral(s) and the wire(s)/element(s) and to prevent
removal of the
wire(s)/element(s) from the spiral(s).
[0014] In each of the prefen-ed embodiment groups, the outer surfaces of the
conductive spiral(s) are substantially surrounded with housing portions that
insulate the
conductive spiral(s) to prevent electric shock and short-circuiting, and that
provide a lock
system to retain the spiral(s) in the tightened configuration and a handle
system that
allows a user to tighten the spiral(s). While the housing portions perform
important
functions for operation of the preferred connectors, the conductive spiral(s),
the terminal
end if any, and the protruding elongated members in modular systems if any,
and the
wires/elements inserted into the conductive spiral(s), are preferably the only
conductive
structure that is required to affect the electrical connection.
BRIEF DESCRIPTION OF THE DRAWINGS, and APPENDICES
[0015] Figure 1 is a perspective view of one embodiment of the invented spiral
electrical connector, with an electrical cable installed in the connector.
[0016] Figure 2 is an exploded, perspective view of the embodiment of Figure
1.
[0017] Figure 3 is a perspective view of the spiral unit of the embodiment of
Figures 1 and 2, that is, wherein said spiral unit has been removed from the
housing. In
this view, the spiral is in its relaxed, relatively large-diameter
configuration.
[0018] Figure 4 is a perspective view of the spiral unit of Figure 3, wherein
the
spiral has been twisted to reduce its diameter to a tightened configuration
wherein it
would grip a wire(s) received therein. The spiral unit of Figures 1 ¨ 4 is
formed so that
7
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
twisting of its terminal end in a counterclockwise direction when viewed from
the
terminal end, when the opposite end is held stationary or twisted in the
opposite direction,
will reduce the diameter of the spiral, for example, as illustrated in Figure
4.
[0019] Figure 5 is a perspective view of an alternative spiral unit, wherein
the
spiral is cut or otherwise manufactured to have space between each wrap of the
spiral.
[0020] Figure 5A is a perspective view of another alternative spiral unit,
having
two parallel cuts spiraling around the tube. Such embodiments may be included
in the
terms "a spiral" and "at least one spiral."
[0021] Figure 6 is an axial cross-sectional perspective view of the embodiment
of
Figures 1 and 2, with the cable is stripped of insulation at its end and the
stripped wires
are inserted axially into the housing and the spiral. Note that, in this
embodiment, the
terminal end has a cylindrical end that is open at one end and closed at the
end from
which the eye extends, and, hence, the wires do not extend to be visible or
accessible at or
near the terminal end of the connector. In other embodiments, the wires may
extend from
the spiral and through all or part of the open cylinder of the terminal end to
be visible
and/or accessible.
[0022] Figure 7 is a side view of the embodiment of Figures 1, 2 and 6, with
the
housing in cross-section.
[0023] Figure 8 is a transverse, cross-sectional view of the embodiment of
Figures 1, 2, 6 and 7, viewed along the line 8 ¨ 8 in Figure 7.
[0024] Figure 9 is a side, cross-sectional view of one embodiment of a
conductive spiral, such as is provided in the embodiment of Figures 1 ¨ 4, and
6 ¨ 8,
wherein the spiral cut extends through the wall approximately transverse
(approximately
90 degrees) to the axis of the spiral.
[0025] Figure 10 is a side-cross-sectional view of another embodiment of a
conductive spiral, which may be made by angled cuts through the wall of a tube
and/or
other methods that result in the inner surface of the wraps/coils being sharp
edges.
8
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0026] Figure 11 is a side-cross-sectional view of another embodiment of a
conductive spiral, wherein the cut between wraps/coils of the spiral extends
through the
wall at an acute angle, thus providing some overlap of the spirals/coils and
increased
rigidity of the tightened spiral.
[0027] Figure 12 is an exploded perspective view of another embodiment of the
invention, which is a double-ended spiral connector, shown without the two
wires/cables/elements that the unit may connect in a "butt" style connection.
[0028] Figure 13 is an assembled, perspective view of the embodiment of Figure
12, wherein the internals of the unit are shown in dashed lines.
[0029] Figure 14 is a side view of one style of prior art butt crimp connector
comprising two crimpable, cylindrical, opposing ends.
[0030] Figure 15 is a side view of one style of prior art crimp connector with
an
eye-type terminal end. The lower end of the conductive portion of the
connector is
generally a cylindrical shape fortned by bending side edges of a flat plate
toward each
other. The top comers of said side edges are visible near the top end of the
insulating
sleeve.
[0031] Figure 16 is a side view of another style of prior art crimp connector
with
a fork-type terminal end. Again, the top corners of plate edges (that arc bcnt
to form a
generally cylindrical lower end) are visible above the top end of the
insulating sleeve.
[0032] Figure 17 is a side view of another style of prior art crimp connector,
which may be called a female rectangular-tubular terminal end for receiving a
male blade,
in a quick-connect and quick-connector style terminal end system.
[0033] Figure 18 is a side view of a prior art threaded wire connector, with
internal threads shown in dashed lines. One may note that the threads
transition from
large diameter near the open end (bottom end in this view) to smaller diameter
near the
closed (top) end. When the threaded wire connector is "screwed" onto ends of
wires, the
individual threads do not move relative to each other or change diameter and
only engage
the wires by means of the entire threaded wire connector moving axially to a
point
9
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
wherein the diameter of the threads matches and/or is smaller than the
combined diameter
of the wires.
[0034] Figure 19 is another embodiment of the invented spiral electrical
connector, with an alternative latch system and an alternative connection
between the
terminal end and the spiral coils.
[0035] Figure 20 is an exploded, perspective view of the embodiment of Figure
19.
[0036] Figure 21 is a perspective view of the spiral unit of Figures 19 and
20,
with the spiral in a relaxed, large-diameter configuration.
L00371 Figure 22 is a perspective view of the spiral unit of Figures 19 ¨ 21,
wherein the spiral has been twisted to reduce its diameter to a configuration
wherein it
would grip wire(s) received therein.
[0038] Figure 23 is a perspective view of an alternative spiral unit, wherein
the
spiral is cut/manufactured to have space between each wrap/coil of the spiral.
[0039] Figure 23A is a perspective view of yet another spiral unit, having two
cuts spiraling around the tube stock.
[0040] Figure 24 is an axial cross-sectional, perspective view of the
embodiment
of Figures 19 and 20.
[0041] Figure 25 is a side view of the embodiment of Figures 19, 20, and 24,
with the housing in cross-section, and wherein the latch mechanism comprises
latch
fingers catching on the upper end of the spiral, which upper end is the same
diameter as
the rest of the spiral.
[0042] Figure 26 is a side view of an altemative embodiment, with housing cut
away in cross-section, wherein the latch mechanism comprises a ring/collar
encircling the
an end of the spiral and protruding out from the side surface of the spiral to
be engaged by
latch fingers.
CA 02779248 2012-04-27
WO 2011/056901
PCT/U52010/055337
[0043] Figure 27 is a top, cross-sectional view, viewed along the line 27 ¨ 27
in
Figure 26.
[0044] Figure 28 is an exploded view of an alternative embodiment of a double-
ended spiral connector, having an alternative housing and an alternative latch
mechanism.
[0045] Figure 29 is an assembly, perspective view of the embodiment of Figure
28.
[0046] Figures 30 and 31 are perspective and exploded perspective views,
respectively, of an alternative embodiment having yet another latch mechanism.
[0047] Figure 32 is a side view of the embodiment of Figures 30 and 31, with
the
housing in cross-section.
[0048] Figure 33 is a top, cross-sectional view of the embodiment of Figures
30 ¨
32, viewed along the line 33-33 in Figure 32.
[0049] Figures 34 and 35 are perspective and cross-sectional views,
respectively,
of yet another embodiment, with a different system for directly attaching the
terminal end
to the spiral.
[0050] Figures 36, 36A and 36B illustrate one but not the only method of
cutting
or stamping a spiral unit from a flat sheet of metal, wherein after separation
of the
multiple flat shapes cut/stamped from the sheet, each flat shape may be curled
into a
generally tubular spiral unit. The spiral unit shown in these figures includes
an eyelet
terminal end that is integral with the spiral portion of the spiral unit.
[0051] Figures 37, 37A and 37B illustrates one but not the only method of
cutting or stamping a double-spiral unit from a flat sheet of metal, wherein,
after
separation of the multiple flat shapes cut/stamped from the sheet, each flat
shape may be
curled into a generally tubular spiral unit. The spiral unit shown in these
figures includes
a central band, a spiral portion on each side of the central band, and end
bands at the outer
ends of the spiral unit.
11
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0052] Figures 38, 38A ¨ E illustrate one, but not the only, embodiment of a
side-by-side wire connector, wherein separate electrical cables are inserted
into a single
spiral and the spiral is tightened by the user rotating the funnel-end housing
portion
relative to the main housing portion.
[0053] Figure 38F illustrates a modification to the embodiment of Figures 38,
38A ¨ F, wherein a terminal end is provided, directly attached to the spiral
and extending
out of the distal end of the main housing.
[0054] Figure 39, 39A ¨ C illustrate another, hut not the only, embodiment of
a
double-ended connector, and the preferred method of using the connector in a
double-
handed twist wherein the two ends are grasped and rotated in opposite
directions but the
user need not touch the central, main housing.
[0055] Figure 40 is an exploded perspective view of an especially-preferred
embodiment of a butt-style connector, wherein the main body of the housing has
curved
latch arms that engage with an interior surface of the cooperating end cap.
[0056] Figure 41 is a longitudinal cross-sectional, perspective view of the
embodiments of Figure 40.
[0057] Figures 42A ¨ C are a perspective view, side view, and end view,
respectively, of the main body of the housing of the embodiment in Figures 40
and 41.
Figure 42D is a side perspective view of one half of the main body, showing to
best
advantage the latch arm system of the main body.
[0058] Figures 43A ¨ D are a side view, an outer end view, an inner end view,
and a longitudinal cross-sectional view, respectively, of the end cap of the
embodiment of
Figures 40 and 41. Figure 43E is a perspective view of an alternative dust
cover that may
be used to cover the opening/passage through the end cap.
[0059] Figures 44A and B are side, and longitudinal cross-sectional views,
respectively, of an altemative embodiment of a connector that receives wires
from
separate cables only into one open end of the connector and electrically all
of those wires.
12
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0060] Figures 45A and B are side, and longitudinal cross-sectional views,
respectively, of an alternative embodiment of a connector that receives wires
into one
open end of the connector and electrically those wires to a terminal end.
[0061] Figures 46 ¨ 50 are perspective views of some, but not the only,
embodiments of block-style connectors, that may be used as stand-alone
connectors, or
that may be modules connected into assemblies, for example, as portrayed in
Figure 50.
[0062] Figure 5IA and B are perspective exploded views of a module such as
shown in Figure 46, with end-plates removed.
[0063] Figures 52A and B are perspective exploded views of a module such as
shown in Figure 47, with end-plates removed.
[0064] Figures 53A and B are perspective exploded views of a module such as
shown in Figure 48, with end-plates removed.
[0065] Figure 54 is perspective view of one embodiment of a holder tube/insert
(removed from a connector), having one spiral, and being connected to one
embodiment
of a dowel for modular connection of multiple connectors.
[0066] Figure 55 is a perspective view of one embodiment of an alternative
dowel made of non-conducting material that may mechanically connect modules
but not
place them in electrical contact with each other.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0067] Referring to the Figures, there are shown several, but not the only,
embodiments of the invented spiral electrical connectors. The invented
connectors allow
one or more stripped, electrically-conductive wires/cables/elements to be
connected to
other un-insulated, conductive wires/cables/elements. One may note that the
term
"conductive" is used in this Description and in the Claims for simplicity, and
is
understood to mean electrically-conductive. The invented connectors may be
used with
wire, cable, and other elongated conducting material, but the term "wire" is
used herein
13
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
for simplicity and includes single-strand, multiple-strand (including those
that are
braided, twisted, woven and/or otherwise grouped) wires and conducting
material having
at least a portion that is elongated for being inserted into the connector.
