# Patent

## Title
Electrical connector assembly with frusto-conical snap fit retaining ring for enhancing electrical grounding of the connector assembly to an electrical box and installation tool therefor

## Abstract

An electric connector assembly made up of a connector body having an inlet end portion, an outlet end portion, and a bore communicating the inlet end portion to the outlet end portion; and having a frustro-conical retaining ring mounted on the outlet end portion wherein the retainer ring includes locking tangs and one or more grounding tangs wherein the free end of the grounding tang defines the trailing end of the retainer ring. The locking tangs effect a snap-fit locking arrangement while the grounding tang effects an electrical grounding of the connector assembly, when connected to a knock-out hole of an electric box or panel. Various embodiments are disclosed wherein the grounding tang is formed so as to enhance the electrical grounding effect between the connector assembly and the electric box or panel connected thereto. An embodiment of the invention also provides for an installation tool to engage the retainer ring so as to facilitate the securing of the connector assembly to a knock-out hole of an electric box or panel.

## Background
RELATED APPLICATIONS
This application is a continuation in part application of application Ser. No. 11/364,435 filed Feb. 28, 2006, now U.S. Pat. No. 7,205,489 entitled Snap Fit Electrical Connector Assembly With Operating Tool for Facilitating the Connection of a Connector Assembly To An Electric Box, which is a continuation in part application of application Ser. No. 11/258,990 filed Oct. 26, 2005, now U.S. Pat. No. 7,057,107 which is a continuation in part application of application Ser. No. 11/151,374 filed Jun. 13, 2005 now U.S. Pat. No. 7,205,007 for Snap Fit Electrical Connector Assembly With conical Outer Snap Fit Retainer And One Or More Internal Snap Fit Wire Retainers, which is a continuation in part application of application Ser. No. 11/100,250 filed Apr. 6, 2005 now U.S. Pat. No. 7,064,272 for Snap In Electrical Connector Assembly With Unidirectional Wire Conductor Retainer Ring, which is a continuation in part application of application Ser. No. 10/939,619 filed Sep. 13, 2004 for Electrical Connector With Frustro Conical Snap Fit Retaining Ring, now U.S. Pat. No. 6,916,988 B1, which are each incorporated by reference herein.


FIELD OF THE INVENTION
This invention is directed to a further advancement in the field of electrical connector assemblies of the kind utilizing a snap fit retaining ring circumscribing the outlet end of a connector body for effecting a snap fit connection to an electrical box of the types heretofore described in U.S. Pat. No. 6,860,758, and co-pending application Ser. No. 10/790,283 filed Mar. 1, 2004 for Snap Fitting Electrical Connector; and in a co-pending application Ser. No. 11/028,373 filed Jan. 3, 2005, which co-pending applications are incorporated herein by reference.
More specifically, this application in addition relates to a snap fit electrical connector assembly having a construction for facilitating the connection of the connector assembly and associated cable, wire conductor and the like to an electrical box. The connector assembly includes a connector body and a readily detachable, outer frustro-conical, snap fit retaining member or ring circumscribing the outer surface of the outlet end of a connector body. In one form of the invention the frustro-conical retaining ring is formed for use with a tool to enhance its connection to an electric box. In another form, the frustro-conical retaining ring can be formed so that it can be connected to an electric box without the use of any tool. The connector assembly may also be utilized with or without a unidirectional cable or wire retainer associated with the inlet end of the connector body for positively securing a wire, cable or conductor to the inlet end so as to prohibit any unintentional separation of the wire, cable or electrical conductor from the connector assembly.
This invention further contemplates a snap fit connector assembly that utilizes a frustro-conical retaining ring constructed so as to enhance or maximize the electrical continuity for grounding purposes between the electrical connector assembly and the electrical box to which it is connected.
BACKGROUND OF THE INVENTION
Electrical connectors are commonly used for attaching electrical conductors, cables, wires, electrical metal tubing (EMT) or the like to an electric box, e.g. a junction box, outlet box, switch box, fuse box, or other similar type of electric box or an electrical mounting panel. Such known electrical connectors are either of a type that are secured to an electric box or electrical panel by a threaded lock nut or by means of a circular snap fit retaining ring of the type disclosed, for example, in U.S. Pat. Nos. 6,860,758; 6,444,907; 5,189,258; 5,266,050; 5,171,164; 2,744,769 and 1,483,218. Reference is also made to U.S. Pat. No. 6,768,057 which is directed to a right angle type connector formed of a pair of sheet metal stampings fitted together and secured to an electrical box with a snap fit arrangement. Connectors formed as connector caps which are adapted to be fitted over the end of a conductor, cable or wires, such as disclosed in U.S. Pat. No. 4,880,387, are also known. Various other known efforts to facilitate the connection of an electrical conductor to an electric box are evidenced by U.S. Pat. Nos. 6,043,432; 6,080,933; 6,114,630; 6,133,529; 6,194,661; 6,335,488; 6,352,439; 6,355,884; 6,444,907; 6,555,750; 6,604,400; 6,670,553; 6,737,584; 6,682,355; 6,780,029 and 6,849,803.
While “snap fit” connectors have been in use for some time, the attachment of such “snap-fit” connectors to an electric box which is concealed in a finished wall is difficult, if not impossible. This is because such “snap fit” retaining rings are formed of spring steel so that the locking tangs, due to the inherent nature of the spring steel, require a good amount of force to flex the locking tangs in order to pass through the conventional knock-out hole to properly seat and lock the connector to a knockout hole of an electric box. For this reason, the installer or user does not have generally sufficient access to the connector assembly so as to apply the necessary force to manually pull the leading end of the connector assembly through the knockout hole due to the relative rigid flexibility of the locking tangs in order to seat and lock the connector assembly to the knockout opening. Usually, the installer or user has to exert a severe pulling force on the wires extending through the connector assembly to seat and lock a snap-fit connector assembly in the knockout hole of an electric box. Applying such pulling force directly on the wires to lock a snap-fit connector assembly to an electric box could seriously damage the conducting wires.
