Compliant cap

A compliant cap for inserting into an aperture of an electrical connector. The cap includes two halves connected by a living hinge. The two radial members in the two halves each extend perpendicular to the living hinge with the second radial member being longer than the first. One of the halves includes a plurality of chamfers, and the other half includes an outer rim surrounding the chamfers such that when the cap is compressed, the rim envelops the chamfers decreasing the area of the cap. In a second embodiment, chamfers include extensions adjacent to the outer rim for wrapping around or extending over the rim and further enhancing the secure fit of the two halves.

FIELD OF THE INVENTION

The present invention relates to a plastic end cap for plugging openings in electrical connectors to prevent particulates from entering the connectors during storage. More particularly, the invention relates to a plastic end cap molded in two halves with a living hinge connecting the two halves of the cap. Each of the two halves further includes a tab molded into each side of the cap, the two tabs being offset from each other.

BACKGROUND OF THE INVENTION

Conventional caps are formed of a rigid material which is solid throughout the entire cap body. When installed in electrical connector apertures, these caps cannot change shape to adapt to the size of the respective aperture because the area between the diameters is inflexible and compact.

This known design prevents caps from covering a wide range of connector opening diameters and tolerances because the diameter does not widely vary. The manufacturing expenses and cost of parts for these types of caps is often high because the caps are made for a specific size of connector opening diameter and tolerance.

Accordingly, a need exists for a compliant cap that is inexpensive to manufacture, easy to insert, and covers a wider range of connector opening diameters and tolerances than that engaged by a conventional solid cap.

SUMMARY OF THE INVENTION

Accordingly, an object of the invention is to provide a compliant cap for an electrical outlet having a living hinge connecting two halves, each half having a tab molded therein.

Another object is to provide a cap having a first diameter in an open position and a smaller, compressed second diameter in a closed position.

A further object is to provide a cap having a plurality of chamfers adjacent to the outer rim.

Still another object is to provide a cap having a living hinge between a first radial member and a second radial member, one of the radial members being longer than the other.

Yet another object is to provide a cap having the first radial member overlapping the living hinge and resting adjacent the second radial member.

The foregoing objects are basically attained by providing a compliant cap for inserting into an aperture in an electrical connector. The cap includes two halves connected by a living hinge. The halves each include a radial member positioned adjacent to the living hinge. Further, one of the radial members is longer than the other. One half includes a plurality of chamfers, and the other half includes an outer rim surrounding the chamfers.

By forming the compliant cap in this manner, a user can insert the cap into an aperture in an electrical connector by collapsing the hinge so the larger and shorter radial members are adjacent one another and the half having an outer rim surrounds the half with the plurality of chamfers.

As used in this application, the terms “top”, “bottom”, and “side” are intended to facilitate the description of the invention, and are not intended to limit the present invention to any particular orientation.

Other objects, advantages, and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Turning toFIGS. 1-4, a compliant cap10is a substantially circular cup shaped structure having a living hinge16on a continuous bottom11connecting a first half12and a second half14of the cap10bound by the continuous bottom member11. The bottom member11is formed by a first bottom surface11aand a second bottom surface11b, as seen inFIG. 4, having the living hinge16midway therebetween. The compliant cap10is mainly used for plugging an aperture18in an electrical connector20with the closed bottom member11.

First half12is a resiliently deflectable body including first radius or radial member22extending through the middle of its body, perpendicular to the living hinge16and perpendicular to the bottom member11. The living hinge16is positioned along the midline of the cap10. Opposite the first half12and completing the remaining structure of the cap10is the second half14. The second half14is a resiliently deflectable body including second radius or radial member24also extending through the middle of its body, perpendicular to the living hinge16and perpendicular to the bottom member11.

As seen inFIG. 4, first half12includes a side member13extending from the first bottom surface11atoward the outer rim30. Similarly, second half14includes a side member15extending from the second bottom surface11btowards the outer rim31. The side members13,15make up the walls between the bottom surfaces11a,11band the outer rims30,31. As seen inFIG. 3, the side members13,15fill the aperture18of the electrical connector20.

First radial member22and second radial member24are not equal in length. As seen inFIG. 1, second radial member24is somewhat longer than first radial member22and extends across the living hinge16when the cap10is inserted into the electrical connector20. The different sizes of the first radial member22and second radial member24enable the cap10to collapse upon itself when the tabs32,34are pulled together, prior to insertion into the connector20. Tabs32,34are the upper portions of the first radial member22and second radial member24, respectively. They can extend along part or all of the entire radial length.