The preferred
embodiments are particularly beneficial in connecting multiple stripped,
conductive
strands (also called "filaments") to each other or to another conductive
elements or
surfaces, as said multiple strands can effectively be inserted into the
enlarged, relaxed
spiral, even though each strand is flexible. Said strands are not required to,
and in fact it
is preferred that they do not, exert significant force on the spiral(s) when
being inserted
into the central passageway of spiral(s), and, specifically, it is preferred
that the strands do
not expand, stretch, or enlarge the spiral(s) when being inserted into the
spiral.
[0068] The preferred conductive spiral extends circumferentially around the
outside of wire multiple times, that is, at least twice for a total of at
least 720 degrees.
More preferably, there are many spiral wraps around the wire, for example, 5 ¨
10 for a
total of 1800 ¨ 3600 degrees. By moving one end of the spiral relative to the
other in
opposite directions around the wire, the wrapping of the spiral may be
tightened or
loosened on the wire depending on the directions chosen. For example, the
spiral may be
moved from a relaxed or relatively loose configuration that allows insertion
of the wire
into the hollow central space ("passageway") of the spiral, to a tightly-
wrapped
configuration that grips the wire all the way around the circumference of the
wire along a
length of the wire that is generally equal to the axial length of the spiral.
In preferred
embodiments, the spiral wraps around a length of the wire that is several
times the
diameter of the wire. The spiral may be a right-hand spiral or a left-hand
spiral, and will
be tightened or loosened accordingly, as will be understood by one of skill in
the art after
reading and viewing this disclosure.
[0069] In both the loosened and the tightened configurations, the preferred
spiral
wraps are all the same or generally the same diameter. The tightened
configuration, the
entire or substantially the entire interior surface of the spiral contacts the
wire. Therefore,
in the tightened configuration, the preferred flat interior surface of the
spiral forms
electrical contact with the wire over a surface area that is generally defined
by a)
circumference of the wire times b) the length of a portion of the wire that is
several times
14
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
the wire diameter. This contact surface area is large compared to a contact
surface area in
a crimped connector that is defined by a fraction of the wire circumference
times a length
of the wire that is typically equal to or less than the diameter of the wire.
This contact
surface area is also large compared to a contact surface area in a threaded
wire connector
that is defined by the thin sharp edges of a few threads of different
diameters.
[0070] In the preferred embodiments, the spiral wraps may be formed from
conductive metal tubular stock, for example, by providing a spiral cut or cuts
through the
wall of a metal tube. The tube wall is preferably rigid and/or thick enough
that, after
being cut, it remains in its original diameter and configuration, which is the
"relaxed"
configuration. The tube diameter is chosen so that the desired wire will
easily slide into
the hollow center of the tube in this relaxed configuration. The tube wall is
preferably
flexible enough that twisting/rotating the tube/spiral ends relative to each
other may be
done, whereby the diameter of the tube/spiral reduces and captures the wire.
Upon
locking the tube/spiral in the tightened configuration, the stripped wire
remains captured
and in electrical contact with the interior surface of the tube/spiral.
[0071] In some embodiments, the spiral may be made from, or be like, a coiled
spring, but unlike prior art spring embodiments discussed above, a spring of
the invented
embodiments would form a relatively large diameter when in the relaxed
configuration
(larger than the combined diameter of any wire(s) being inserted), and is
tightened by the
user around the wire(s) to a smaller-diameter configuration to grip the wire,
and then
latched/locked in that smaller-diameter configuration. A spiral that is made
from, or like,
a coiled spring may have the disadvantage of each coil/wrap being circular or
oval in
cross-section, rather than flat or generally flat, and therefore not
presenting and pressing
as much internal coil surface area against the wire being held. Alternatively,
therefore,
the internal coil surface may be modified or sharpened to better grip the
wire.
[0072] In especially-preferred embodiments, the spiral unit is formed by
cutting
or stamping a flat shape from a conductive, flat metal sheet, and then curling
(rolling,
bending) the flat shape into the desired spiral shape. The flat shape, and
hence the
resulting spiral shape, may include a terminal end if desired. Many of said
flat shapes
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
may be cut or stamped out of the same sheet at the same time, with little or
no waste
metal. Once separated from the adjacent flat shapes, an individual flat shape
may be
curled (rolled, bent) into the desired spiral unit and its ends may be welded
or otherwise
tacked/fixed to remain in the proper generally cylindrical tubular shape. See,
for
example, Figures 36, 36A, 36B, 37, 37A, and 37B. One may note that the
rolling,
curling, or bending of flat shapes to form spirals, in manufacturing
techniques such as
those described herein, is conducted during manufacture of the connector, is
done well
before insertion of wire(s) into the spiral, and is not wrapping a strip,
wire, or tape,
around the wire(s) to be captured.
[0073] The metal sheet from which the flat shapes are cut/stamped preferably
are
sufficiently rigid that, after being curled and its ends are fixed, it remains
in the desired
spiral shape and configuration, which is the "relaxed" configuration. The
spiral is curled
to have a diameter such that the desired wire will easily slide into the
hollow center of the
spiral in this relaxed configuration. The chosen metal sheet is preferably
flexible enough
that twisting/rotating the tube/spiral ends relative to each other may be
done, whereby the
diameter of the tube/spiral reduces and captures the wire, but the metal is
chosen so that,
once tightened on the wire, the coils tend not to deform, flex, curl, stretch,
or separate to
an extent that the would allow accidental loosening and release of the wire.
Upon
twisting and locking the tube/spiral in the tightened configuration, the
stripped wire
remains captured and in electrical contact with the interior surface of the
tube/spiral.
[0074] The spiral is preferably not formed by wrapping a strip or wire around
the
wire to be captured, but, instead, is formed from a self-standing (self-
supporting)
tube/spiral that is inherently biased into a relaxed, loose condition, and yet
that may be
twisted into a tensioned tightened, smaller-diameter condition (in the
direction parallel to
the length of the coil of the spiral and generally transverse to the axial
length of the
spiral). Further, the spiral is preferably not manufactured by wrapping a
strip or wire
around any object that remains in the spiral during its use as a connector.
For example,
the preferred spirals are not flexible wires, strips, strings, or tape that
are wound or tied
around the conductive wire(s) to be captured, but rather are self-supporting
members that
16
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
retain their shape so that wire(s) may be inserted into their central
passageways with little
or no pressure of the wire(s) against the inside surfaces of the spiral.
[0075] The material that is rolled/curled/bent into a generally tubular shape
remains in said generally tubular shape, preferably biased by its resiliency
into a
relatively-larger diameter tubular shape into which the wire(s) may be
inserted, but
flexible enough so that twisting its ends relative to each other, or one end
relative to a
central region, moves the tubular shape into a relatively smaller-diameter
tubular shape
that may be latched/locked to grasp the wire(s). As in cut-tube embodiments of
the
conductive spiral, such a rolled/curled sheet embodiment of the conductive
spiral is
preferably substantially rigid, so that it may firmly and continuously grip
the inserted
wire(s) when the spiral is tightened on the wire(s).
[0076] Said rolling/curling/bending of said flat shape preferably includes
rolling/curling/bending of each end of the conductive spiral (and also a
central region if
the connector is a double-ended connector) into a ring-shape. Opposing edges
that come
together to from each ring-shape may be straight, notched, tongue-and-groove,
or other
shapes, wherein-non-straight edges may help with mating of said opposing
edges. Said
opposing edges may be fixed to each other or may simply be retained near each
other to
maintain the ring-shape by virtue of being received within a collar and/or
housing portion,
for example.
[0077] Alternatively, but less preferably, the self-standing/self-supporting
tube/spiral may be inherently biased into a tight condition relative to the
wire and yet may
be loosened by rotation/twisting of the spiral (in the opposite direction to
the tightening
direction) into a compressed (in a direction parallel to the spiral cut)
larger-diameter
condition. In such an embodiment, a lock or latch is needed to retain the
spiral in the
loosened condition until insertion of the wire into the spiral and until it is
desired to
capture the wire in the spiral.
[0078] In preferred embodiments, at least one spiral of conductive material is
provided in a housing, with one end of the spiral fixed to the housing and the
other end of
the spiral rotatable relative to said housing. Once a wire end(s) is/are
inserted into the
17
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
interior space of the spiral (which is in its large diameter configuration),
the rotatable end
may be rotated or "twisted" relative to the housing and relative to the wire
end(s) to move
the spiral into said smaller diameter configuration to an extent that the
spiral tightly grips
the wire end(s). Preferably, the rotation/twisting, and the consequent
tightening of the
spiral is continuous, and may be done to the full extent necessary to tightly
grip the wire.
The rotatable end is then locked, latched, or otherwise fastened to prevent
loosening of
the spiral again to a larger diameter, and, hence, to prevent disengagement of
the wire
end(s). Preferably, the lock, latch, or other fastener that retains the spiral
in the reduced
diameter configuration is not easily released, and/or not capable of being
released, so that,
once installed in the wire, the spiral unit will remain firmly and immovably
fixed to the
wire. Force on the wire in a direction intended to pull it out of the spiral
tends, if
anything, to tighten the grip of the preferred spiral on the wire, as such a
force works to
axially-lengthen the spiral, and, in doing so, to reduce the diameter of the
spiral for an
even tighter grip.
[0079] A preferred embodiment comprises a single spiral for connecting
stripped
wire to a eye, fork, or other terminal end, which single spiral may be twisted
relative to its
housing and to the inserted wire. One hand will typically hold the housing,
while the
other hand twists the terminal end that is preferably rigidly connected to the
spiral in
order to twist the spiral into the tightened configuration. Preferably, a
latch automatically
engages, for example, by a ratchet mechanism, so that a hand is not needed to
manually
latch the spiral and so that the spiral does not loosen when the hands holding
the housing
and the terminal end are released. In other words, the preferred ratchet
allows movement
in the tightening direction but does not allow significant movement in the
loosening
direction. In alternative embodiments, the latch may be manually engaged
and/or
manually disengaged at the discretion of the user. For example, "pivot-in to
lock" (and
"pivot-out to unlock") systems, or "push-in to lock" (and "pull-out to
unlock") systems
may be used for latching and unlatching the spiral.
[0080] Another preferred embodiment comprises two spirals that are provided
parallel and coaxially at opposite ends of a connector. Each of the two
spirals may be
twisted independently, relative to a first housing portion and relative to its
respective
18
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
stripped wire received inside its interior space. One hand will typically hold
the first
housing portion, while the other hand twists another housing portion that is
preferably
rigidly connected to a first spiral in order to twist said first spiral into
the tightened
configuration to capture a first wire. Then the user continues to grasp the
first housing
portion, perhaps switching hands, and, with the other hand, twists yet another
housing
portion that is preferably rigidly connected to a second spiral in order to
twist said second
spiral into the tightened configuration to capture a second stripped wire. The
two spirals
are electrically connected to each other and, hence, the two stripped wires
are electrically
connected to each other. Preferably, latches automatically engage for each of
the two
spirals, for example, by ratchet mechanisms, so that a hand is not needed to
manually
latch each spiral and so that each spiral does not loosen when the hands
holding the
various connector portions are released. In alternative embodiments, the
latches for the
two spirals may be manually engaged and/or disengaged at the discretion of the
user.
[0081] Alternatively, if the tightening directions of the two spirals of a two-
spiral
embodiment permit, the user may grasp the housing portions at opposite ends of
the
connector that are preferably rigidly connected to the first and second
spirals and twist
said housing portions in opposite directions, thus tightening both spirals at
the same time
with a simple "two-handed twist." Such an action will be permitted, for
example, if the
spiral directions are both right handed, or alternatively both left handed.
[0082] The preferred spiral connectors may be made in many diameters and
lengths, to accommodate many different types of stripped/un-insulated wire,
that is, many
different diameters, strand-numbers, and strand-types of electrical wire. When
wire is
installed in the connector and the connector is in use, inner surface of the
spiral portion(s)
of the preferred connectors must be in direct contact with outer surface of
the single
stripped/un-insulated wire, or with outer surface of at least some of the
stripped/un-
insulated, multiple strands or multiple wires, captured in the spiral
portions. When in a
reduced-diameter configuration, the entire or substantially the entire inner
surface area of
the preferred spiral contacts the wire. Therefore, the reduced-diameter spiral
wraps
around, and squeezes, preferably the entire circumference of the wire(s) along
a
19
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
significant axial distance along the wire(s), to create a large surface area
of electrical
contact between the spiral and the wire(s).