It has also been noted that the typical metallic electrical boxes, e.g. wall boxes, ceiling boxes, junction boxes, electrical panels and the like, which are provided with knock-out openings or holes for receiving an electrical connector assembly, have varying thicknesses. As a result, the degree of electrical grounding that can be attained between the electrical connector assembly and an electric box can vary from box to box. Heretofore, electrical connector assemblies utilizing a so-called external snap fit ring to effect a snap fit connection to an electric box were formed with circumferentially spaced grounding tangs arranged to engage the internal periphery of the knock-out opening provided in such electric boxes to effect the required grounding. As a result, such circumferentially spaced grounding tangs provided only a minimum degree of contact between the electrical connector retainer ring and the metallic electric box or panel for effecting any electrical grounding. The amount of electrical grounding achieved by such grounding tangs may vary from box to box, depending upon the material thickness of a given electric box or panel. As a result, a positive or desired amount of electrical grounding, attained between the connector assembly and the electric box, will vary from installation to installation.
SUMMARY OF THE INVENTION
An object of this invention is to provide an electrical connector with a frustro-conically shaped retaining ring having integrally formed locking tangs and electrical grounding tangs.
Another object of this invention is to provide an electrical connector assembly having a snap fit retaining ring constructed to enhance or maximize the electrical grounding between an electrical connector assembly and an electric box or panel when such snap fit connector is secured to a metallic electric box or panel.
Another object of this invention is to provide an electrical connector with a frustro-conically shaped retaining ring having integrally formed locking tangs and electrical grounding tangs wherein the grounding tangs circumscribe a major portion or the entire periphery of the trailing end of the frustro-conical retaining ring that is in contact with the internal periphery of a knock-out hole.
Another object of this invention is to provide for an electrical connector assembly that includes an electrical connector body having an outlet end with a frustro-conical outer surface having a complementary frustro-conical retaining ring that is readily fitted to and retained on the outlet end portion of the connector body.
Another object is to provide a connector assembly having an outlet end about which there is disposed a retaining ring having an opening sized to receive the working end of a tool functioning as a lever to transmit a pulling force on the connector and associated retaining ring to pull the connector and associated retaining ring through a knockout hole to seat and lock the connector assembly to the electric box with a minimum of effort or force.
Another object is to provide a unique tool for engaging an enlarged retaining slot formed in the retaining ring having laterally outwardly bent locking tangs wherein the tool functions as a lever for exerting a pulling force on the connector and associated retainer ring to seat and lock the same to an electric box.
Another object is to provide a connector assembly comprising a connector body having an outlet portion free of any retaining flange, and an associated snap fit retainer ring circumscribing the outlet end portion.
Another object is to provide a retaining ring having a face portion with outwardly flaring circumscribing arms or sides having locking and grounding tangs that are formed out of a surface of the respective arms or sides.
Another object is to provide a retaining ring, adapted to be fitted onto the outlet end of a connector body, and having a frustro-conical shape with a first series of tangs for securing the connector body relative to an electrical box and a second series of tangs for affecting a positive electrical ground with an associated electrical box.
Another object is to provide a frustro-conically shaped retaining ring that can be readily formed from a blank of spring steel.
Another object is to provide an electrical connector assembly having a connector body with a frustro-conical outer retainer ring circumscribing the outer surface of the connector body outlet end and a unidirectional retainer ring or sleeve associated with the inlet end of the connector body for securing an electrical wire or conductor thereto.
Another object is to provide an electrical connector assembly that includes an internal unidirectional sleeve insert for frictionally retaining a wire conductor to the connector assembly so as to prevent any unintentional separation of a wire conductor therefrom.
Another object is to provide an electrical connector assembly with an outer frustro-conical retainer ring for attaching a connector assembly to an electrical box with a snap fit and including an inner unidirectional retainer ring or sleeve for securing a wire conductor thereto in a manner to prohibit any unintentional separation of the wire conductor from the connector assembly.
Another object is to provide an electrical connector with an improved wire retainer sleeve or ring whereby a wire conductor is positively secured thereto simply by inserting the wire conductor into the connector so that unintentional separation of the wire conductor from the connector assembly is prohibited.
Another object of this invention is to provide an electrical connector with a wire retainer ring whereby a helical wound wire conductor can be secured upon mere insertion or threading the armored conductor wire into the wire retainer ring to prohibit any unintentional separation of the wire conductor from the electrical connector.
Another object is to provide or an electrical connector assembly that is relatively simple to fabricate and positive in operation.
Another object of this invention is to provide an electrical connector assembly having an outer frustro conical retainer ring for positively connecting the connector assembly to an electrical box and having multiple inlet ends, each fitted with an internal wire retainer ring for unidirectional locking therein a wire conductor in each of the multiple inlets.
Another object of this invention is to provide an improved multiple cable or wire conductor connector assembly that is relatively simple in structure, easy to assemble and having a minimum of component parts.
Another object is to provide a connector assembly having multiple inlet ends, each inlet end being fitted with internal spring steel internal retaining ring arranged to maximize electrical conductivity or grounding.
Another object is to provide an electrical connector assembly having an outer frustro-conical retainer ring forming a snap fit attachment to an electric box or panel and having an improved unidirectional wire conductor retainer in the form of a retaining finger projecting into the inlet end of a connector body so as to provide a snap fit wire retention device which prohibits any unintentional separation of the wire conductor form the connector.
Another object is to provide a relatively simple and positive acting snap fit wire conductor retaining device for securing and retaining a wire conductor to an electrical connector in a manner to prohibit any unintentional separation of a wire conductor from the connector.
Another object is to provide a snap fit wire retainer that extends inwardly of an electrical connector body constructed so that the wire retainer is externally secured to the exterior of the connector body so as to facilitate the assembly of the associated wire retainer within the inlet end of a connector body.
Another object is to provide an electrical connector assembly having a wire retainer arranged to be externally secured to the connector body in a fixed relationship relative to the connector body so that the free end thereof extends into the inlet end portion of the connector body so that a wire conductor may be unidirectionally snap fitted thereto.
The foregoing objects and other features and advantages are attained by an electrical connector assembly that includes a connector body having an inlet end portion for receiving an electrical conductor and an outlet portion which is adapted to be inserted through a knockout hole of an electrical panel or electric box, e.g. an electric outlet box or the like. A radially outwardly extending flange circumscribes an intermediate portion of the connector body to function as a stop to limit the insertion of the outlet end portion of the connector body through the knockout hole of an electric box. The outlet end portion may be provided with an outer surface that converges or tapers inwardly toward the outlet opening thereof. Formed on the surface of the outlet end portion are one or more retaining lugs, which may be circumferentially spaced about the outlet end portion. A frustro-conically shaped snap-fit ring is fitted onto the outlet end portion.
