Abstract:
An electrical connector is provided comprising a frame and at least one set screw. The frame comprises a connector head having multiple intersecting conductor receiving passageways capable of receiving an electrical conductor in one of a plurality of directions. The at least one set screw is connected to the connector head to intersect the conductor receiving passageways. The frame is formed from a single piece of flat conductive material.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to electrical connectors and, more particularly, to set screw electrical connectors. 
     2. Prior Art 
     Set screw electrical connectors are generally well known in the art. One example is found in U.S. Pat. No. 2,920,305, which shows an electrical terminal connector employing a set screw to secure a conductor. 
     SUMMARY OF THE INVENTION 
     In accordance with one embodiment of the present invention, an electrical connector is provided comprising a frame and at least one set screw. The frame comprises a connector head having multiple intersecting conductor receiving passageways capable of receiving an electrical conductor in one of a plurality of directions. The at least one set screw is connected to the connector head to intersect the conductor receiving passageways. The frame is formed from a single piece of conductive material. 
     In accordance with another embodiment of the present invention, an electrical connector is provided comprising a frame and a set screw. The frame comprises a block section and a tongue section formed from a single piece of conductive material. The block section comprises receiving passageways with a recessed area in each of the passageways. The set screw is connected to the frame. When a conductor is received in one of the conductor receiving passageways, a portion of the conductor can be clamped between the set screw and the frame along a surface of one of the recessed areas. 
     In accordance with another embodiment of the present invention, an electrical connector frame is provided comprising a head section and a tongue section. The head section has at least one tab on an end of the head section. The tongue section is connected to the head section. The tongue section contains at least one notched area. The tab interconnects with the notched area to form a latch. The head section and the tongue section are formed from a single piece of flat conductive material. 
     In accordance with one method of the present invention, a method for manufacturing an electrical terminal connector is provided comprising steps of providing a single piece of conductive material; and forming the piece of conductive material to form a latching system and conductor receiving passageways with recessed areas. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein: 
     FIG. 1 shows an exploded perspective view of an electrical terminal connector incorporating features of the present invention; 
     FIG. 2 is an enlarged view of area  2  shown in FIG. 1; 
     FIG. 3 is a cross-sectional view along line  3 — 3  of the frame shown in FIG. 1; 
     FIG. 4 is a top plane view of a blank used to form the frame shown in FIG. 1; 
     FIG. 5 is a partial perspective view of an alternate embodiment of the present invention; and 
     FIG. 6 is a partial perspective view of another alternate embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1, there is shown an exploded perspective view of an electrical connector  10  incorporating features of the present invention. Although the present invention will be described with reference to the embodiment shown in the drawings, it should be understood that the present invention could be embodied in various different types of electrical connectors. In addition, any suitable size, shape or type of elements or materials could be used. 
     The connector  10  generally comprises a frame  12  and a fastener  14 . The connector  10  is generally intended to mechanically and electrically connect an electrical conductor A or B to another member  16 . The frame  12  generally comprises a head section  18  and a tongue section  20 . However, in alternate embodiments the frame could comprise additional components or sections. In a preferred embodiment the frame  12  comprises a single one-piece member, such as a sheet metal member which has been stamped and formed into the shape shown. The sheet metal member is preferably flat, but can be stamped or coined as described below with reference to FIG.  5 . The frame could also be formed from a rod or tube which is flattened during manufacturing, such as based upon materials requirements. Thus, the term “flat” is intended to include a tube or rod which has been substantially flattened. 
     The head section  18  generally comprises a loop or ring shape. However, other shapes could be provided. The ring shape provides a first conductor receiving passageway  22  extending between lateral sides  24 ,  26  of the frame  12 . In alternate embodiments the frame  12  could be bent or formed to provide multiple parallel conductor receiving passageways between the lateral sides  24 ,  26  or any other suitable passage(s). The head section  18  also comprises two apertures  28 ,  30  extending through the frame into the first passageway  22 . The first aperture  28  is preferably threaded to interact with the fastener  14 . The first aperture  28  extends through a top wall  32  of the head section  18 . The second aperture  30  extends through an end wall  34  of the head section  18 . In this embodiment the opposite end wall  36  is connected to the bottom wall  38 . 
     Referring also to FIG. 2, the end wall  36  includes two legs  40 . The bottom wall  38  includes two apertures or slots  42 . In this embodiment the slots  42  extend into the lateral sides  24 ,  26 . In alternate embodiments the slots could be spaced from the sides  24 ,  26 . In addition more or less than two slots and two legs could be provided. They also could have any suitable shape. In this embodiment the slots  42  also include a recess  44 . A portion  46  of each leg  40  is bent or latches into its respective recess  44  to thereby interlock the legs  40  with the bottom wall  38 . In alternate embodiments other suitable types of interlocking shapes or configurations could be used to interlock the two walls  36 ,  38  to each other. 