[0083] The housing(s) of the connectors are preferably sleeve(s) that encircle
the
spiral(s) and that provide means for securing an end of each spiral so that
that spiral end
is inunovably or substantially immovably fixed to a housing or housing
portion, an
opening though the housing for the insertion of the wire, and an opening
through the
housing through which a terminal end and/or another conductive element may
extend.
The housing(s) may be of various shapes and sizes, with optional but preferred
fins or
knurling to provide a sure grip, and with optional transparency or opaqueness
and/or
color-coding for different wire gauges or types. The preferred latch(es) may
be provided
in, or may extend from the housing(s), and preferably are designed so that
they may not
be unlocked or unlatched, or, at least, may not easily or accidentally be
unlocked or
unlatched.
[0084] The Figures illustrate some, but not the only, embodiments of housings,
spirals, spiral ends, terminal ends, and latch systems. The preferred latch
systems
comprise one or more fingers that extend inwardly from the housing to gouge
into,
protrude into, catch, abut against, or otherwise engage an end of the spiral
or a ring,
collar, or protrusion on the end of the spiral, to stop or limit reverse
rotation of the spiral.
Thus, once the spiral has been tightened and latched, the stripped/un-
insulated wire(s)
is/are captured and gripped inside the spiral, and the spiral will not loosen
to allow
removal of the wire(s). Alternatively, other latch mechanisms may be used, for
example,
plunger members, pins members, or other protruding or gripping members that
contact or
otherwise interfere with the spiral or an attachment fixed to the spiral, to
prevent or limit
reverse movement of the spiral. The latch mechanisms portrayed in the Figures
are
typically automatic and non-releasable. Alternatively, latch mechanisms may be
provided
that are manually engaged by the user, and/or releasable/unlatchable by
purposeful
manual action by a user, for example, by pulling of a plunger or pin member
radially
outward relative to the spiral and the housing.
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0085] Important features of the preferred embodiments include a large
electrical
contact surface area, for example, 1/6 ¨ 1 square inch of surface area, in
many
embodiments, and even more for large cable applications. This may be compared
to a
small fraction of an inch, for example, less than 1/10 square inch of contact
surface area
between a conventional crimped connector and a wire. Further, the preferred
spiral
connectors may be installed, without tools, by simply inserting the wire in
the relaxed
connector, followed by a simple and quick twisting of one end of the connector
relative to
the other. The preferred automatic latching/locking of the latch mechanism
takes place
without further manipulation of the connector or the wire.
[0086] While spirals extending in a particular direction are portrayed in the
Figures, for example, a "right hand spiral" in Figure 2, "left hand spirals"
may also be
used, with associated adaptations in the latch mechanisms to prevent or limit
reverse
movement by the spiral once the spiral has been tightened. It should be noted
that the
preferred spirals are not coils of wire wrapped around the wire inserted into
the
connector, but rather preferably rigid or substantially rigid spiral coils
formed so that
twisting/rotating one end will tend to tighten the entire spiral around the
inserted wire.
Preferably, when one end of the spiral is moved relative to the other (see
arrow in Figure
3), including when both ends are caused to rotate in opposite directions, the
entire spiral
moves, with all of the spiral wraps or "coils" sliding relative to each other
or otherwise
moving in a direction parallel to their length (see representative small
arrows in Figure 4,
and note that said moving in a direction parallel to their length comprises
both radial and
axial movement components). An important distinction between prior art
"threaded wire
connectors" and preferred embodiments of the present invention is that prior
art threaded
wire connectors have fixed immovable threads, of decreasing diameter, inside a
casing,
wherein the user threads the threaded wire connector onto a wire and, during
this
installation, there is no movement of any of the threaded wire connector
threads relative
to each other. In the preferred embodiments of the present invention, on the
other hand,
the spiral wraps or "coils" move relative to each other during the tightening
process (and
also during a loosening process, if the embodiment is provided with that
option). In the
preferred embodiments, the wraps/coils may start out at the same or
substantially the
21
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
same diameter, but, during the tightening process, they move/slide relative to
each other
to form a smaller-diameter structure that is typically smaller-diameter, and
typically
substantially a uniform smaller-diameter, all along the length of the
structure.
[0087] It should be noted that, during use, the wire is captured and
preferably
immovable in the spiral and that the terminal end is preferably directly fixed
to, or is
integral with, the spiral. The connector is not adapted or intended to create
force on the
wire or the terminal end that would cause movement of the wire and/or the
terminal end
relative to the spiral. Also, the connector is not adapted so that electrical
current through
the wire creates any force on the spiral or terminal end that would cause
movement of the
spiral or terminal relative to the wire. The connector is not a solenoid
system for
converting electrical energy into axial movement via electromagnetism and/or
for
converting movement via electromagnetism into electrical current. Preferably,
there are
no magnets associated with or attached to the connector.
[0088] Now referring specifically to the Figures, there are shown some, but
not
the only embodiments of the invented connectors and methods of making and
using the
connectors. Figures 1 and 2 shown a spiral connector 10 that comprises housing
12,
spiral 14 comprising multiple coils 15, terminal end 16 with eye 18, and
stripped wire 20
protruding from the insulation 22 (the insulation having been stripped off of
the end of
the wire 20 to bare multiple wire strands). The combination of the spiral 14
and the
terminal end 16, which are preferably directly attached to each other and/or
manufactured
as an integral, single unit, may be called a "spiral unit." Wire 20 and
insulation 22 are
intended to represent the many possible versions of wire, cable, and other
elongated
conductive materials that may be used with the connector 10, as discussed
above, and
especially the multiple-strand (multiple-filament) wire for which the
preferred connectors
are particularly beneficial. Figure 6 illustrates to best advantage how the
stripped wire
strands extend into the spiral of the preferred connectors, but that the
insulated portion of
the wire (covered by insulation 22) preferably extends only part way into the
preferably
funnel-shaped opening at the proximal end of the housing 12; this way, the
spiral may
exert force on, compress, and/or "bundle" the wire strands without any
interference by the
insulation 22.
22
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0089] After the multiple strands of the preferred stripped wire 20 are
inserted
into the spiral 14 of the connector 10, the spiral 14 is tightened as
described elsewhere in
this document. Said tightening of the spiral 14 will reduce the diameter of
the spiral 14 to
an extent that is determined by the combined outer diameter of the "bundle" of
stripped
wire strands. Said tightening will squeeze the strands into a compact bundle,
with little or
no space between the strands, that is substantially cylindrical in shape. The
outer surfaces
of the outer-most strands of the bundle will be the surfaces contacted and
pressured by the
inner surface of the spiral, and said outer-most strands will contact and
apply pressure to
the inner strands. The conductive spiral electrically connects to the outer-
most strands,
which electrically connect to the inner strands, so that all strands are
electrically
connected to the spiral. During the tightening, the strands may tend to shift
relative to
each other, until the strands are fully squeezed into a tight bundle by the
spiral that is tight
against the strands. In this fully-tightened condition of spiral and strands,
the spiral
should be latched, preferably automatically.
[0090] One may note That these preferred methods of installation and use are
different from prior art "spring" connectors wherein a solid, rigid pin is
shoved into a
spring so that the pin expands the spring to create the force causing the
spring to grip the
pin. One may note that the preferred multiple, at least somewhat flexible,
strands of wire
20 could not be effectively shoved into a spring with a diameter smaller than
the
combined diameter of the "bundle" of the strands, because the strands would
bend and
fail to properly enter the spiral, and, particularly, would fail to expand the
spring.
[0091] Also, one may note that the preferred methods of installation and use
are
also different from apparatus and methods for wrapping, strain-relieving, or
other
supporting of insulated electrical cords, and are different from apparatus and
methods of
reinforcing or otherwise supporting conventional electrical cords at their
connections to
conventional electrical plugs. Thus, the preferred apparatus and methods are
not the
supporting apparatus and methods that reinforce the strength of the insulated
electrical
cord and/or that prevent bending or axial sliding of the insulated electrical
cord at or near
a plug.
23
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0092] One may note that the preferred embodiments and methods of the
invention forming electrical contact between conductive spirals and conductive
wires,
rather than forming housings or cases for insulated cords. On may note that
the preferred
embodiments and methods of the invention will not work if the captures wire(s)
is/are
insulated inside the spiral and will not work if electrical insulation is
provided in the
spiral between the spiral and the wire(s). Also, one may note that many
embodiments of
the invention, more fully described below, comprise electrical connection
between
multiple wires inserted into the spiral, or between wire(s) inserted into the
spiral and a
terminal end that is integral with or directly electrically connected to thc
spiral. Thc wire
inside the spiral(s) does not pass through the spiral to a distant electrical
connection or
plug. The stripped distal ends of the wires preferably terminate inside of, or
very near
(within 0 ¨ 10 millimeters of) the spiral, and the stripped distal ends
preferably do not
contact any structure other than the spiral.
[0093] The terminal ends that may be portions of the spiral units of the
preferred
connectors are conductive material that is directly electrically connected to
the spiral or
manufactured to be integral with (in a single, unitary piece) the spiral, that
is, there is no
intermediate structure between the terminal and the spiral. A terminal may be
directly
electrically connected to the distal end of a spiral by spot-welding, for
example, or may be
made an integral portion of the spiral unit by the flat-sheet-cutting or -
stamping methods
described elsewhere in this document. Thus, the terminal end may be
differentiated from
an electrical plug or other electrical connection that is separate and
distanced from the
spiral and mechanically connected to the spiral only by virtue of an insulated
cord
extending between the spiral and the plug or separate connection.
[0094] The spiral 14 of Figure 2 comprises a proximal end 30 that has recesses
32 spaced around its circumference that may assist in fixing of the proximal
end 30 to the
housing 12. After inserting the spiral 14 into the housing, sonic welding may
fix the
proximal end 30 into the interior cavity of the housing, as shown to best
advantage in
Figures 6 and 7 at fixed connection 34. Said sonic welding may cause polymeric
housing
material to flow into said recesses 32 and then re-harden, thus fixing the
proximal end to
the housing. The interior wall surface of the housing may comprise a slightly-
protruding
24
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
ring (at 34 in Figure 7) that surrounds the proximal end 30, some of which
will be likely
to soften and flow into the recesses 32. Other fixing methods may be used,
with the
adaptation preferably being that the proximal end 30 of the spiral not be
moveable
relative to the housing 12. For example, in this and the following
embodiments, one or
more protrusions (not shown), in addition to or in place of the recesses 32,
may be
provided in/on the proximal end 30 of the spiral for becoming embedded or
otherwise
gripping or engaging the material of the housing upon sonic welding, adhesive
connection, molding or other fixing of the proximal end to the housing.
Alternative
spiral proximal end configurations may be envisioned by one of skill in the
art after
viewing this disclosure and the drawings.
[0095] The spiral 14 also comprises distal end 40 that may also have recesses
42
spaced around its circumference. Recesses 42 may (in a similar manner to
recesses 42
cooperating with the interior wall of the housing) cooperate with plastic
collar 44
provided on said distal end 40. Collar 44 protrudes radially outward from the
side surface
of spiral 14. Collar 44 may be sonically welded to distal end 40. Other fixing
methods
may be used, with the adaptation preferably being that the distal end of the
spiral not be
moveable relative to the collar 44, so that locking the position of the collar
44 will lock
the position of the spiral 14. For example, in this and the following
embodiments,
protrusions (not shown) from the side surface of spiral 14, in addition to or
in place of the
recesses 42, may be provided in/on the distal end of the spiral for becoming
embedded or
otherwise gripping or engaging the material of the collar 44 upon sonic
welding, adhesive
connection, molding or other fixing of the distal end to the collar 44. As
discussed
elsewhere in this disclosure, alternative collars or spiral distal end
configurations, and/or
entirely different locking mechanisms may be envisioned by one of skill in the
art after
viewing this disclosure and the drawings.