In accordance with this invention, the outer retaining ring is initially formed from a blank of sheet metallic material, e.g. spring steel, having a cruciform shape that includes a face portion with a central opening wherein the radiating arms of the cruciform blank are disposed about the face portion to define a frustro-conical ring or cup. The ring so formed is provided with blanked out or die cut tangs to define locking tangs and grounding tangs. The frustro-conical ring so formed also has a slot adapted to receive the retaining lug when the retaining ring is fitted onto the outlet end portion of the connector body so that the free or trailing ends of the ring define grounding tangs that engage the inner periphery of the knockout hole of an electric box for effecting positive electrical continuity or electrical grounding.
To form the retaining ring, the cruciform arms are arranged to be folded relative to the front or face forming portion of the blank, which is provided with a central opening, to define a unitary frustro-conically shaped cup-like member to compliment or be fitted onto the outlet end portion of the connector body. The retaining ring thus formed is fitted over or onto the outlet end portion whereby the retaining slot formed in the ring is adapted to receive the complementary retaining lug formed on the surface of the outlet end portion for retaining the ring on the outlet end portion of the connector body. In one form of the invention, as will be described herein, the retainer ring is provided with an enlarged slot, i.e. the slot has a width which is greater than the width of the lug to be received therein.
In another form of the invention, the outer retaining ring is initially formed from a blank of sheet metallic material, e.g. spring steel which is generally circular in shape and from which a pair of spaced locking tangs are blanked, formed or die cut, out of the plane of the blank. The portion of the blank extending between the opposed locking tangs define the opposed grounding tangs. The arrangement is such that the grounding tangs encompass almost the entire trailing end of the retaining ring, so as to maximize the electrical grounding effect between the electrical connector provided with such snap fit retaining ring and a metallic electrical box or panel to which the electrical connector assembly is secured.
With the construction described, the connector assembly can be readily inserted through the knockout opening of an electric box wherein the locking tangs will initially be flexed inwardly to pass through the knock-out hole of an electric box, and then spring outwardly to lock the connector assembly to the electric box with the grounding tangs or free ends of the retaining ring or arms being inherently biased or urged against the internal periphery of the knockout hole of an electric box or panel to effect a positive electric ground therebetween, due to the inherent resiliency of the respective grounding tangs and the material from which they are formed.
Because the locking tangs are formed of spring steel and are relatively short, considerable force is required to flex the locking tangs inwardly to overcome the inherent spring bias of the locking tangs sufficiently to push the connector assembly through the opening or knockout hole of an electric box. When such electric box is concealed within a wall, considerable difficulty has been encountered in attaching a connector assembly provided with a “snap fit” retainer ring to such electric box. In such situations, electric connectors having a threaded outlet end have been generally used, whereby such threaded connectors could be readily secured by a lock nut from within the electric box.
This invention further contemplates providing a tool that will engage an enlarged slot of a modified frustro-conical retainer ring embodiment of this invention whereby the tool functions as a lever to transmit the necessary pulling force on the modified connector assembly to pull the “snap ring” connector assembly through the knockout opening of an electrical box with a minimum of ease.
This invention further contemplates providing the inlet end of the connector with an inner or internal conductor retainer ring which is uniquely formed for positively securing thereto a wire conductor by merely inserting the wire conductor into the inner retainer ring, so that the wire conductor is prohibited from being unintentionally separated therefrom. The inner retainer ring is preferably formed of a blank of spring metal material which is rolled to form a cylinder or sleeve having an outer diameter which can be frictionally retained within the inlet end of a connector, e.g. by a press or friction fit.
A further embodiment of the disclosed invention utilizes a simplified clamping arrangement for securing the wire conductor to the inlet end of the connector by a mere insertion. In the event the wire conductor has a helical wound armored shield, e.g. a BX wire conductor, such armored wire conductor may be alternatively secured to the wire retainer ring or sleeve by threading the armored conductor to the wire retainer ring or sleeve.
A further embodiment of the invention utilizes a connector body having complementary housing or body sections which can be mated together and secured by a fastener. One of the body sections is formed with a leading end that is provided with an outer frustro conical surface and a trailing end having multiple chambers interconnected to the leading end by a transition section. The other body section defines a trailing end complementing the trailing end portion of the other housing section. An outer frustro conical retainer ring circumscribes the leading end of the connector body to provide a snap fit connection for the connector assembly to a knockout hole of an electric box. The respective chambers, defined by the mated complementary trailing ends of the connector, are each fitted with a spring steel retainer sleeve to provide a snap fit connection between a wire conductor and its corresponding inlet end of the assembled connector body section. The arrangement is such that each of the respective wire retainers is securely clamped between the respective body sections to provide a very positive surface to surface contact between the wire retainer and the associated body sections to enhance the electrical continuity between the assembled connector body sections and the wire retainer clamped therebetween.
A still further embodiment of the invention utilizes a modified connector body provided with a frustro conical outlet end having a frustro conical shaped external snap fit retaining ring by which the connector assembly can be readily attached to an electrical panel or electrical box by a snap fit, and having a uniquely formed wire retainer device that clips onto the inlet end of the connector body and is externally secured to the connector body for enhancing ease of assembly while providing the wire retainer to extend into the inlet end of the connector body with sufficient flexibility and range of movement for retaining a wire conductor or conductor sheath within the connector body in a manner to prohibit any unintentional separation of the wire conductor or sheath from the connector body.



IN THE DRAWINGS
FIG. 1 is an exploded perspective view of the electrical connector assembly.
FIG. 2 is a plan view of the blank from which the outer retaining ring of the present invention is formed.
FIG. 3 is a detail front view of the outer retainer ring.
FIG. 4 is a detail top plan view of the outer retainer ring.
FIG. 5 is a detail end view of FIG. 4.
FIG. 6 is a sectional view of the outer retainer ring taken along line 6-6 on FIG. 3.
FIG. 7 is a side view of the connector assembly illustrating the alignment thereof relative to the knockout opening of an electric box.
