Abstract:
A connector assembly is shown which includes a receptacle connector and a plug connector assembly. The plug connector assembly is comprised of a plug housing and upper and lower flanges. The plug connector housing is spring-loaded rotationally relative to the upper and lower flanges, and includes a stop feature to orient the plug connector to the upper and lower flanges. The plug connector can rotate relative to the flanges, but there is always a home position for the plug polarized position.

Description:
[0001]    This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/354,117 filed Feb. 4, 2002, the complete disclosure of which is hereby expressly incorporated by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The subject invention relates to a power connector for commercial and utility use, for example, for lighting fixtures and the like.  
           [0003]    It is well known in the art of fixture systems, such as for lighting fixtures and ceiling fan fixtures, that most of the wiring between the fixture and the intended power wiring is done by hand, typically through conventional connectors known as wire nuts. Typically the ceiling of the building to include the fixture includes a junction box located where the fixture is to be located, with a portion of a power cable ready for connection. The person hanging the fixture typically requires a ladder to hold the fixture, and in many cases requires a second person to perform the connection function. It should be appreciated then that holding the fixture while at the same time connecting two wires with a wire nut is not an easy task to be completed.  
           [0004]    Some manufacturers have provided an eyelet hook extending from the junction box, which can then hold the fixture while the wires are connected. While this design solves a portion of the problem, the fixture itself is awkward while hanging, and the hook itself becomes an encumbrance to the fixture once the wiring is completed.  
           [0005]    Some manufacturers also provide a connection system such that one connector is in the junction box while the other connector is in the fixture such that longitudinal movement between the two connectors connects the fixture to the power conductors. This too has created some difficulty in that the fixture must be rotated to complete the installation, and therefore the connector within the fixture must always be properly oriented. Some installers can have the connector system, which is located in the fixture, rotated relative to the fixture which can cause damage to the connection system or a misconnection between the two connector halves, or simply difficult connection between the fixture and power connector.  
           [0006]    The object of the invention is then to provide a solution to the above-mentioned shortcomings.  
         SUMMARY OF THE INVENTION  
         [0007]    The objects of the invention have been accomplished by providing an electrical connector for connecting a device to a power source. The device connector being connectable along a generally longitudinal axis, the device connector comprising a first housing portion, and a second housing portion which is rotatable relative to the first housing portion about the longitudinal axis. The second housing portion is spring-loaded relative to the first housing portion causing a moment on the second housing portion about the longitudinal axis.  
           [0008]    In the preferred embodiment of the invention, the first and second housing portions also define a home position, whereby the second housing portion may be rotated relative to the first housing portion, yet spring loadably returned to the home position. Also preferably, the first and second housing portions define an extreme position of rotation. The first housing portion is comprised of a mounting member, which is preferably in the form of mounting flanges which overlap the second housing portion. The second housing portion includes an annular flange in surrounding relation, with an annular channel therein. The spring is positioned within the channel, with a first end connected to the first housing portion and a second end connected to the second housing portion. The first housing portion includes a recess into which the second housing portion flange resides. The annular channel includes stop walls, and the first housing member includes a tab member positioned between the stop walls, the second housing member being rotatable relative to the first housing member, with the home position and the extreme position being defined by the interference between the tab member and the stop walls. The first housing portion is defined by stamped metal shell halves, which trap between them the second housing portion flange.  
           [0009]    In another aspect of the invention, an electrical connector assembly is comprised of plug and receptacle connector portions. The plug connector is connectable to the receptacle connector along a generally longitudinal axis. The plug connector comprises a housing portion and a mounting flange portion, which retains the housing portion in a position rotatable relative thereto about the longitudinal axis. The housing portion is spring-loaded relative to the flange portion causing a moment on the housing portion about the longitudinal axis.  