     Referring also to FIG. 3, the interior side of the bottom wall  38  comprises two concave groove sections  48 ,  50 . A first one of the concave groove sections  48  extends between the sides  24 ,  26  generally along and parallel with the first passage  22 . The second concave groove section  50  extends from the hole  30  generally perpendicular to the passage  22 . The hole  30 , groove section  50  and a part of the passage  22  form a second conductor receiving passage  52  generally perpendicular to the first passage  22 . Thus, the head section  18  can receive the conductor A in the first passage  22  or alternatively receive the conductor B in the second passage  52 . In this embodiment the two groove sections  48 ,  50  intersect each other at a right angle. However, in alternate embodiments any suitable angle of intersection could be provided. 
     The groove sections  48 ,  50  generally provide the function of assisting in locating the conductors A or B directly under the hole  28 . Thus, when the fastener  14  is screwed into the hold  28  and its tip  54  presses down against the conductor, there is less likelihood that the conductor will slip out from underneath the tip  54 . In the embodiment shown the fastener  14  is a set screw. However, in alternate embodiments any suitable type of fastener could be used. The connector could also include multiple fasteners for connecting multiple conductors to the frame. When the fastener  14  tightens down on the conductor A or B and pushes the conductor against the bottom wall  38 , forces are exerted against the top wall  32  by the fastener  14  to attempt to move the top wall away from the bottom wall  38 . The interlocking connection of the legs  40  at end  37  of the wall  36  prevents the wall  36  from pulling away from the wall  38 . 
     The tongue section  20  extends from the head section  18 . The tongue section  20  could have any suitable shape or size. In this embodiment the tongue section  20  includes a hole  56 . The hole  56  is provided such that a fastener  58  can pass through the hole  56  and attach to the member  16  to thereby electrically and mechanically attach the tongue section  20  to the member  16 . However, in alternate embodiments any suitable connection system could be used to connect the tongue section to another member. 
     The present invention, unlike connectors such as disclosed in U.S. Pat. Nos. 4,946,405 and 2,920,305, allows the frame to be formed from sheet metal that is stamped and formed rather than being cast. Thus, the connector according to the present invention can be less expensive to manufacture, faster to manufacture, and lighter in weight. The present invention, unlike connectors such as disclosed in U.S. Pat. No. 5,197,907, can also allow the frame to accept a conductor in multiple different directions or position. Thus, the present invention can be used to provide a multi-axis conductor receiving connector with a frame formed from stamped and formed sheet metal providing combined advantages not heretofore available. 
     Referring also to FIG. 4, a flat sheet metal blank  12 ′ is shown which is used to form the frame  12 . The blank  12 ′ is preferably stamped from sheet metal. However, in alternate embodiments other suitable forming techniques or materials could be used. The sheet metal is stamped to form the holes  28 ′,  30 ,  56 , holes  42  and legs  40 ′. The hole  28 ′ can then be threaded to form the hole  28 . The recesses  44  can be formed. However, it is not necessary to provide the frame with the recesses  44 . The concave grooved sections  48 ,  50  can be formed before or after the flat blank  12 ′ is bent. The flat blank  12 ′ is bent in three locations  60 ; 90° at each location  60 . However, more or less bend locations could be provided and, at any suitable angles, such as for triangular or other polygonal shapes. When the legs  40 ′ are inserted into the holes  42  the legs  40 ′ can then be bent into recesses  44 . 
     Referring now to FIG. 5, an alternate embodiment is shown. In this embodiment the bottom wall does not comprise concave groove sections. Instead, the bottom wall  38 ′ comprises raised ridges  62 . In this embodiment the ridges  62  are formed by stamping the bottom wall  38 ′ forming recesses  63  on the bottom side of the bottom wall. The ridges could alternatively be formed by coining. However, any suitable method could be used to form the ridges  62 . The ridges  62  are arranged as pairs of spaced parallel ridges forming areas  64 ,  65  therebetween. The areas  64 ,  65  intersect each other at an angle; in this case a perpendicular angle. The ridges  62  act as guides for the conductors to keep the conductors in the areas  64  or  65  as the fastener  14  is tightened against the conductors. In other alternate embodiments, any suitable type of conductor guide or position holder could be provided on the bottom wall. 
     Referring now to FIG. 6, another alternate embodiment will be described. In this embodiment the wall  36 ″ has a leg  40 ″ formed as a snap-lock latch. The bottom wall  38 ″ or tongue section  20 ″ has an aperture  42 ″ which forms a snap-lock receiving aperture. The aperture  42 ″ has a through-hole section  43 ″ and a recess section  44 ″ with a latch surface  45 ″. The leg  40 ″ has a latch surface  47 ″ and an angled surface  41 ″. Thus, the leg  40 ″ can be completely formed before it is inserted into the aperture  42 ″ and subsequently snap-lock mounted through the aperture  42 ″. 
     It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.