FIG. 8 is a section side view illustrating the connector assembly secured to an electric box, taken along line 8-8 on FIG. 10.
FIG. 9 is a sectional side view taken along line 9-9 on FIG. 10 and rotated 90°.
FIG. 10 is a fragmentary front view of the connector assembly secured to an electric box as viewed from the inside of the electrical box.
FIG. 11 is an exploded perspective view of a modified form of the invention.
FIG. 12 is a sectional side view of the modified form of the invention of FIG. 11.
FIG. 13 is a top plan view of the blank from which the internal wire conductor retainer is formed.
FIG. 14 is a fragmentary top view of a portion of the blank forming the inner retainer sleeve or ring.
FIG. 15 is an end view of the inner wire conductor retainer ring or sleeve.
FIG. 16 is a top view of the inner retainer ring or sleeve of FIG. 15.
FIG. 17 is a section view taken along 17-17 on FIG. 16.
FIG. 18 is a side view of the inner retainer ring or sleeve.
FIG. 19 is a sectional side view of still another embodiment.
FIG. 20 is a perspective view of a further embodiment of the invention.
FIG. 21 is an exploded perspective view of the embodiment of FIG. 20.
FIG. 22 is a top plan view of the embodiment of FIG. 20 having parts thereof broken away.
FIG. 23 is a sectional view taken along line 23-23 on FIG. 22.
FIG. 24 is the interior plan view of one section of the connector housing of the embodiment illustrated in FIG. 20.
FIG. 25 is an outer end view of FIG. 24.
FIG. 26 is an end view of the connector housing section of FIG. 24.
FIG. 27 is a sectional view of the housing section taken along line 27-27 on FIG. 26.
FIG. 28 is an inside plan view of the complementary housing section of the embodiment illustrated by FIG. 20.
FIG. 29 is an end view of FIG. 28.
FIG. 30 is an inlet end view of FIG. 28.
FIG. 31 is a sectional view taken on line 31-31 on FIG. 30.
FIG. 32 is a sectional view taken on line 32-32 on FIG. 28.
FIG. 33 is a perspective exploded view of a further embodiment of the invention.
FIG. 34 is a top plan view of the blank from which the wire retainer device is formed.
FIG. 35 is a side view of the blank of FIG. 34.
FIG. 36 is a side view of the blank of FIGS. 34 and 35 as formed to define wire retainer.
FIG. 37 is a top view of a slightly modified form of a wire retainer.
FIG. 38 is a perspective view of the connector body embodying the invention.
FIG. 39 is a side view of FIG. 38.
FIG. 40 is a top plan view of FIG. 39.
FIG. 41 is a left end view of FIG. 38.
FIG. 42 is a right end view of FIG. 38.
FIG. 43 is a perspective view of the assembled connector embodiment shown in FIG. 33.
FIG. 44 is a side sectional view of the connector assembly of FIG. 43.
FIG. 45 is an exploded perspective of another modified form of the invention.
FIG. 46 is a perspective view similar to FIG. 45 illustrated in the assembled position.
FIG. 47 is a side view of FIG. 46.
FIG. 48 is a side view of the connector assembly of FIG. 47 in engagement with a pulling tool of the present invention.
FIG. 49 is a bottom plan view of FIG. 48.
FIG. 50 is a side elevation view illustrating the initial insertion of the connector assembly of FIG. 45 into a knockout hole of an electric box.
FIG. 51 is a side elevation view similar to FIG. 50 illustrating the connector assembly fully seated and locked in the knockout hole of an electric box which is affected by the lever action of the operating tool.
FIG. 52 is a perspective view of the operating tool embodiment for facilitating the locking of an electrical connector to an electric box.
FIG. 53 is a plan view of the tool of FIG. 52.
FIG. 54 is an edge view of FIG. 53.
FIG. 55 is a bottom plan view of FIG. 54.
FIG. 56 is a left end view of FIG. 55.
FIG. 57 is a perspective view of a slightly modified tool.
FIG. 58 is a left end view of FIG. 57.
FIG. 59 is a perspective view of still another modified operating tool.
FIG. 60 is an exploded perspective view of another form of the invention embodying a modified frustro-conical retaining ring for enhancing the electrical grounding effect.
FIG. 61 is a plan view of the blank from which the modified frustro-conical retaining ring of FIG. 60 is formed.
FIG. 62 is a detail front view of the retainer ring formed from the blank of FIG. 61.
FIG. 63 is a detail top plan view of FIG. 62.
FIG. 64 is a detail left end view of the retainer ring of FIG. 63.
FIG. 65 is a sectional side view of the electrical connector assembly of FIG. 60 connected to an electric box.
FIG. 66 is a section view taken along line 66-66 taken on FIG. 65.
FIG. 67 is a perspective exploded view illustrating the connector assembly of FIG. 60 in alignment relative to a knock-out hole of an electric box.
FIG. 68 is a plan view of a modified blank from which another modified frustro-conical retaining ring is formed.
FIG. 69 is a front elevation view of the formed modified frustro-conical retaining ring.
FIG. 70 is a top view of FIG. 69.
FIG. 71 is a left side view of FIG. 70.
FIG. 72 is a sectional view of an electrical connector assembly with the modified frustro-conical retainer of FIG. 69 secured to an electrical box or panel.



DETAILED DESCRIPTION
Referring to the drawings, there is shown in FIG. 1 an electrical connector assembly 10. The connector assembly 10 includes a connector body 11, which is usually formed of metal casting, e.g. zinc or other suitable metallic alloy. The connector body 11 is formed with an inlet end portion 11A and an outlet end portion 11B and having a bore 12 extending therethrough. Intermediate the connector body 11 or between the inlet end portion 11A and outlet end portion 11B there is provided a radially outwardly extending flange 13 which functions as a stop to limit the amount that the connector body 11 may be inserted through the knockout hole 14 of an electric box 15, as noted in FIG. 8.
As shown in FIGS. 1 and 8, the outer surface S of the outlet end portion 11B slopes, tapers or converges toward the outlet opening 16 whereby the outer surface S of the outlet end portion 11B has a generally frustro-conical configuration. Formed on the surface S of the outlet end portion 11B is an outwardly projecting retainer lug 17. In the illustrated embodiment, two such lugs 17 are shown disposed 180° apart about the outer circumference of the outlet end portion 11B.