[0096] The collar 44 and its generally smooth and continuous outer surface 46
will rotate inside the housing when the terminal end 16 is twisted by one
hand, the
housing 12 being held by the other hand. During said twisting, preferably to
the extent at
which the spiral 14 is very tight against the wire 20 outer surface, at least
one finger 50
(preferably two, as shown in Figures 2, 7 and 8) flex to slide along the outer
surface 46.
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
The material of the collar 44 and the material and orientation of the fingers
50 relative to
the collar 44 are adapted so that, upon release of the twisting motion, and/or
any reverse
force, the fingers 50 will bite into, frictionally grip, and/or otherwise
engage the outer
surface 46 of the collar 44 to limit, and preferably prevent, reverse motion
of the spiral
14. Thus, this cooperation of the fingers 50 with the collar surface 46 acts
as a latch or
lock for retaining the spiral in the tightened configuration. Said generally
smooth and
continuous outer surface 46 provides for a continuous, non-incremental amount
of
twisting and tightening, and locking of the spiral in that position without
any significant
loosening after the user released his/her hands.
[0097] The finger 50 and collar 44 system is one, but not the only, example of
a
ratchet-type lock, wherein motion of allowed in one direction but not in the
reverse. One
may note that the fingers 50 are drawn to be small plates embedded in the
housing and
each having a bend that places the end of the finger in a position wherein the
finger will
flex out of the way during the desired twisting, but will catch and latch upon
the spiral or
collar moving in the reverse direction. Other shapes may be effective, for
example, a flat,
unbent plate that is embedded at an angle into the housing wall to "point" in
the direction
of the desired twisting.
[0098] Preferably, the entire spiral 14, including proximal and distal ends
30, 40,
is entirely electrically-conductive and, most preferably, a conductive
metal(s). The collar
44, however, may be a non-conductive material, as its role is in latching
rather than
electricity flow. Having the collar 44 be plastic or other non-electrically-
conductive
material may be particularly beneficial if the fingers are metal, whereby the
latch system
would be metal to plastic contact rather than possibly corroding metal to
metal contact.
In alternative embodiments, both the fingers and the collar may be metal, or
both the
fingers and the collar may be plastic/polymer. In alternative embodiments, for
example,
those discussed later in this disclosure, the collar may be absent and the
fingers or other
latch member directly contact and engage the surface of the distal end of the
spiral, rather
than having an intermediate member between the finger/latch member and the
spiral.
26
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0099] Figures 3 and 4 illustrate the preferred spiral 14 in relaxed and
tightened
configurations, respectively. Figures 5 and 5A illustrates alternative
versions of the
spiral, with spaces between the spiral wraps/coils (Figure 5) and with two
spiral cuts
forming two side-by-side spirals that will both extend and tighten around the
wire.
[0100] Figures 9 ¨ 11 illustrates some, but not the only, possible designs for
spiral 14. Figure 9 illustrates a spiral version 14', wherein a spiral cut
extends
transversely, or nearly transversely, across the tube wall from which the
spiral is
preferably formed. Figure 10 illustrates a less-preferred spiral 14 " wherein
two cuts or
other forming techniques may be used to make the interior surface of the
spiral
wraps/coils sharp edges. This Figure 10 embodiment is less preferred relative
to
embodiments wherein the internal surfaces of the wraps/coils are generally
flat and broad
and thus maximize contact with the wire. Figure 11 illustrates an alternative
spiral 14"'
wherein the cut that creates the wraps/coils is slanted so that interior
surfaces of the
wraps/coils have acutely-angled edges E. Twisting of the spiral 14" of Figure
11 may
create some slight overlap of -the wraps/coils and, thus, a sturdier, more
rigid structure
around the wire.
[0101] Figures 12 and 13 illustrate to best advantage a preferred double-ended
spiral connector 100 for connecting two wires together. The spiral unit 114
comprises
two spirals 116, 118 (which each may also be called a "spiral portion") that
are provided
on opposite ends of a central region 120 that is not spiraled. The housing
comprises
multiple portions, including end sleeves 121, 122, and central sleeve 123.
Central sleeve
123 is preferably fixed to the central region 120 so that sleeve 123 does not
rotate relative
to the spiral unit 114. This may be accomplished by various means, for
example, sonic
welding of the plastic sleeve 123 to the metal central region 120 with the aid
of plastic of
the interior surface of the central sleeve 123 flowing into, and then re-
hardening in,
recesses 132, 142 provided around the central region 120. End sleeves 121 and
122 are
slid onto spiral unit 114 to cover their respective spirals 116, 118, and the
outer ends 146
and 148 of the spirals 116, 118, respectively, are sonically welded or
otherwise fixed to
the interior surfaces of the sleeves 121, 122. This fixing may be done by
sonic welding, as
described above for the embodiment of Figures 1 and 2 and the central region
120 and
27
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
central sleeve 123, wherein material from the interior surfaces of the sleeves
121, 122
flows into, and then re-hardens, in recesses 156, 158.
[0102] Upon installation of the central sleeve 123 and the end sleeves 121,
122 as
described above, the connector 100 will appear as it does in Figure 13. The
central sleeve
123 is fixed to the center region 120 of the spiral unit 114, but the end
sleeves are
rotatable relative to the central sleeve 123 and the central region 120.
Therefore, after
inserting wire (not shown in Figures 12 and 13) into the open ends of end
sleeves 121,
122, the central sleeve 123 may be grasped in one hand and one of the end
sleeves (either
121 or 122) may be twisted. This twisting will tighten the respective spiral,
and, upon the
preferred automatic latching, the wire will be captured and retained tightly
in the spiral.
For example, in Figure 13, one may see the twisting/rotation arrow for end
sleeve 121,
and the arrow for end sleeve 122, which happen to be in opposite directions
because of
the direction of the spirals 116, 118. As in the single-end-insertion
connections, the
spirals 116, 118 of this embodiment, when in the relaxed configuration, are
larger in
interior diameter than the combined diameter of the wire(s) being inserted
into the
passageway of the spirals. This way, even if the inserted wires are many,
thin, and/or
flexible, they may be inserted easily and are not required, and in fact
preferably do not,
exert significant force on the interior surface of the spirals or expand the
diameters of the
spirals.
[0103] For ease of viewing, call-outs 161, 162 are provided in Figure 13 to
point
out the fixed attachment of spirals 116, 188 to end sleeves 121, 122,
respectively. The
opposite ends of the spirals, at call-outs 171, 172, are free to rotate in the
end sleeves 121,
122, respectively, with the rotation being only in one direction due to
adaptations that
preferably include the ratchet-type of latch/lock discussed before.
[0104] The preferred ratchet-type of latch/lock comprises fingers 150, 150'
(similar to fingers 50) sliding, during the desired twisting, along the
circumferential outer
surface 147, 147' of the extensions 181, 182 of central sleeve 123. However,
upon
release of the twisting motion, and/or any reverse force, fingers 150, 150'
will bite into,
frictionally grip, and/or otherwise engage the outer surface 147, 147' of the
central sleeve
28
CA 02779248 2012-04-27
WO 2011/056901 PCT/US2010/055337
123 to limit, and preferably prevent, reverse motion of the spiral. Thus, this
cooperation
of the fingers 150, 150' with surfaces 147, 147' acts as a latch or lock for
retaining the
spirals in the tightened configuration. Surfaces 147, 147' are preferably
generally smooth
and continuous, so that a continuous, non-incremental amount of twisting and
tightening
may be done and locked without any significant loosening after the user
released his/her
hands.
[0105] As will be understood from the above disclosure and the Figures,
connectors according to the invention may be used to connect multiple wires
together,
without the need for any terminal end included in the connector. For example,
the
connector 100 of Figures 12 and 13 electrically connects multiple wires
together without
any terminal end, as will be understood by one of skill in the art. Other
embodiments
according to the invention may be used also to connect multiple wires
together, without
the need for a terminal end in the connector, in a "side-by-side"
configuration wherein the
multiple wires inserted into a single spiral rather than into two spirals.
See, for example,
Figures 38, 38A -38E, which are described in more detail later in this
document. Thus,
one may describe the connector 100 of Figures 12 and 13 as an "end-to-end",
"generally
coaxial", or "butt" connection, and one may describe the connector of the type
shown in
Figures 38, 38A -38E, as a "side-by-side" connection. The multiple wires used
in the
connectors of Figures 12 and 13 and Figures 38, 38A -38E may be many types,
for
example, wires, cables, single or multiple strands, or other elongated,
conductive
elements. As in the spirals discussed earlier in this document, the spiral of
the
embodiment of Figures 38, 38A - E, when in the relaxed configuration, are
larger in
interior diameter than the combined diameter of the wire(s) being inserted
into the
passageway of the spirals. This way, even if the inserted wires are many,
thin, and/or
flexible, they may be inserted easily and are not required, and in fact
preferably do not,
exert significant force on the interior surface of the spiral or expand the
diameters of the
spiral.
[0106] Figures 14 ¨ 17 illustrate some of the many possible prior art terminal
ends that may be adapted for attachment to a spiral or spirals according to
embodiments
of the invention. As noted earlier in this document, it is preferred that the
terminal end be
29
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
attached directly to, or manufactured integral with, the spiral. Figure 18
illustrates a prior
art threaded wire connector, as described earlier in this disclosure.
[0107] Figure 19 illustrates an alternative embodiment of the invented spiral
connector 200 comprising housing 212 and spiral 214 with terminal end 216. The
combination of the spiral 214 and the terminal end 216, which are preferably
directly
attached to each other and/or manufactured as an integral, single unit, may be
called a
"spiral unit." The spiral distal end 240 does not have a collar encircling it.
The latch
mechanism comprises direct contact of the fingers 250 with the distal end
outer surface,
that is, the outer circumferential surface of the end of the tube from which
the spiral is
formed. Many closely-spaced notches or recesses 252 are provided around said
circumferential surface, over which the fingers 250 will slide during the
desired twisting.
However, upon release of the twisting motion, and/or any reverse force, the
fingers 250
will fall into and become lodged in, or otherwise engage, the notches or
recesses 252 or
otherwise engage to limit, and preferably prevent, reverse motion of the
spiral 214. Thus,
this cooperation of the fingers 250 with the distal end 240 acts as a latch or
lock for
retaining the spiral in the tightened configuration. This is an example of a
metal end of
the spiral being part of the latch mechanism, preferably for cooperation with
metal fingers
250. Fingers 250, however, may alternatively be formed of plastic to create
plastic-metal
cooperation if desired.
[0108] One may note the alternative terminal end 216 of the connector 200,
wherein the terminal end 216 is connected to a closed end 217 on the distal
end 240 and
extends along a central plane that intersects the spiral. This is one, but not
the only,
alternative may of forming a spiral with attached or integral terminal end. In
this
connector 200, therefore, the entire spiral 214, terminal end 216, and closed
end 21'7 are
preferably conductive, and, even if the fingers 250 are also of metal or other
conductive
material, the housing 212 insulates and protects the user from contact with
the conductive
portions of the connector 200.
[0109] Figures 21 and 22 illustrates the spiral 214 of the connector 200
removed
from the housing 212 and in both a relaxed configuration (Figure 21) and a
twisted,
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
tightened configuration (Figure 22). Here, one may note that relative larger
and fewer
recesses 232 that are provided on the proximal end of the spiral for helping
with sonic
welding fixing of that end to the housing. And, one may note the relative
smaller and
greater number of notches/recesses 252 that are part of the latch mechanism.
These
notches/recesses 252 will provide latching in an incremental, rather than a
continuous,
fashion, but, if enough are provided, they may still retain a sufficiently
tight configuration
for the spiral.
[0110] Figures 23 and 23A illustrates alternative spirals similar to that
shown in
Figures 21 and 22, wherein one spiral 214 is formed with space provided
between
wraps/coils (Figure 23) and one spiral 214 " is formed with multiple spiral
cuts parallel
and spaced -from each other, thus, forming two spirals, side-by-side,
encircling the
stripped wire (Figure 23A).
[0111] Figure 24 illustrates in cross-section the connector 200 of Figures 19
and
20. The terminal end 216 is portrayed in this figure as extending through the
"closed
end" 217 for possible electrical contact with the wire itself and even with
the spiral
wraps/coils themselves. Figure 25 illustrates the embodiment of Figures 19, 20
and 24 in
axial cross-section.