The size differential between the first radial member22and the second radial member24accounts for the ability of the cap10to collapse upon itself because the second radial member24crosses over the living hinge16and rests adjacent to the first radial member22. The tabs32,34are offset by lead-ins in the form of chamfers or radii.

The collapsing motion of the cap10reduces the diameter of the cap10. The cap10has a first diameter d1when the cap is in a closed position (FIGS. 1,6) and a second diameter d2when the cap is in an open position (FIGS. 4,5). The living hinge has the cap halves disposed towards their open position. The ability of the cap10to collapse upon itself allows the cap10to cover a wide range of apertures in electrical connectors20. The second diameter d2is therefore greater than the first diameter d1because the radial members22,24are at a distance from each other and do not perfectly match up to constitute an even diameter.

When the cap10is in a closed position, the cap10is insertable into an aperture18in an electrical connector20. This collapsible position eases the placement of the cap10into the connector20because the cap10is at its narrowest orientation, thus easily fitting within the border of the aperture18. Each half12,14includes an outer lip or rim30,31, respectively to prevent the cap10from slipping completely into the electrical connector20by engaging an electrical connector aperture rim19about aperture18. The rim31of the second half14is further defined by chamfers26,28for advancing the second half14into the closed position of the cap10.

Rims30,31clamp the wall of the junction box to hold the cap10in place. When the cap10is inserted, the rims30,31are pinched together such that inwardly projecting tabs32,34are pulled towards the living hinge16. As the cap10is compressed, the living hinge16flexes to pull the tabs32,34inwardly.

Also, when crossing over, the second half14sits within a portion of the first half12. This crossover junction is enabled by the plurality of chamfers26,28disposed on the outer edge of the second half14. The chamfers26,28are narrower than the outer rim30of the first half12such that the outer rim30surrounds the chamfers26,28when the cap is in a closed position (FIG. 1,6).

The second embodiment, as seen inFIGS. 5 and 6, is similar to the cap10as described above with the exception of the relationship between the plurality of chamfers. Cap100is a substantially circular cup shaped structure having a living hinge116connecting a first half112and opposite second half114of the cap100. First half112includes a radial member122perpendicular to the living hinge116and across from the second half114with a second radial member124also perpendicular to the living hinge116.

As seen inFIG. 1, first radial member122and second radial member124are not equal in length so the cap100collapses upon itself when the tabs132,134are pulled together, prior to insertion into the connector20. These tabs132,134can extend along part or all of the entire radial length, but preferably extend along part of the radial length closest to the hinge116. This enables the user to pull the sides of the cap100towards the hinge116into a closed position as the collapsing motion of the cap100reduces the diameter of the cap100.

Each half112,114includes an outer lip or rim130,131respectively to prevent the cap100from slipping completely into the electrical connector20. The rim131of the second half114is further defined by chamfers126,128for advancing the second half114into the closed position of the cap100. The chamfers126,128are received within the area of the first half112such that a rim extension136,138adjacent each chamfer126,128wraps around or extends over the rim130of the first half creating a close fit. The crossover junction is enhanced by a plurality of rim extensions136,138that clamp the rim130to further hold the cap in its closed position. The rim extensions136,138are oriented substantially perpendicular to said chamfers126,128such that the rim extensions136,138tightly fit over the rim130of the first half112.

Operation

Regarding each disclosed embodiment, when the cap10is selected to plug the aperture18of an electrical connector20, a user grabs the tab32of the first half12and the tab34of the second half14, or the rims30,31, and pulls them towards each other against the opening biasings of the living hinge. The living hinge16controls the expandability and collapsibility of the cap10.

The chamfers26,28of the second half adjacent its rim31are received within or on top of the exterior rim30of the first half12. This coupling pulls the tabs32,34towards each other as the living hinge16enables the flexibility of the halves12,14. This decrease in cap10diameter aids the user with insertion into the electrical connector20.

When the desired depth of the cap10fills the aperture18, the user releases the tabs32,34, or the rims30,31, and allows the force of the living hinge16to expand the cap10. The cap10expands from a closed diameter d1to a maximum open diameter d2depending on the diameter of the aperture18.