The connector assembly 10 also includes a snap fit retaining ring 18. In accordance with this invention, the retaining ring 18 is integrally formed from a blank 19 of spring steel material. As best seen in FIG. 2, the blank 19 is initially formed or stamped to define a generally cruciform shape. The cruciform shape is provided with a face portion 20 having central opening or hole 20A and having four generally radially extending arms defining two pairs of oppositely disposed arms AA and BB.
As illustrated in FIG. 2, the opposed pair of arms AA are each provided with a retaining slot 21. The opposed pair of arms BB, as best seen in FIG. 8, are blanked or formed to define a locking tang 22 and to either side thereof an electrical grounding tang 23, 23. As shown, the locking tang 22 is slightly shorter than the adjacent grounding tangs 23, 23. The arrangement is such that the free end of the locking tangs 22 are formed so as to engage the inside surface of the electric box 15 in the assembled portion, as best seen in FIG. 9, to secure the connector assembly 10 to the electric box 15 and prohibit any unintentional withdrawal of the connector assembly 10 from the electrical box 15, whereas the free ends of the grounding tangs 23 are biased in engagement with the internal periphery of the knockout hole 14. Also, the free ends 24, 24 of arms A, A in the assembled position will also function as electrical grounding tangs, as noted in FIG. 8.
In forming the retaining ring 18 from blank 19, the respective arms A,A and B,B are subjected to a series of progressive bending dies which will gradually bend the respective arms about a foldline f, which defines the face or front portion 20, whereby arms A,A and B,B form a cup having circumscribing frustro-conical or outwardly flaring sides to define a frustro conical ring 18 which complements the conical surface S of the leading or outlet end portion 11B, as seen in FIG. 1. In doing so, the locking tangs 22 are outwardly and cantileverly bent or displaced relative to the surface of the ring at a slightly greater outwardly angle or slope than the adjacent grounding tangs 23 and the slope of arms A,A. With the retaining ring 18 so formed, it can be readily fitted onto the outlet end portion 11B whereby the inherent resiliency of the arms A,A will cause the retainer slots 22 to snap fit onto the retaining lug 17 when slots 21 are placed in alignment with lugs 17. The arrangement is such that the retainer ring 18 will be firmly and positively secured to the outlet end portion 11B as seen in FIG. 8. Yet, due to the inherent resiliency of the material of the retaining ring 18, it can be easily detached from the outlet end portion 11B when removal is desired, without destroying the ring 18 by lifting arms A,A free of the retaining lugs 17.
With the retainer ring 18 properly secured to the outlet end 11B of the connector body 11, the connector assembly 10 can be readily secured to an electric box 10 by simply aligning the assembly 10 with a knockout hole 14, as best seen in FIG. 7, and inserting the leading or outlet end portion into the knockout hole 14 until the flange 13 engages the outer side of the electric box 15. In doing so, the tangs 22, 23 and the free ends 24 of arms A,A, respectively, will depress inwardly to permit insertion of the assembly 10. When the assembly is fully seated in the knockout hole 14, the locking tangs 22 will normally spring outwardly to secure the assembly 10 to the electric box 15, as noted in FIG. 9. The inherent resiliency of the grounding tangs 23, 23 and the free end 24 of arms A,A are normally biased in engagement with the internal periphery of the knockout hole 14 to ensure a positive electrical ground with the electric box 15. The engagement of the free ends 24 of arms A,A against the inner periphery of the knockout hole 14, as noted in FIG. 8, further ensures the firm securing of the retaining slot 21 with the retaining lugs 17, so as to prohibit any disengagement of the outer retaining ring 18 from the connector body 11.
It will be understood that the wire conductor 25 may be secured to the connector assembly 10 either before or after the assembly 10 has been secured to the electric box 15. In the illustrated embodiment, the conductor wire 25 is simply inserted into the inlet end portion 11A and secured in position by a suitable securing means. In the illustrated embodiment of FIG. 1, the securing means is illustrated as a set screw 26. However, it will be understood that other forms of securing means may be used, than the set screw 26 illustrated.
From the foregoing, it will be apparent that the disclosed connector assembly is quite novel and simple in construction. The snap fit retaining ring 18 can be simply formed from a cruciform shaped blank 19 whereby the opposed radially extending arms A,A and B,B can be readily formed into a cup having a generally frustro-conically shaped sidewalls complementing the slope of the outlet end portion 11A, and whereby the outer retainer ring 18 can be readily secured to the connector body simply by the inter-engagement of slots 21 with its complementary lugs 17.
In the assembled position, the outer retainer ring 18 is positively secured to the connector body in a manner to prohibit any unintentional separation. Also the tangs 22 and 23, which are formed integral with ring 18, are shaped and formed so that the locking tangs 22 secure the assembly 10 to an electric box 15 while the grounding tangs 23 ensure a positive electrical ground of the assembly 10 with the associated electric box 15.
FIG. 11 illustrates a perspective view of a modified form of the invention. As illustrated in FIG. 11, the connector assembly 30 includes a connector body 31 which may be formed as a casting form of a suitable metal or alloy, e.g. zinc and the like, as hereinbefore described. The connector body 31 includes a conically shaped outlet end 31A similar to that described with respect to FIG. 1, and a cylindrical inlet end 31B. A circumscribing internal shoulder 31C is formed intermediate the opposed ends of the connector body 31. As shown in FIG. 12, the internal shoulder 31C defines the demarcation between the bore 32A defining the outlet end 31 and the bore 32B defining the bore of the inlet end. Circumscribing the connector body 31 about the exterior thereof is a radially outwardly extending stop flange 33.
The outlet end 31A of the connector body 30 is provided with opposed retaining lugs 37 adjacent the outlet opening 36. Circumscribing the sloping or conical surface S of the outlet end 31A is the outer retaining ring 38, similar to that hereinbefore described with respect to FIGS. 1 to 10.
In the embodiment illustrated in FIG. 11, the connector assembly 30 includes an internal wire retainer 39 in the form of a ring, cylinder or sleeve which is fitted to the bore 32B of the connector body 31, and which retainer 39 functions as a unidirectional retainer means arranged to permit a wire conductor to be readily inserted and secured thereinto, and which will resist any applied force imparted to the wire conductor in the opposite direction to prohibit any unintentional separation of the wire conductor from the connector body 31. Wire conductor, as used herein, means any wire, cable, helical wound metal covering or sheath (BX) wire, plastic sheath wire conductor and the like.