[0112] Figures 26 and 27 portray to best advantage fingers 250' extending into
and catching in notches/recesses 252' of an alternative distal end/collar 240.
This distal
end/collar 240' features a slightly larger diameter than the diameter of the
spiral wall, and,
hence, protrudes radially outward slightly from the spiral. A recessed ring
region 254
may be provided inside the housing to accommodate the distal end/collar 240'.
[0113] Figures 28 and 29 portray an alternative, double-ended connector 300.
Major differences between this connector 300 and the connector 100 of Figures
12 and 13
include the following: The central sleeve 323 is fixed to the central region
320 of the
spiral unit 314 by welding, adhesive, or other methods that result in sleeve
323 not being
movable relative to the spiral unit 314. Said central sleeve 323 does not
extend to cover,
and does not cooperate with, the notches/recesses 332, 342 provided at the
inner end of
each spiral 316, 318 (each of which may also be called a "spiral portion" of
spiral unit
31
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
314). The recesses 346, 348 at the outer ends of the spirals may be used for
sonic
welding to the interior surface of the respective end sleeves 321, 322, as
described above
for recesses 146, 148 in Figures 12 and 13. The fingers 350, 350' cooperate
with, and
latch in, recesses 332, 342, to effect the latching/locking desired after
twisting of the
spirals. As in the connector 100 of Figures 12 and 13, the user will grasp the
central
sleeve 323 and twist first one end sleeve and then the other, to tighten both
spirals 316,
318 on their respective wires. Upon release of the twisting motion, and/or any
reverse
force, fingers 350, 350' will fall into and catch inside, and/or otherwise
frictionally grip,
and/or otherwise engage the notches/recesses 332, 342 of the spiral unit 314,
to limit, and
preferably prevent, reverse motion of the spirals. Thus, this cooperation of
the fingers
350, 350 with notches/recesses 332, 342 acts as a latch or lock for retaining
the spirals in
the tightened configuration. Call-outs 361 and 362 are provided on Figure 29
to point out
the fixed attachments of the spirals to the end sleeves. Call-outs 371 and 372
are
provided on Figure 29 to point out the rotatable/twistable relationship of the
notches inner
ends of the spirals 316, 318 to the fingers 350, 350' of the end sleeves 321,
322.
[0114] Figures 30 - 33 portray yet another connector 400 that comprises a
distal
spiral end 440 having many, narrow, axial grooves 442 around the circumference
of the
end 440. These grooves provide smaller increments of latching after twisting
of the
spiral, as the fingers 450 may catch on any of the closely-spaced grooves to
latch the
spiral in the tightened configuration. One may note that great size difference
between the
grooves 442 in the distal end and the recesses 432 on the proximal end, as the
grooves
442 are a portion of the accurate, and finely-adjustable latching system,
while the recesses
432 are merely for assisting in the sonic welding of the proximal end to the
housing. One
may note that this embodiment, like the others drawn in this disclosure,
include two
fingers in the latch system, but it should be noted that other numbers, from
one to many
may be effective. Also, one may note that all the embodiments drawn herein
include
recesses such as those called-out as 432, but that these may not be required
for other
methods of fixing the spiral to the housing.
[0115] Figures 34 and 35 portray yet another connector 500 that includes a
collar
544 that surrounds the distal end of the spiral and that may be used in the
latch system.
32
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
This collar 544 may be plastic and, therefore, the terminal end 516 is shown
extending
through the collar 544 electrically connect to a spiral wrap/coil itself and
optionally to
contact the end of the wire 20.
[0116] Figures 36, 36A, 36B, 37, 37A, and 37B illustrate some, but not the
only,
embodiments of invented flat-sheet-cutting or -stamping methods and conductive
spiral
portions formed thereby. The structure for the spiral may be stamped, cut, or
otherwise
formed from a flat or generally flat metal or other conductive sheet. For
example, in
Figures 36 and 36A, many flat shapes 600 are cut/stamped from a single flat
sheet,
wherein the terminal end T is connected to, and distanced from, band B1 by a
long,
diagonal portion D. The diagonal portion D may have a longitudinal cut through
it,
whereby both the strips of material Sl, S2 on both sides of the cut each form
a spiral
wrap, similar, for example, to the multiple-cut spiral shown in Figure 23A.
One may note
from Figure 36 that many of said flat shapes 600 may be cut/stamped side-by-
side on the
single flat sheet of metal, with little or no waste metal between said shapes
600, thus,
minimizing waste of the metal and minimizing or eliminating "trimming" of each
shape
to its proper shape and size. This method greatly increases the types of metal
that may be
economically used for the spiral, as one may start with a flat sheet of metal
rather than
tubular stock.
[0117] Each flat shape 600 is separated from the adjacent flat shapes and/or
extra
metal, and then rolled/curled/bent into the generally tubular shape (spiral
unit 600'), by
methods that will be understood by those of skill in the metal arts. Bands B1
and B2 are
similarly roller/curled/bent and their outer edges may be fixed together to
assist in
strengthening the spiral unit 600', for example, by spot-welding or other
techniques. The
resulting spiral unit 600', as shown in Figure 36B, has opening 0 through
which wire(s)
may be inserted so that stripped/exposed metal of the wires may extend deep
into the
spiral to be contacted by the spiral wraps. Tightening of the spiral unit 600'
on the wires
causes movement of the spiral wraps relative to each other to form the
previously-
discussed relatively-small diameter spiral grasping the wire(s). There may be
some
spaces between the wraps of the spiral, which spaces are not shown in Figure
36B, which
may become smaller or close completely. Note that, in Figures 36, 36A, and
36B, the
33
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
housing is not shown, but it will be understood that, after said
rolling/curling/bending of
the shape 600 into the spiral unit 600', rotating of end E2 clockwise relative
to end El, in
the directions indicated by arrows in Figure 36B, will tighten the spiral.
[0118] Recesses R (or alternatively, cuts, apertures, or protrusions), and/or
serrations SE (or other cuts, recesses or protrusions) may be provided near
end El and
E2, respectively. Recesses R may assist in preferably anchoring end El to a
housing, and
serrations SE preferably may assist in latching E2 (after tightening) to the
housing. Thus,
as discussed previously in this document, after tightening and latching, both
ends of the
tightened spiral are fixed or latched to the housing, so that the housing
maintains the
tightened condition of the spiral, preferably permanently.
[0119] Figures 37 and 37B show flat shape 700, which is cut/stamped from a
flat
sheet to allow formation of a double-ended connector spiral unit 700'. End El
and
center CE are connected by, and distanced apart by, a long, diagonal portion
D1. Center
CE and end E2 are connected by, and distanced apart by, a long, diagonal
portion D2.
The diagonal portions D1 and D2 may each have a longitudinal cut C through
them,
whereby both the strips of material Sl, S2 on both sides of cut C each form a
spiral wrap,
similar, for example, to the multiple-cut spiral shown in Figure 23A. One may
understand from Figure 37B that counterclockwise rotation of end El relative
to center
CE will tighten the spiral portion called out as "spiral 1," and clockwise
rotation of end
E2 relative to the center CE will tighten the spiral portion called out as
"spiral 2". Thus,
one may see that a user who twists ends El and E2 in opposite directions at
the same time
(in a "two-handed twist" motion) without grasping or maneuvering the center
CE, -will
effective tighten both spiral portions at the same time.
[0120] As the flat shape 700 is rolled/curled/bent into the generally tubular
shape
(spiral unit 700'), the bands of El, E2, and CE are preferably similarly
roller/curled/bent
and their outer edges may be fixed together to assist in strengthening the
spiral unit 700',
for example, by spot-welding or other techniques. Stripped wires may be
inserted into the
spiral unit 700' in opposite directions, into the openings 01 and 02 of the
spiral unit 700'
and deep into their respective spiral portions ("spiral 1" and "spiral 2" in
Figure 37B), so
34
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
that stripped/exposed metal of the wires may be contacted by the spiral wraps.
Tightening
of the spirals on the wires would cause movement of the spiral wraps relative
to each
other to form the previously-discussed relatively-small diameter spirals
grasping the
wire(s). There may be some spaces between the wraps of the spiral, which
spaces are not
shown in Figure 37B, which may become smaller or close completely. Note that,
in
Figures 37A and B, the housing is not shown, but it will be understood that
housing
portions may be provided, and recesses, protrusions, and/or other systems may
be
provided to fix and latch the housing portions to the spirals for operation of
the device as
described above for other embodiments.
[0121] Figures 38, 38A ¨ F, and 39, 39A and B illustrate additional,
especially-
preferred embodiments of the invention. Figures 38 and 38A ¨E illustrate one,
but not
the only, connector 800 featuring a "side-by-side" configuration having no
terminal end
and wherein the electrical contact apparatus consists only of the spiral unit
814 that
connects multiple wires or cables inside the spiral. Multiple wires, cables,
or other
stripped/un-insulated, conductive, elongated members are inserted into and
gripped
preferably by a single conductive spiral, and thereby placed in electrical
connection with
each other, but which connector does not include a separate terminal end
attached to the
spiral. For example, two separate electric cables 22, 22' extending from
different
equipment/devices have their ends stripped of insulation, and all of the
resulting stripped
strands 20 from both cables are inserted side-by-side in the same direction
into a single
spiral unit 814 rather than into two spirals. The strands optionally may be
twisted
together if desired before insertion into the spiral, but this is not
typically necessary, as
the end of the housing having the opening preferably has a large funnel-shaped
interior
surface (large relative to the combined diameter of the strand bundle) and the
spiral, as
discussed previously is significantly larger than said combined diameter. This
way, the
strands, which tend to be at least somewhat flexible, will enter the connector
easily by
sliding into the housing opening, along the slanted inside of the funnel, and
into the
spiral. Such a connector may be used, for example, in place of the connectors
in Figures
12, 13, 28, 29, 39, and 39A - C (further discussed below) to connect multiple
of said
wires, cables, or other conductive, elongated members from different
equipment/devices
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
in electrical contact inside a single spiral rather than in end-to-end
multiple spirals. The
multiple wires, cables or other conductive, elongated members will, at their
distal ends,
be generally "side-by-side" inside the spiral, rather than "coaxial" or "end-
to-end."
[0122] Connector 800 comprises spiral unit 814 having a funnel-opening housing
portion 812 with wings W, a spiral portion with spiral coils 815, and
protruding teeth 853
around the circumference of the spiral unit near the funnel-opening housing
portion 812.
While not detailed in the drawings, funnel-opening housing portion 812 has an
opening 0
into a funnel-shaped interior passageway, which guides the strands 20 into the
spiral.
Housing portion 813 encircles the spiral at an end opposite of housing portion
812, and
comprises closed end 819. Multiple ratchet bars 850 are spaced around the
inside of the
housing portion 813 for engagement and interaction with teeth 853, for
operation of the
latching system. The spiral end to which housing portion 812 is fixed may be
called the
proximal end of the spiral and the opposite, distal end of the spiral is
inserted into
housing portion 813 and fixed to the inside surface of housing portion near
closed end
819, for example, by sonic welding, adhesives, pinning, or other preferably
permanent
methods. As suggested in Figure 38E, the multiple strands of multiple cables
may be
inserted into the connector 800, and a user may grasp the housing portion 812
(especially
wings W) with one hand, and housing portion 813 with the other hand, and may
twist the
two housing portions relative to each other. In the connector 800 of Figures
38, 38A ¨ E,
the user would twist housing portion 812 so that the top wing W in Figure 38E
would
come out away from the paper and would twist housing portion 813 toward the
paper, as
suggesting by the arrows in Figure 38E. As will be understood by those reading
and
viewing this disclosure, the spirals of the preferred embodiments may be
manufactured in
the reverse direction, which would result in twisting/rotation in opposite
direction being
operable to tighten the spirals. The latching system, comprising ratchet bars
850 and
teeth 853, is illustrated to best advantage in Figures 38A and B.
[0123] Figure 38F illustrates one, but not the only, embodiment wherein the
connector of Figures 38, 38A ¨ E has been adapted into connector 800', which
includes a
terminal end 816 protruding out through housing portion 813'. Terminal end 816
is a
conductive material directly electrically connected to or integral with the
spiral of the
36
CA 02779248 2012-04-27
WO 2011/056901 PCT/US2010/055337
connector 800', and extends out through a hole 819' in the end of housing
portion 813'.