           [0010]    In the preferred embodiment of this version, the housing portion and mounting flange portion define a home position, whereby the housing portion may be rotated relative to the mounting flange portion, yet spring loadably returned to the home position. The housing portion and mounting flange portion also define an extreme position of rotation. The housing portion and mounting flange portion have polarizing members to align them. The mounting flange portion is comprised of mounting flanges, which overlap the housing portion and trap it therebetween. The housing portion includes an annular flange in surrounding relation, with an annular channel therein. The spring is positioned within the channel, with a first end connected to the mounting flange portion and a second end connected to the housing portion. The mounting flange portion includes a recess into which the housing portion flange resides. The annular channel includes stop walls, and the mounting flange portion includes a tab member positioned between the stop walls, the housing member being rotatable relative to mounting flange portion, with the home position and the extreme position being defined by the interference between the tab member and the stop walls. The mounting flange portion is defined by stamped metal shell halves, which trap between them the second housing portion flange. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    The invention will now be described by way of the drawing figures where:  
         [0012]    [0012]FIG. 1 is a perspective of the connector system in a fully terminated position;  
         [0013]    [0013]FIG. 2 is a perspective view showing the connector system of FIG. 1 in an exploded position;  
         [0014]    [0014]FIG. 3 is a lower perspective view taken of the connector system of FIG. 2, as the connector system would be viewed from the ground;  
         [0015]    [0015]FIG. 4 is a side plan view of the receptacle connector which is shown in FIG. 2 or  3 ;  
         [0016]    [0016]FIG. 5 is a front plan view of the receptacle of FIG. 4;  
         [0017]    [0017]FIG. 6 is a rear plan view of the receptacle of FIG. 4;  
         [0018]    [0018]FIG. 7 is a cross-sectional view through lines  7 - 7  of FIG. 6;  
         [0019]    [0019]FIG. 8 is a perspective view of the plug connector which is shown in FIG. 2 or  3 ;  
         [0020]    [0020]FIG. 9 is a top plan view of the connector system of FIG. 8;  
         [0021]    [0021]FIG. 10 is a rear plan view of the plug connector shown in FIG. 8;  
         [0022]    [0022]FIG. 11 is a cross-sectional view through lines  11 - 11  of FIG. 10;  
         [0023]    [0023]FIG. 12 is a cross-sectional view through lines  12 - 12  of FIG. 10; and  
         [0024]    [0024]FIG. 13 is a perspective view of the cap for enclosing both the plug and receptacle connector shown in FIG. 1.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0025]    With respect first to FIGS. 1 and 2, the connector assembly of the present invention is shown generally at  2  and includes a receptacle connector  4 , covered by a cap member  6 . The plug connector assembly is shown generally at  8  to include a plug housing  10 , an upper flange member  12  and a lower flange member  14 . The plug housing  10  is also closed off by a cap member  6 ′, and it should be understood that caps  6  and  6 ′ are identical and thus only one will be described in great detail. It should be understood from viewing FIG. 2 that the receptacle connector  4  would be that connector intended for mounting in the ceiling or in the junction box, while the plug connector assembly  8  is intended for mounting within the fixture.  
         [0026]    With respect now to FIGS.  4 - 7 , the receptacle connector will be shown in greater detail. The receptacle connector  4  includes a mating face  20 , a wire connecting face  22 , and a plurality of terminal receiving passageways  24  extending therebetween. The receptacle connector housing  4  is generally cylindrical in nature to include a front mating shell  26  having a lead-in surface  28  and a polarizing rib at  30 . A mounting flange  32  extends around the shell  26  and includes a plurality of mounting apertures  34 . Finally, the plug receptacle includes a rear housing portion  36  having a plurality of latching members at  38  for retaining the cap  6  as will be described herein.  
         [0027]    With respect now to FIGS. 8 through 12, the plug connector housing  10  will be described in greater detail. With respect first to FIG. 8, the plug housing  10  generally comprises a central housing portion  40  having a mating face  42 , a wire connecting face  44 , and a plurality of terminal receiving passageways  46  therebetween. A shroud  48  extends upwardly from the central body portion  40  to define a cylindrical wall having an inner surface at  50 . The wall is interrupted at  52  to define a polarizing slot, which cooperates with the polarizing rib  30  as will be described further herein. The inner diameter of the wall  48  as defined by the surface  50  is profiled to receive the cylindrical shell portion  26  of the receptacle connector.  
         [0028]    The plug connector  10  further comprises an annular ring at  56  and which opens downwardly to form an internal channel at  58 , as best shown in FIG. 10. The ring  56  includes a spring retaining post at  60  extending into the channel as best shown in FIGS. 8 and 12. The post  60  is integrally molded with the remainder of the plug housing  10  and therefore an upper opening  62  (FIGS. 8, 9) is defined through the upper face of the annular ring  56  which defines the top portion of the post, whereas the remainder of the post is formed through the channel itself in the molding process. As best shown in FIG. 10, the channel  58  is interrupted by stop walls at  66  and  68  thereby defining two sections of the channel, a spring receiving section labeled  58 A, and a positioning section shown at  52 B, as will be described in greater detail herein. Finally, as shown in FIG. 8, plug housing  10  includes latching lugs at  70 .  
         [0029]    With respect now to FIGS. 1 and 2, upper flange  12  will be described in greater detail. Upper flange  12  includes a generally rectangular flange plate at  80  including an upturned annular ring  82  thereby defining a central opening at  84 . The flange plate  80  includes a first set of mounting apertures  86  in a rectangular pattern, and a second set of mounting apertures  88  in a larger rectangular pattern.  