Referring to FIGS. 13 to 15, the internal retainer 39 is preferably formed from an elongated blank 40 of spring steel. The retainer blank 40, as best seen in FIG. 13, comprises an elongated generally rectangular blank having a longitudinal leading edge 40A, a trailing edge 40B and opposed end edges 40C and 40D. End edge 40C is provided with a pair of spaced apart notches 41, 41 and a projecting tongue 42. The other end edge 40D of blank 40 is provided with a pair of projecting tongues 43, 43 arranged to complement notches 41, 41 and a complementary notch 44 for receiving tongue 42 in the formed or rolled position of the retainer sleeve 39, as shown in FIG. 18.
Blanked, lanced, cut or stamped out of the plane of blank 40 are one or more tangs 45. In the form of the invention as shown in FIG. 13, tangs 45 are formed out of the plane of the blank. The respective tangs 45 are bifurcated to define a pair of finger tangs 45A, 45A longitudinally spaced along the longitudinal axis of the blank 40 at a distance, which, when the blank 40 is rolled to form the retainer sleeve 39, the respective pairs of finger tangs 45A are oppositely disposed, as best seen in FIG. 15.
As shown in FIGS. 15 and 18, the respective finger tangs 45A, 45A are inwardly bent out of the plane of the retainer sleeve 39. In the illustrated embodiment, the respective finger tangs are provided with a pair of intermediate transverse fold lines F1 and F2 whereby the free end of the respective finger tangs is directed toward the longitudinal axis of the sleeve 39, as shown in FIG. 18.
Referring to FIG. 15, it will be noted that the retainer sleeve is provided with a flattened portion 46 on one side thereof.
The connector body of FIGS. 11 and 12 may be formed with an internal complementary flat surface along a portion of the inner circumference thereof. The arrangement is such that the retainer sleeve 39, when inserted into the inlet end 31B of the connector body, is oriented so that the flattened surface 46 of the sleeve 39 complements the internal flattened surface 47 of the connector body. The orientation is such that the opposed finger tangs 45A are oppositely disposed to firmly grip the wire conductors, e.g. an armored conductor or other covered conductor.
The outer circumference of the inner retainer sleeve or ring 39 is proportioned so that it can be press fitted or frictionally fitted into the inlet end 31B of the connector body 31 by a force sufficient to firmly secure the inner retainer ring or sleeve 39 within the inlet end so as to prohibit any separation of the retainer ring or sleeve 39 from the inlet end of the connector body. The complementary flattened surfaces 46 of the internal sleeve 39 and 47 of the inlet end of the connector body insures proper orientation of the internal sleeve 39 within the inlet end of the connector body.
FIG. 14 illustrates a fragmentary portion of the blank 40 to show an intermediate step in forming the tang fingers 45A, 45A so that when the formed blank 40 is rolled to form the internal retaining sleeve, the tang fingers will be disposed in parallel as seen in FIGS. 15 and 16. This is attained by fold line F3 which is disposed at an angle, as noted in FIG. 14, so that when the blank is rolled to form the internal retaining sleeve 39, the tang fingers 45A, 45A will be disposed in parallel. The free ends 45B of the respective fingers 45A are angularly offset to engage the grooves of an armored conductor, as noted in FIG. 12 or other covering sheath of a wire conductor that will resist a force attempting to effect separation of the conductor from the connector assembly. The respective free ends 45B may also be laterally offset so that an armored conductor may be threadedly connected to the internal sleeve 39, as well as by simply inserting the armored covered conductor into the retainer sleeve to effect a snap fit connection.
FIG. 19 illustrates a further embodiment of the invention. The embodiment of FIG. 19 is directed to a connector assembly 50 which is generally similar to that disclosed in FIGS. 1 to 10. The embodiment of FIG. 19 differs from that disclosed in FIGS. 1 to 10 and FIGS. 11 to 18 in that the connector body 51 is provided with a slotted opening 52 in the inlet end 51A thereof positioned adjacent to the radially outwardly extending flange 53. Intermediate between the inlet end 51A and the flange 53, the inlet end is provided with a tapped or threaded hole 54 for receiving a set screw 55.
In this form of the invention, the wire retainer means comprises an inverted U shape clamp 56 having opposed leg portions 56A, 56B and an interconnected web 56C. The web 56C is provided with an aperture or hole 57 arranged to be disposed in alignment with the tapped or threaded hole 54. The web 56C is sufficiently wide so that one leg, e.g. leg 56B, is extended through the slotted opening 52 and the other leg 56A extends over the inlet opening 58 to the inlet end portion 51A. The retaining clamp 56 is adjustably secured to the connector body 51 by the set screw 55 extending through hole 54 disposed in alignment with screw hole 54. By having one leg 56B extending through the slotted opening 52 and the other leg 56A extending over the inlet opening 58, the clamp 56 can be readily adjusted relative to the connector body by turning the set screw 18 in one direction or the other. The arrangement is such that as the set screw 55 is tightened, the opposed and spaced apart free ends of the respective clamp legs 56A, 56B will exert a bearing force on the wire conductor sheath to positively secure a wire conductor to the inlet end of the connector assembly. In all other respects, the connector assembly of FIG. 19 is similar to that disclosed in FIGS. 1 to 10, and need not be repeated.
FIGS. 20 to 32 are directed to a further modification of the disclosed invention. As best seen in FIGS. 20 and 21, the connector assembly 60 includes a housing or connector body formed of a pair of complementary sections or members 61 and 62. The respective complementary sections or members 61 and 62 are preferably formed as casting of any suitable metal or alloy material, e.g. zinc, aluminum and the like.
As best seen in FIG. 21, one of the housing complementary members, e.g. 61, is provided with a projecting leading or outlet end 61A, which is adapted to be inserted through a knockout hole 14 of an electric box or panel 15. The leading or outlet end 61A is formed with an annular configuration to define an outlet opening 63, through which the conductor leads or wires 80A may extend as noted in FIG. 20. The outer surface S of the leading end 61A slopes or tapers downward toward the central axis of the connector assembly to define a frustro conical outer surface S on the leading end 61A.