As housing portion 813' is preferably immovably fixed to the distal end of the
spiral and
the terminal is preferably immovably fixed to the spiral, terminal end 816
need not move
relative to the housing portion 813' and terminal end 816 may either extend
out from a
hole 819' or may simply extend through housing portion 813' without
signiticant space or
gap between the terminal end and the housing wall.
[0124] The terminal end Figures 39, 39A and B illustrate another embodiment
of,
and a method of using, an "end-to-end" connector 900. Connector 900 comprises
a
double-ended spiral unit 914, having funnel-opening ends 912 on each end. A
generally
tubular housing 913 circumferentially surrounds the spiral unit 914, and is
immovably
fixed to the spiral unit near its center. Latching systems are provided at
each of the ends
of the spiral unit for latching/locking the ends of the spirals (also called
"spiral portions")
to the tubular housing 913 after the spirals have been twisted. Preferably,
said
latching/locking comprises engagement of cooperating ratchet members provided
on the
spiral unit (on or adjacent funnel-opening ends 912) and interior end surfaces
of the
housing 913, in a manner similar to the ratchet bars 850 and teeth 853 of
connector 800.
Figure 39A and B illustrate to best advantage how separate cables, with
stripped/stripped
strands ends may be slid into the funnel-opening ends 912 and deep into the
spiral unit
914. Upon twisting (rotating) of the ends 912 in opposite directions
(preferably in a
"two-handed twist" that does not require the person twisting the ends 912 to
touch
housing 913), the two spirals twist/rotate along with the ends 912 to tighten
on their
respective stripped/un-insulated strands. As discussed earlier in this
document, as the
ends 912 are twisted, preferably to the full extent possible with an adult
applying
moderate strength, the latching systems will automatically latch and the
strands will be
captured and preferably permanently be locked in the connector 900.
Preferably, the
insulated portion of the wire/cables will extend part way into the funnel-
opening ends 912
but will not extend into the spiral portions of the connector; thus, the
spiral tightens on
the stripped/un-insulated strands and squeezes said strands into a tight
bundle, wherein
the spiral is therefore electrically-connected to the strands on the outside
of the bundle
and the strands on the outside of the bundle are electrically-connected to the
strands on
37
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
the inside of the bundle. As may be noted in Figure 39C, this connector 900
may be
described as double the structure of connector 800, as if two connectors 800
are placed in
mirror-image at each end of connector 900.
[0125] In summary, preferred embodiments of the invention may be said to
include at least one conductive spiral that is moveable from at least one
relatively large
diameter configuration into which wire(s), cable(s), or other conductive
elongated
elements may be inserted, to at least one relatively smaller, or reduced,
diameter
configuration that grips said wire(s), cable(s), or other elongated elements.
The preferred
at least one conductive spiral may be used for electrically connecting one or
more wires,
cables, or other elongated, conductive members to any other conductive
element. For
example, one or more wires, cables, or other elongated, conductive members,
strippcd of
any insulation or other non-conductive material, may be inserted into the at
least one
spiral, may be electrically connected to each other by virtue of their contact
with each
other and contact with the conductive spiral, or may be electrically connected
to another
conductive element such as a terminal end, a fixed conductive element, or
other
conductive elements. If more than one conductive spiral is used in a
connector, it is
preferred that the multiple spirals be electrically connected to each other
either by being
integral portions of a single conductive tube that is cut or otherwise formed
to comprise
multiple spirals, or by other electrically conductive connection means.
[0126] While the term "spiral" is used throughout this document, it should be
noted that the conductive element of the preferred embodiments may also be
called by
other names, for example, the terms "coil", "wrap", or "helix" may be
appropriate. As
discussed above, many different shapes, sizes, spacings, and surface contours
of the
wraps or coils of the conductive element may be used. It is preferred that
that the wires,
cables, or other elongated, conductive members do not enlarge or expand the
spiral when
inserted into the spiral, but rather that the spiral starts significantly
larger than the
combined (total, overall) diameter of the wires/members being inserted into
it, and then is
manually reduced in diameter by a user in order to grip, capture, and
electrically connect
to the inserted wires/members. Thus, the spiral is moved by a user to engage
and
electrically connect to the inserted wires/members, rather than the insertion
of the
38
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
wires/members affecting the electrical connection. Insertion of the
wires/members into
the preferred spiral might, by chance, affect some temporary electrical
connection
because portions of the wires/members may rest against or otherwise touch the
interior
surface of the relaxed spiral. However, a reliable and permanent connection is
not made
until the user purposely tightens the spiral by twisting/rotating the spiral
into firm and
permanent engagement with the wire/member.
[0127] Many different shapes, sizes, and contours of the housing, housing
portions, or other insulating members may be used in the connectors, and many
different
latch/lock systems may be used. It is preferred that the various housing
portions, or at
least our surfaces of the housing portions, be insulating/non-electrically-
conductive, for
safe grasping by a user and for shielding of the conductive portion(s) of the
device during
installation and use. The housing portions may be rigid, or may be somewhat
flexible as
long as the twisting force applied by a user to the housing portion(s) is
effectively
transmitted to the spiral. It is also preferred that the entire spiral be
covered by one or
more insulating housing portions so that the spiral is not reachable by a user
(except for
an exposed terminal end in some embodiments). It is preferred that no part of
the spiral
extends out of the housing (except for an exposed terminal end in some
embodiments)
and not part of the spiral is broken or removed during installation on wire
and/or during
use. In view of the above preferences, it may be noted that it should not be
necessary to
wrap the connector or any part of the wire(s) extending into the connector
with
electricians tape.
[0128] Various systems for operative connection of the housing or housing
portions to the conductive portion(s) may be provided and these may comprise
the
latch/lock systems. The latch/lock systems may themselves be conductive, non-
conductive, or part conductive and part non-conductive, as desired for
optimizing
manufacturing and cost, however, any conductive portions of the latch/lock
systems
should not be exposed or otherwise left un-insulated/un-shielded.
[0129] It may be noted that, when wire(s) are inserted into the preferred
embodiments of the invented connectors, that the user will be able to easily
judge and/or
39
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
feel when the wire(s) are fully and properly inserted. Structure of the
connector may
provide a stop/limit for insertion, for example, in the embodiments of Figures
1 -7, 19 ¨
27, 30 ¨ 35, 36, 36A and B, the stripped/tut-insulated wires may abut into
structure at the
distal end of the spiral such as a portion of the terminal end or such as a
plug (not shown)
inserted into the spiral distal end that does not interfere with tightening of
the spiral.
Alternatively, but less preferably, the stripped/un-insulated wires may
slightly protrude
(preferably, less than 1 cm) from the distal end of the spiral to be seen by
the user.
Alternatively or combination with the above methods, the user may strip the
wire a
predetermined amount and be able to judge proper insertion by knowing how much
stripped wire extends from the insulation and, hence, how far to insert the
wire(s). In
some embodiments, the insulation will abut into the funnel-shaped opening
surfaces and
therefore indicate full insertion, but this is unlikely in many cases because
a single
connector may be used with many different wire/cable diameters and, hence, the
funnel(s)
will typically not be sized to match a single insulation diameter. In the
closed-end
embodiment of Figure 38, 38A ¨ E, for example, the user may insert the wire(s)
until they
abut into the closed end of the housing.
[0130] In double-ended embodiments, such as Figures 12, 13, 28, 29, 37, 37A
and B, 39, 39A ¨ C, the user may insert the wire(s) from opposite directions
into the
spiral unit and feel when they abut into each other near the center of the
spiral unit.
Altematively or combination with the above methods, the user may strip the
wire a
predetermined amount and be able to judge proper insertion by knowing how much
stripped wire extends from the insulation and, hence, how far to insert the
wire(s). A
stop or limiting structure may be provided (not shown) at or near the center
of the double-
ended spiral units, but the plug should be chosen and installed so that it
does not interfere
with spiral tightening.
[0131] The preferred embodiments may provide flexibility in the type and
diameter of wire(s) that can be inserted and tightened into the connector. For
example,
while a connector according to the invention may be designed to optimally
capture a
single diameter/gauge of wire, many of the connectors according to the
invention will
have a structure capable of receiving and tightening to capture a range of
CA 02779248 2012-04-27
WO 2011/056901 PCT/US2010/055337
diameters/gauges of wire. For example, many connectors and their spirals may
tighten to
capture at least two gauge sizes, for example, 2 gauge (American Wire Gauge)
and 4
gauge, or 6 and 8 gauge, or 10 and 12 gauge. However, the inventor envisions
that a
single connector may be built with the flexibility to receive and tighten to
capture even a
wider range of gauge sizes, due to various inventive features of the
spiral(s), housing(s),
and latching systems. This flexibility is provided because there is preferably
no structure
inside the spiral except for the stripped/un-insulated wire(s) being captured;
prior to
insertion of the wire(s), the spiral passageway is preferably empty. Also,
this flexibility is
provided because the cooperating members of the latching system preferably may
slide
axially relative to each other a distance of at least a few millimeters,
preferably about 5 ¨
mm for smaller connectors and preferably about 10 - 25 mm for large
connectors.
Also, this flexibility may be enhanced by axial spaces/gaps being supplied
between the
spiral coils in the relaxed configuration, as discussed previously in this
document, so that
the spiral coils may tighten in diameter without abutting axially into each
other (the axial
spaces/gaps may close upon tightening), and, hence, without the spiral ends
moving so far
outward axially that they compromise the spiral latching mechanism or housing
integrity.
[0132] Therefore, some embodiments may be tightened over a wide range of
diameters, for example, to reduce the spiral internal diameter by preferably 5
- 30 percent
(and more preferably 10 ¨ 30 percent). Other embodiments may reduce the spiral
internal
diameter 5 - 50 percent (more preferably, 10 50 percent). In a 30 percent
reduction, the
resulting tightened diameter may be reduced to 70 percent of the relaxed
diameter. In a
50 percent reduction, the resulting tightened diameter may be reduced to 50
percent of the
relaxed diameter, for example, a relaxed internal diameter of 1 cm could
tighten by 50
percent to become 5 nun in diameter. In terms of American Wire Gauge (AWG), a
50
percent reduction in diameter may be roughly equated, by "rule of thumb," to
an increase
in 6 AWG numbers. So, a connector capable of reducing the spiral diameter by
50
percent would operate with 2 gauge wire but also with smaller wire diameters
such as
those represented by 4 gauge, 6 gauge, and 8 gauge (or sizes in-between). Or,
with said
50 percent reduction, a connector working well with 8 gauge wire could also
operate with
10 gauge, 12 gauge, and 16 gauge (or sizes in-between). Thus, a single
connector may
41
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
be used for a variety of wires and cables, and the electrician, auto mechanic,
computer
technician, and especially the "do-it-yourselfer," may not have to use
different connectors
for each different size or gauge of wire.
[0133] It is also envisioned that embodiments of the invention may be used in
applications typically called "burial" connections, wherein cables are
connected and
buried in the ground, for example, between multiple buildings or equipment on
a single
site, or for electrical utility lines that travel long distances underground.
The preferred
connectors are expected to be extremely efficient and effective, because they
create a sure
and reliable connection in few steps. As an added feature, a moisture-proofing
material,
or components that react to form a moisture-proofing material, may be included
inside the
connector at the time of manufacturing of the connector. For example, most
connectors
that would be used in a burial application would be butt-style connectors,
such as the
example in Figures 39, 39A ¨ C, and such connectors may be made with one or
more of
the moisture-proofing components/compositions in a solid, semi-solid, or
encapsulated or
otherwise contained liquid form, inside the housing 913. See, for example,
moisture-
proofing material MP in Figure 39C, which is inserted, stuck, glued, or
otherwise
provided, and temporarily retained, in the otherwise empty spaces inside the
housing 913.