         [0030]    With respect now to FIGS. 2 and 3, the lower flange member  14  will be described in greater detail. Flange member  14  includes a generally upper mounting ring at  90  and is drawn to define a recess at  92  which includes an internal annular wall at  94  and an end wall  96  having an opening therethrough at  98 . It should be appreciated from viewing FIG. 2 that the opening  98  is profiled to receive the body portion  40  of plug connector  10  therethrough, while at the same time the recess  92  is profiled to receive the annular ring  56  therein. The mounting ring  90  includes mounting apertures at  100 , which are in the same rectangular pattern as the mounting apertures at  86 .  
         [0031]    With respect now to FIG. 3, the end wall  96  includes a first tab section  102  struck therefrom and as shown is defined as a hook section, profiled to receive a spring end therearound. As also shown in FIG. 3, a second tab member  104  is struck from the end wall  96  and is defined as a generally upstanding rectangular tab. The function of tabs  102  and  104  will be described in greater detail herein.  
         [0032]    Finally, with respect to FIG. 13, the retaining cap  6  includes a circular plate  110  having semi-cylindrical walls  112  upstanding therefrom, thereby defining wire receiving and exiting passageways at  114 . Portions of the semi-cylindrical walls  112  are interrupted at  116  to define latching arms  118 .  
         [0033]    With respect now to FIG. 3, the assembly of the device and its operation will be described in greater detail. It should first be understood that a plurality of contact assemblies (not shown) will be loaded in both of the receptacle and plug housings  4 ,  10 , for example pin and socket style contacts which are matable one to the other. It should also be understood that the receptacle connector  4  is appropriately mounted in the ceiling or junction box by way of retaining screws (not shown) positioned through the apertures  34  retaining the plug housing  4  in the ceiling with the cylindrical shell portion  26  and polarizing rib  30  extending downwardly into the room.  
         [0034]    The plug assembly  8  is pre-assembled to the fixture by positioning a spring member  120  end position in channel  58 , such that a spring end  124  is hooked around the post  60  to lie in channel portion  58 A, whereas spring end  122  is hooked around tab portion  102  of the lower flange member  14 . The housing portion  10  is then lowered into the recess  92  such that tab member  104  is within slot  58 B and due to the spring load, will abut stop wall  66 . The upper flange member  12  is now positioned over connector housing  10  such that the apertures  86 ,  100  are aligned. It should be appreciated that fastener members are used to retain the upper flange  12 , lower flange  14 , and intermediate connector housing  10  together. Prior to the installation of the plug assembly  8  to its associated fixture, the contacts are properly terminated to the wiring within the fixture.  
         [0035]    The recess portion  92  is defined such that the plug connector housing  10  can rotate within the recess against the spring pressure. Thus, as shown in the perspective of FIG. 3, the connector housing  10  could rotate in the counter-clockwise position, whereupon the wall  66  will rotate away from tab portion  104 . It should be appreciated that stop wall  68  is defined as an extreme position whereupon the connector housing cannot rotate beyond the interference between stop wall  68  and tab  104 . This prevents damage to the wire cables, their connections, or the spring  120  itself. It follows then that, fastener members (not shown) can be positioned through apertures  88  of the top flange  12  to retain the entire plug assembly to the fixture to which it is to be connected. It should also be appreciated that the cover  6  and  6 ′ can be snapped in place at any time during the manufacture thereof to lace the wires in an organized manner for the wiring. The entire assembly of the plug connector assembly will be done with the assembly of the fixture or ceiling fan.  
         [0036]    The installation of the entire fixture or ceiling fan is therefore accomplished as follows. It should be understood that a hanging bracket is included for mounting adjacent to or over the junction box and receptacle connector  4  for mounting the fixture and that the mounting bracket will require a proper orientation relative to the fixture. It is anticipated that the fixture itself will be polarized relative to the hanging bracket, and will rotate into a locked position, in a bayonet/locking lug style connection. Thus, the corresponding mounting elements on the lighting fixture or ceiling fan will cooperate with the orientation of the mounting bracket. It should be appreciated also that the connector assemblies  4 ,  6  will be appropriately oriented that when the lighting fixture is properly aligned vis-a-vis the mounting brackets, the mating connectors  4 ,  10  must also be properly polarized. This prevents the occurrence where the user, somehow in preparing to assemble and install the fixture or fan assembly, misaligns the receptacle connector assembly. Thus, in the present invention, the receptacle connector is always spring-loaded to the home position, where the bracket and fixture are properly aligned. This allows the installer to move the fixture into the mounting bracket, whereby both the fixture/bracket and mating connectors  4 ,  10  are polarized. The fixture is thereafter rotated, to lock the fixture to its associated bracket. As the connector is rotatable, the fixture is rotated relative to the connector, which remains fixed, and the fixture is locked in place. If the fixture must be taken down, the connector returns to its home position, where it again is polarized.