The complementary member 61 also includes a trailing or inlet end 64. As shown in FIG. 21, the trailing or inlet end 64 is formed as a pair of semi-cylindrical chambers 64A, 64B disposed in parallel side by side arrangement separated by an intermediate wall or division 65. The opposed ends of the respective chambers 64A, 64B are defined between an inturned lip 66A circumscribing the inlet opening 66 to the respective chambers 64A, 64B and a transverse web 67. A transition section 68 connects the respective chambers 64A-64B to leading or outlet end 61A.
Extending through the intermediate wall 65 is a tapped hole 68B having internal threads. Also formed on the wall 65 is an aligning depression or recess 69. Circumscribing the leading or outlet end61A is a radially outwardly extending flange 70 which functions as a stop to limit the distance the connector assembly 60 can be inserted through a knockout opening 14 of an electric box or panel 15.
The complementary housing section or member 62 is formed with a pair of semi-cylindrical chambers 64A′, 64B′ disposed in parallel relationship and arranged to complement chambers 64A, 64B in the assembled position of the respective housing members 61, 62, as best noted in FIGS. 20 and 31. Housing member 62 is provided with a hole 71 extending therethrough which is arranged to be disposed in alignment with the tapped hole 68B whereby the respective housing sections 61, 62 can be secured in the assembled position by a threaded fastening screw 72 inserted through hole 71 and threaded into the tapped hole 68 of the other housing member 61. Housing member 62 is also provided with a transition section 68A that complements transition section 68 of the other housing member or section 61.
To facilitate the alignment of the two housing sections 61 and 62 in assembling the sections 61, 62, there are provided complementary aligning means. In the illustrated embodiment, the aligning means comprises a notch 73 formed at the leading end of the housing member 62 which is arranged to mate with a complementary projection or lug 74 formed on the outlet end portion of the housing member 61. Another alignment means includes a recess or depression 69 formed in the dividing wall 65 of housing member 61 arranged to be disposed in alignment with the projection or dimple 69A formed on the dividing wall 65A of housing member 62.
In this form of the invention, the outlet or leading end 61A is provided with retainer lug 75 projecting outwardly from the conical surface S of the outlet end 61A. In the illustrated embodiment, two such retaining lugs 75 are oppositely disposed. Disposed about the outer sloping or tapered surface S of the outlet end 61A is a frustro-conical retainer ring 76. The conical retaining ring 76 is formed and constructed in the manner hereinbefore described with respect to FIGS. 2 to 4 and need not be repeated. As seen in FIGS. 20 and 21, the frustro conical external retainer ring 76 can be readily slipped onto the outlet end 61A so that upon engagement of the retainer lugs 75 with the complementary slots 76A formed on the retainer ring 76, the retainer ring 76 is maintained in position on the external surface S of the leading or outlet end 61A as hereinbefore described.
In this form of the invention, a wire conductor retainer ring or sleeve 77 is arranged to be disposed and clamped between the complementary chambers defined by the respective housing sections or members 61, 62 when assembled. The respective wire retainer rings or sleeves 77 are similar in construction and function to that described with respect to FIGS. 13 to 16, which need not be repeated. It will be noted that dividing wall 65, 65A of the respective housing members 61, 62 are arranged to engage the flat area 77A of the respective wire retainer sleeves 77 thereby functioning as a means for effecting proper orientation of the respective wire retainer sleeves 77 within their respective chambers in the assembled position of the housing sections or members 61, 62.
To assemble the connector 60 of FIGS. 20, 21, a formed conductor wire retainer ring 77 as hereinbefore described, is position in each semi-cylindrical chamber defined in one of the housing sections, e.g., as illustrated in FIGS. 21 or 22; noting that the flat portion 77A of the respective wire conductor retainer sleeves 77 are positioned against the adjacent opposing surfaces 65B of the dividing wall 65, as best seen in FIG. 23. In this position, the opposite ends of the respective sleeves 77 abut the interior lip 66A adjacent the inlet opening and the transverse web 67. With the wire retainer rings 77 thus positioned within their respective chamber, the other housing member, e.g. member 62, is fitted to housing member 61 whereby the respective housing sections clamp the respective wire retaining sleeves 77 therebetween as the fastening screw 72 is rotated to secure the two housing sections together as shown in FIGS. 20 and 23. It will be noted that the outer diameter (OD) of the wire retainer sleeves 77 are substantially equal to or slightly greater than the internal diameter of the respective chambers in the assembly position of the housing sections 61, 62, as noted in FIGS. 20 and 23. The arrangement is such that the respective retainer sleeves 77 are firmly secured within their respective chamber, when assembled, so that the wire retainer sleeves are prohibited from being separated from the connector body or housing. With the housing members 61, 62 thus secured, the external retainer ring 76 can be readily fitted onto the leading end 61A of the connector body or housing, as hereinbefore described.
With the connector body of FIG. 20 thus assembled, it will be noted that the connector assembly 60 can be readily secured to an electric box or panel simply by inserting the leading or outlet end 61A through a knockout hole of a panel or electrical box so as to be readily secured thereto with a snap fit as hereinbefore described. Also with the arrangement described, a wire conductor or cable can be readily attached to the trailing end of the connector assembly 60 with a simple snap fit.
FIG. 20 illustrates a wire conductor having an external helically wound sheath or outer covering 80 which can be readily inserted through the inlet opening of one of the respective chambers formed in the trailing end whereby the gripping tangs 78 formed in the wire retainer sleeves 77, as hereinbefore described, securely grips the armored cable or wire conductors with a snap fit, the arrangement being such that the wire so secured is prohibited from becoming accidentally separated from the connector body, as hereinbefore described. While a conventional armored type conductor 80 is illustrated in FIG. 20, it will be understood that the described connector assembly herein can be suitable for use with other types of wire conductors, e.g. conductors having an external plastic or fabric like sheath.
By simply removing the single fastening 72, the entire assembly can be readily taken apart to effect the separation of the wire conductor if so desired. If desired, the transition portions 68, 68A of the respective housing sections 61, 62 may be provided with peep holes 70 to view the individual conductor wires 80A arranged within the connector body to facilitate an electrical installation.