Preferably, this material MP is placed in several of the "otherwise empty
spaces" that are
outside of the spiral and against the inner wall of the housing 913. From
Figure 39C, one
may see that such empty/void spaces may exist between the spiral and the
housing near
the housing wall, between each set of ratcheting latch mechanism L and the
central ring R
that extends to and is fixed to the spiral 914. With the material MP thus
positioned, it
will not interfere in the insertion of the wires into the spiral, but, after
tightening of the
spiral on the wires, the connector may be subjected to heat or other
activation that starts
the reaction(s) that create and/or expand the moisture-proofing effect.
[0134] The material MP may bc various compositions that will be understood by
one of skill in the art after reading this disclosure. The preferred moisture-
proofing
material helps protect the connector, and especially the conductive spiral and
stripped
wires, from becoming corroded or damaged by water and ground moisture over
many
years. Those reading this disclosure and being familiar with expanding
polymeric foams
42
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
and caulking materials will understand how to select a material that may be
used to seal
the spiral-and-wire combination and water-proof the connector as necessary for
burial
applications. For example, a heat-activated material may be used that creates
a moisture-
resistant or moisture-proof foam that expands into all or nearly all the empty
spaces that
would otherwise available for entering moisture. Other expanding foams or
materials
may be used that are heat-activated, radiation-activated, or other-wise
activated to expand
and fill spaces only when purposely activated by an installed. Alternatively,
the
expansion may be activated by breaking a membrane(s) between two or more
chemical
sacks or capsules that are provided inside the housing, for instance, upon
twisting of the
spiral of other pricking or tearing of a membrane(s). It is preferred that the
expanding
material fill the spaces around the outside of the spiral, between the housing
and the
spiral, and the spaces between the housing 913 and the housing ends 912, 912',
so that
the moisture-proofing substance may even expand out of each end of the
connector. The
moisture-proofing substance may even seep or expand into the spiral as long as
the
tightening has already been performed and the electrical connection has
already been
made. Therefore, it is an option for expanding material to be placed inside or
at the ends
of the spiral, as long the activation of it occurs at a time that does not
interfere with the
tightening and proper electrical contact.
[0135] The electrically-conductive parts of the preferred connectors may be
selected from many commonly-available conductive materials available in
industry, and
from materials to be made available in the future. For example, many metal and
metal
alloy tubular materials and flat sheet materials are known in the electrical
arts, including
but not limited to copper and copper alloys, and those of skill in the art
will understand
how to select materials from these commercially-available stock materials.
[0136] The simplicity of the preferred embodiments allow economical
manufacture and use. For example, some embodiments of thc invented connector
may be
described as consisting essentially of, or consisting only of, a spiral unit,
a single housing
portion, and a terminal end, wherein one or more wires with stripped ends are
inserted
into and tightened in the spiral. Other embodiments of the invented connector
may be
described as consisting essentially of, or consisting only of, a spiral unit,
and two housing
43
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
portions that may be twisted relative to each other, wherein multiple wires
with stripped
ends are inserted into and tightened in the spiral. Other embodiments may be
described
as consisting essentially of, or consisting of, a spiral unit, and three
housing portions
wherein multiple portions may be twisted relative to the others and preferably
the two
outer end housing portions are twisted simultaneously in opposite directions
to tighten the
spiral unit, wherein wires with stripped ends are inserted into each end of
the connector
and tightened in the spiral by said twisting of two of the housing portions.
Other
embodiments may be described as consisting essentially of, or consisting of, a
spiral unit,
three housing portions wherein multiple portions may be twisted relative to
the others and
preferably the two outer end housing portions are twisted simultaneously in
opposite
directions to tighten the spiral unit, wherein wires with stripped ends are
inserted into
each end of the connector and tightened in the spiral by said twisting of two
of the
housing portions, and moisture-proofing material located inside at least one
of the three
housing that is heat-activatable or otherwise activatable to expand into empty
spaces
inside the connector, and optionally out from between the three housings, to
block water
and moisture from entering the connector.
Especially-Preferred Embodiments
[01371 Referring to Figures 40 through 43A - E, there is shown an especially-
preferred embodiment of butt-style connector 1000, which is similar to the
butt-style
connector shown in Figures 39A ¨ C, but with modified housing 1013 and ends
1012,
1012'. The housing 1013 may also be called the "main housing body" or "central
housing portion", and ends 1012, 1012' may also be called "end caps" or
"housing end
portions", as both housing 1013 and ends 1012, 1012' may be considered
portions of one
housing that generally surrounds and insulates the conductive spiral and the
conductive
wires. As will be understood from the description of other embodiments earlier
in this
document, the housing 1013 is fixed to a central region of the spiral 1014,
midway or
generally midway between the two end of the spiral 1014, and the two ends of
the spiral
are fixed to their respective ends 1012, 1012', so that twisting of the ends
1012, 1012'
44
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
relative to the housing 1013 tightens the spirals to grip wires inserted
therein.
[0138] The latch interaction between the housing 1013 and ends 1012, 1012'
comprises curved latch arms 1050 with teeth 1051 that engage cooperating end
cap teeth
1052 on the inside circumferential surface of a generally cylindrical skirt
1056. Thus,
portions of the housing 1013 comprising said latch arms 1050 extend into an
annular
space in each end 1012, 1012', and the shirt 1056 extends outside of, and
axially along,
the portions of the housing 1013 comprising the latch arms 1050. The latch
arms 1050
are preferably inherently biased to press outward against said end cap teeth
1052 to mate
with teeth 1052. Upon twisting of the ends 1012, 1012' relative to the housing
1013,
latch arms 1050 are slightly resilient, that is, sufficiently resilient to
allow relative motion
of the ends 1012, 1012', each in one direction, relative to the housing 1013
to tighten the
spiral 1014. Specifically, end cap 1012 will be rotated clockwise in a view
from the left
in Figure 40, and end cap 1012' will be moved clockwise in a view from the
right in
Figure 40. The latch arm teeth 1051 and end cap teeth 1052 are each slanted to
allow this
relative motion of the ends 1012, 1012' and latch arms during tightening of
the spiral,
with the teeth 1051 and teeth 1052, in effect, sliding over and past each
other, as will be
understood from the drawings. Upon release of the tightened ends 1012, 1012',
the bias
of the latch arms 1050 will cause them to continue to press out against the
grooves 1052,
and the teeth 1051 and 1052 will mate and catch on each other to stop motion
in the
reverse. Thus, the latch retains the spiral in the tightened, smaller-diameter
configuration.
[0139] Viewers of Figures 40 ¨ 43E will see and understand the structure of
connector 1000 in view of the earlier drawings and discussion in this document
regarding
other embodiments of the invented spiral-based connectors. 0-rings 1060 or
other seals
may be provided to form a liquid-seal between the ends 1012, 1012' and the
housing
1013, to keep moisture/water out of the connector. Also, or instead, the o-
rings 1060 may
keep moisture proofing material inside the connector (see the discussion of
such material
MP above for Figure 39C) and/or keep any other expanding foam components or
other
chemical compositions inside the connector, such as any chemical compositions
that may
be used to contact or chemically treat the spiral or housing interior for any
purpose. Also,
one may see in the drawings dust covers 1070 that may be used on each end cap
1012,
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
1012' to keep the connectors clean "on the shelf" and that may remain on the
connector
when in use. A easily-broken-through portion of the end cap, such as the X-
shaped
portion 1072 of cover 1070, may be used to allow the wires through a
resilient/flexible
portion of the cover 1070 during insertion of the wire ends; other opening or
apertures
may also be used, for example, as portrayed by the alternative cover 1075 in
Figure 43E
that has a weakened/thin spiral pattern through which the wire ends may be
inserted.
[0140] Figures 44A and B, and Figures 45A and B illustrate especially
preferred
embodiments, respectively, of a connector 1100 of the general type shown in
Figures 38 ¨
38E, and of a connector of the general type shown in Figures 1-7, 19 ¨26, 30 ¨
35.
Connector 1100 receives multiple stripped or otherwise un-insulated wires ends
into one
end of the connector and electrically connects all of said wires. Connector
1200
comprises a terminal end 1216 electrically-connected to the spiral and
extending out from
the housing to be connected to other conductive equipment, as described
earlier in this
document. As also discussed earlier, the terminal end may be selected from
many
different shapes and styles of terminal ends. One may see in Figures 44A and
B, and 45A
and B, that one end 1112, 1212 is provided on connectors 1100 and 1200,
respectively,
for gripping and turning/twisting relative to housing 1113, 1213 to tighten
the spiral
inside each cormector. End 1112, 1212, and the latch arms of housing 1113,
1213 are
similar to the housing ends 1012, 1012' and latch arms 1050 described above
for
connector 1000, and their interaction for housing and latching the spiral will
be
understood by those reading and viewing this document.
[0141] While wires or cables are not shown in Figures 40 ¨ 45B, it will be
understood that said wire/cable ends are inserted into the open ports, or
through
cover/caps on the ports into the connectors, as described above for other
embodiments.
One may see a funnel-shaped interior surface of the housing end caps to best
advantage in
Figures 41 and 43D, 44B, and 45B, and this may help accurate and sure
insertion of the
wires through the ends, as discussed previously in this document. Such a
funnel-shaped
surface is preferred but not always required, as long as enough space is
provided in the
ends to receive the wire ends and allow them to travel into the spiral(s).
46
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0142] Referring to Figures 46 - 55, there are shown some, but not the only,
embodiments that could be used in the environments/applications in which a
block-style
connector is typically desired. One example of prior art commercially-
available block
connectors are PolarisTM brand block connectors. Block connectors are
desirable for
heavy-duty applications such as utilities, for example, wherein very heavy
gauge wire(s)
are used. For example, 4 or 6 gauge wire may require the special adaptations
of the
preferred embodiments shown in Figures 46 ¨ 55.
[0143] Examples of preferred embodiments of the invented block-style connector
are shown in Figures 47 ¨ 50. Figure 46 portrays a connector 2000 with a
single port
2001 for entry of multiple wires that are to be electrically connected, for
example in a
manner similar to that described for connector 800 in Figures 38 ¨ 38E. Figure
47
portrays a connector 2100 that has two ports 2101, 2102, each receiving
wire(s) in what
may be likened as a "butt-style" connection, as discussed earlier in this
document, so that
the ports 2101, 2102 may be called "opposing" ports. Figure 48 portrays a
connector
2200 with two, side-by-side ports 2201, 2202. Figure 49 portrays a connector
2300 with
four ports 2301, 2302, 2303, 2304, wherein two ports are side-by-side on each
side of the
connector so that ports 2301 and 2302 are side-by-side, ports 2303 and 2304
are side-by-
side, ports 2301 and 2303 are opposing and 2302 and 2304 are also opposing. By
"side-
by-side" is meant that ports are on the same side of the generally cylindrical
main housing
body of the connector, and preferably each has a longitudinal axis, extending
out from the
main housing body and coaxial with the axis of its end cap, that is parallel
to the adjacent
(side-by-side) ports. By "opposing" is means that ports are on opposite sides
of the
generally cylindrical main housing, and preferably each has a longitudinal
axis, extending
out from the main body of the connector and coaxial with the axis of its end
cap, that is
coaxial with the longitudinal axis of the opposing port. Side-by-side ports
may be said to
be preferably 0 degrees from each other, or approximately 0 degrees from each
other (0 ¨
degrees, for example). Opposing ports may be said to be 180 degrees from each
other,
or approximately 180 degrees from each other (170 ¨ 180 degrees, for example).
47
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
Longitudinal axes of multiple ports on a connector may be at angles other than
0 and 180
to each other, and other than approximately 0 and 180 degrees to each other,
for example,
90 degrees, 45 degrees, or any angle between 10 degrees and 170 degrees.
[0144] Connectors 2000, 2100, 2200, 2300 comprise conductive spiral(s) inside
their main housing bodies that preferably are coaxial with said longitudinal
axes of the
provided ports. In the case of opposing ports, one spiral unit, or multiple
spirals, may
extend between the ports on a single axis, for example, that single axis being
coaxial with
the ports. In the case of side-by-side ports, each port will cooperate with a
spiral, and the
spirals will typically be electrically-connected by a conductive holder tube
or other holder
member or insert that extends between the spirals inside the main body of the
housing.
[0145] Connectors 2000, 2100, 2200, 2300 may be stand-alone connectors, which
are closed at their ends by end portions of the main body of the housing, or
by end plates
that snap into or otherwise attach to said main body to close the ends of the
housing. The
preferred end plates 2010 are called-out in Figure 46 but also may be seen in
all of
connectors of Figures 46 ¨ 49. If the connectors are to be used solely as
stand-alone
connectors, these end plates may be permanently attached, and/or may instead
be integral
portions of the main body. But, if the connectors 2000, 2100, 2200, 2300 are
to be used
as modular connectors, as will be discussed in detail below, the end plates
2010 may be
removable for connection of multiple connectors together.
[0146] Figure 50 portrays one embodiment of a modular connector assembly
2400, which is constructed of three modules that are (left to right)
connectors 2100, 2000,
and 2200, with end plates removed from their housings as appropriate to
connect them
together. This is but one embodiment of many assemblies that may be put
together from
multiple modules, for example, to increase the number of the wire ports and
wires being
connected. Various combinations of connectors may be assembled by a
manufacturer or
a user, wherein the combinations may comprise, for example, one or more of: a
single
connector (2000), a single butt-style or "single pass-through" connector
(2100), a side-by-
side or "double" connector (2200), or a double butt-style or "double pass-
through"
connector (2300). Electrically-conductive dowels or other protruding members
extend
between and connect the modules, with each dowel/member preferably being sized
so
48
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
that it extends all the way between spirals in adjacent modules. Each
protruding
dowel/member may be press-fit (or otherwise secured) into the opened end of
another
module (having removed the end cap EC of that "another module"). This way
electrical
connection may be made with multiple modules, and the electrician may carry
several
modules for forming virtually any combination and number of modules.
[0147] Preferably, each dowel/protruding member is electrically-conductive, so
that all the connected modules are electrically connected to each other by the
dowel/member passing between the modules to electrically connect all the
spirals
contained therein, and also to preferably mechanically connect the modules.
This way,
one or more "incoming" wires/cables may be installed in one or more ports, and
"outgoing" wires/cables may be installed in other port(s), with all
electrically connected.
While wires or cables are not shown in Figures 40 ¨ 43E, it will be understood
that said
wire/cable ends are inserted into the open ports, or through cover/caps on the
ports into
the connectors, as described above for other embodiments.
[0148] Figures 51- 55 illustrate details of the preferred modular connectors.
The
ports of these connectors have port housing collars 2020 and endcaps 2030,
respectively,
that are the same or similar to structure shown in Figures 40 ¨ 45B, that is,
to portions of
the housings 1013, 1113, and 1213, and to ends 1012, 1012', 1112, and 2112
that
cooperate with said portions of the housings. Thus, one will understand from
the earlier
description in this document how the latch arms with teeth, ends with teeth,
endcap skirt,
and o-rings are constructed and operate to allow tightening of the spiral(s)
and latching of
the spiral(s) in the smaller-diameter configuration that grips and retains the
wires in the
connector. Specifically, Figure 51A shows connector 2000, with its endplates
removed,
wherein one may see upper half 2031 and lower half 2032 of the main housing
body,
which are fixed/secured together around the conductive spiral unit 2040. Other
housing
constructions may be used for this connector and the other modular connectors,
but this
construction of two halves may be useful when inserting the spiral unit into
the housing.
The conductive spiral unit 2040 comprises a spiral 2014 that extends into the
port 2001 to
receive wires at its distal end, with its proximal end integral with or fixed
to the
conductive holder tube 2050 received in the generally cylindrical interior
space of the
49
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
main body of the housing. Thus, the wires are received and gripped in the
spiral 2014,
the spiral is electrically-connected to the holder tube 2050, and, in the
event that the
connector 2000 is used as a module connected to other modules, a conductive
elongated
member, such as dowel(s) 2070, mechanically and electrically connects the
holder tube
2050 to one or two holder tubes of adjacent modules. This way, the conductive
dowel(s)
electrically connect the holder tubes of adjacent modules, and preferably the
radial end
surfaces 2055 of the adjacent holder tubes will also be touching and therefore
in electrical
contact. This results in large surface area of conductive material of each
module being in
contact with adjacent modules, for a sure electrical connection between the
modules.
One may understand that the holder tube 2050 inay be connected by one dowel
2070 to
only one module on either end of the connector 2000, or by two dowels to two
modules
(one on each end of connector 2000). Preferably, the spiral 2014 extends into
the center
of the hollow passageway 2057 of the holder tube 2050, so that it creates a
stop/limit for
the inserted dowel, to ensure that the dowel will be positioned in the module
so that it
protrudes far enough out of the module to connect to an adjacent modules, and
so that it
does not become forced all the way into the holder tube 2050.
[0149] In the instance of connector 2000, it will be understood that the
holder tube
2050 need not be electrically-conductive if the connector 2000 is to be only a
stand-alone
connector that is not to be electrically connected to another connector. Or,
in the instance
of connector 2000 being mechanically connected to other module(s) but not
electrically
connected, the dowel unit be a non-conductive connector. One such non-
conductive
dowel unit is shown in Figure 55, wherein it has the polygonal dowel portions
plus a plate
to shield the holder tubes of the modules from each other, to mechanically
connect
modules but not to electrically connect them. This may be done for various
reasons, for
example, for the convenience of having a single connector unit wherein not all
ports are
in electrical contact with all other ports.
[0150] Figures 52A and B portray details of connector 2100, with endplates
removed, wherein one may see that the main body of the housing may be made
from an
upper half and a lower half, that are fixed/secured together around spiral
unit 2140.
Spiral 2140 is made of two conductive spirals 2114, 2114' fixed to, and in
electrical
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
contact with conductive holder tube 2150, wherein the spirals 2114, 2114' are
preferably
coaxial and extend out from the cylindrical side-surface of holder tube 2150
transverse to
the longitudinal axis of the holder tube 2150. One may see, therefore, that
wires installed
in the ports and gripped by the spirals 2114, 2114' will be in electrical
contact with each
other and with the holder tube 2150, and, if the connector is modularly
connected to other
modules by a conductive dowel(s) and preferably electrical contact between
the3 holder
tube end surfaces, the wires will be in contact with the conductive portions
of the adjacent
modules. The two spirals 2114, 2114' may be two separate spirals that are
individually
connected to the holder tube, preferably with their inner ends protruding far
enough into
the holder tube to be stops, that is, surfaces that limit how far into the
holder tube the
dowels may' be pushed. Or, the two spirals 2114, 2114' may be end portions of
a single
spiral piece that extends all the way through the holder tube, again serving
inside the
passageway of the tube holder as a stop/limit for the dowels.
[0151] Figures 53A and B portray exploded views of a modular connector such as
connector 2200, with its two side-by-side ports. The spiral unit 2240 in this
connector
comprises a holder tube 2250 with two side-by-side spirals 2214, 2214' that
extend out
from the holder tube 2250 in a direction transverse to the longitudinal axis
of the tube
2250. The spirals are preferably parallel to each other.
[0152] From the above description, one may see how to construct and use
various
modules according to embodiments of the invention. For example, while it is
not shown
in exploded view herein, connector 2300 will be understood to have a holder
tube that has
four spirals extending out from it to extend into the four ports. In a similar
manner as
described above for connector 2100, each pair of opposing spirals may be
separate
spirals, or may be portions of a single spiral that extends all the way
through the holder
tube. In either event, it is preferred that the spirals act as stops/limits
for the dowel.
[0153] It should be noted that the spiral for each port is fixed to the holder
tube
inside the housing, and the holder tube is shaped and received inside the
housing so that it
will not rotate when the spirals are tightened. Thus, the inner (proximal
ends) of the
spirals are held stationary inside the housing by their attachment to the
holder tube,
without being fixed directly to the housing itself. In alternative
embodiments, the
51
CA 02779248 2012-04-27
WO 2011/056901 PCT/US2010/055337
spiral(s) inner (proximal) ends may be mechanically fixed to the main body of
the
housing, as long as an electrical connection is also provided between the
spiral(s) and a
conductive member(s) inside the housing for the desired electrical connection
between
spirals and for the desired electrical connection between the spirals to other
modules.
Thus, the shape of the holder tube or alternative conductive members inside
the housing
may be altered from that shown.
[0154] Both the passageway in the preferred holder, and the preferred dowel
that
is inserted into or otherwise resides in the passageway, are preferably mating
polygonal
shapes. This will prevent the modules from rotating relative to each other,
that is, each or
any of the modules rotating on its housing main body longitudinal axis
relative to the
other modules. The polygon shape shown is an octagon shape for both passageway
and
dowel, but others may be used, such as hexagon, pentagon, or rectangular, or
other non-
circular shapes. Also because of the preferred polygonal connection, modules
may be
connected together at various "rotational angles" relative to each other. For
example, all
the ports of the three modules connected in Figures 50 are generally co-
planar, that is, the
longitudinal axis of all the ports is on a single plane. But one or more of
the modules
could be connected to the others so not all the ports are generally co-planar.
For example,
any module of the assembly could be rotated relative to the others, before
connection of
the modules, in some increment of 45 degrees (the dowel and passageway polygon
shape
being 8-sided). Or, for example, one module could be 45 degrees from the next,
and that
module could be 90 degrees from the next. If the outer surface of the dowel
and the inner
surface of the passageway is an octagon, then ports of one module may extend
at 45
degrees, at 90 degrees, at 135 degrees, or at 180 degrees from other modules'
ports, for
example. If the outer surface of the dowel and the inner surface of the
passageway is a
hexagon, then ports may extend at 60 degrees, at 120 degrees, or at 180
degrees from
other modules' ports. This may be convenient for electricians that need to
make a
connection between wires/cables that are extending from/to different
locations, for
example, one extending horizontally and another extending vertically, in which
a 90
degree connection would be ideal and would be possible and convenient with the
invented modular block connector.
52
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0 1 55] Alternatively, the dowel(s) or other protruding elongated member(s)
may
be permanently affixed to modules, and therefore, not removable. This way, the
dowels
would not be "loose parts". Non-removable dowels are less preferred, however,
as female
modules without dowels would also have to be made to allow mating of male
modules
and the female modules. Also, in order to cover the ends of the male and also
the female
modules, the cover plate and/or other covers would need to be adapted to
provide either
two styles or one larger or more complex style that could cooperate with both
types of
modules.
[0156] Various materials may be used for the connector described herein. For
example, housings, including main bodies and ends, may be various electrically-
insulating polymer or composites. Especially-preferred housing materials are
glass-filled
polymers such as 10% glass filed ABS. Electrically-conductive portions, such
as spirals,
holder tubes, and dowels may be various conductive materials, such as copper,
including
but not limited to CU120, or other low-oxidation, low-rust, and high-
conduction metals,
alloys and compositions. 0-rings and dust covers may be rubber or neoprene,
for
example. It will be understood by those of skill in the arts that various
fasteners, welding,
sonic welding, plastics-joining, metal-joining, adhesives, press-fit
techniques, cutting,
forming and molding techniques may be used to form the embodiment shown
herein.
[0157] Additional adaptations may be made in the invented devices to maintain
the spiral(s) in a tightened condition. For example, selection of materials
may prevent
creep of plastic and/or other causes of possible loosening of the spiral over
time and/or
due to heating/cooling cycles. The latch/lock system materials may be selected
for
resilience or bias, so that the spiral is constantly urged into a tightened
configuration to
counteract heating or cooling effects that might otherwise loosen the spiral.
Also, further
adaptations of the spiral may be made to ensure tight and sure gripping of
wire(s) and no
or minimal hot-spots; for example, barbs or protrusions may extend from the
spiral into
the center space of the spiral to grip/engage wire(s) to an even greater
extent when the
spiral is tightened on the wire(s). Adhesives, expanding foam, or other
chemicals that
harden around at least portion of the spiral(s), after installation of wires
into the
connectors and after tightening of the spiral(s), are envisioned.
53
CA 02779248 2012-04-27
WO 2011/056901
PCT/US2010/055337
[0158] Although this invention has been described in this document and in the
drawings with reference to particular means, materials and embodiments, it is
to be
understood that the invention is not limited to these disclosed particulars,
but extends
instead to all equivalents within the broad scope of the following claims.
54