From the foregoing, it will be noted that the connector assemblies disclosed herein utilize a frustro conically shaped outer retainer ring which is uniquely secured to the leading end of a connector body, with securing tangs and grounding tangs arranged to effect both a positive securement of the connector assembly to a knockout hole of an electric box or panel and a positive electrical ground. In association with an external frustro conical retaining ring, other disclosed embodiments include a trailing end constructed to receive one or more wire conductors and retaining the same to the connector body with a simple snap fit motion. While the embodiment of FIG. 20 has been illustrated and described as having a duplex trailing end portion, it will be understood that the subject matter described can be utilized with one or more chambers formed in the trailing end of the connector body described herein, depending upon the number of wire conductors one may wish to connect to a single connector body.
With respect to the embodiment of FIGS. 20 to 32, the arrangement is such that the connector body, being formed of two component housing sections, and secured together with a fastener as described imparts a clamping force onto the spring steel wire retaining ring or sleeve with a surface to surface contact to enhance electrical conductivity or grounding between the component housing sections, and the wire retaining sleeves clamped therebetween.
FIGS. 33 to 44 illustrate a further modification of the invention. In this embodiment, the connector assembly 80 includes a connector body 81, an outer frustro conical external snap-fit retainer ring 82, a wire retainer device 83, and an optional plastic electrical insulating end ring insert 84.
As shown, the connector body 81 includes an inlet portion 81A and an outlet portion 81B, formed as a casting of a suitable metal, e.g. zinc or other suitable metal alloy. The inlet portion 81A, for the greater portion thereof, is defined by a cylindrical body having a circumference which is greater than 180°, and preferably about 320° plus or minus a few degrees. The open portion of the cylindrical body defining the inlet end portion 81A, as viewed in FIGS. 33 and 43, is provided with a flat closure 85 which is integrally connected to the opposed edges of the cylindrical body by interconnecting opposed side walls 85A and 85B. Projecting outwardly of the flat closure 85 is an anchoring pin or boss 86.
The outlet portion 81B comprises a frustro conical end similar to that hereinbefore described with respect to the embodiments of FIGS. 1, 11, 19 and 21. Also, the external snap fit ring 82 adapted to be disposed about the outlet end portion 81B is structurally and functionally similar to that hereinbefore described, and need not be repeated.
In the embodiment of FIGS. 33 and 44, a wire retainer or device 83 is arranged to extend into the inlet portion 81A, whereby a wire conductor 90, adapted to be inserted into the inlet portion 81A, is retained therein merely by inserting the wire conductor into the inlet end portion 81A. The arrangement is such that the wire conductor 90, once inserted into the inlet portion 81A and past the free end 83C of the wire retainer 83, positively retains the wire conductor 90 so as to prohibit any unintentional separation of the wire conductor 90 from the connector body 81, as best seen in FIG. 44.
The wire or conductor retainer 83 is formed from an elongated rectangular blank 87, preferably a blank of spring steel. The blank 87 is provided with a plurality of longitudinally spaced apart transverse foldlines F1 to F6, whereby the blank 87 can be readily formed to define the spring steel retainer 83.
As shown, the elongated blank 87, intermediate the length thereof and adjacent the longitudinal edges 87A, 87B, is provided with die cut or slit 87C to form opposed projecting prongs 88 that are bent out or project beyond the plane of the blank 87. The right end of the blank 81, as seen in FIG. 35, is reversely bent or folded about foldlines F1 and F2 so as to overlie the projecting prongs 88, as best seen in FIG. 36, whereby the reversely bent end 83A is spaced above the projecting prongs 88. Formed in the bent end 83A is an aperture or hole 89 which is positioned to receive anchor pin or boss 86 in the assembled position. The portion of the blank 87 to the left of the prongs 88 are bent about transverse foldlines F3, F4, F5 and F6 at longitudinally spaced intervals to configure the blank 87 with a series of angular bends, as shown in FIG. 36. The angle of respective bends about the respective foldlines F3 to F6 is not critical and may vary depending upon the internal diameter of the inlet end 81A. As shown in FIG. 44, the retainer device 83 may be angularly bent so that the free end 83B extends to a position sufficient to engage the wire conductor or the wire covering or sheath 90, as noted in FIG. 44.
In the illustrated embodiment, the wire conductor, as shown, includes a typical helically wound metallic sheath or covering 90 that houses the conducting insulated wires 90A. To facilitate the retention of the sheath 90, the free end of the retainer device 83 may terminate in a curvilinear arc 83B to complement the circumference of the sheath 90 disposed between the adjacent helical ridges as best seen in FIG. 44.
To assemble the wire retainer 83 to the inlet portion 81A of the connector body 81, the reversely bent end portion is fitted to or clipped onto the end of the flat closure or top 85, as best seen in FIGS. 43 and 44 so that the anchoring pin 86 is received in the hole 89. To secure the retainer device 83 to the connector body 80, the top of the anchor pin is swedged so as to deform the end of the anchor pin 86, whereby the deformation of the anchor pin 86 firmly and fixedly secures the retainer device 83 to the connector body. In the swedging operation, the prongs 88 formed in the blank 87 are caused to “bite” into the under surface of the flat closure or top 85, as best seen in FIG. 44, to enhance the attachment of the retainer device 83 to the connector body 81. To complete the assembly of the connector assembly, the frustro conical external ring 82 is snap fitted onto the conically formed outer end portion 81B as hereinbefore described. While the means for securing the wire retainer 83 to the connector body portion 81A is described by means of a swedged pin, it will be understood that other suitable fastening means may be used, e.g. screws, bolts, welding, solder and the like.
As will be best noted in FIG. 44, the retainer device is so formed that the free end 83B is arranged to extend into the inlet portion 81A of the connector body 81 and is angularly disposed so as to enable a wire conductor or sheathing 90 to be unidirectionally inserted into the inlet end portion 81A so as to be retained by the free end 83A of the retaining device 83 in a manner whereby the wire conductor 90 is prohibited from being unintentionally separated from the connector body.
To effect the release of the wire conductor, one need only to insert an appropriate tool to effect displacement of the retainer device away form the wire conductor or covering sheath 90, to effect the withdrawal of the conductor sheath 90.
FIG. 37 illustrates a slightly modified wire retainer device 91. The modified wire retainer device 91 is similar to that the wire retainer 83, herein described, with the exception that the free end of the blank 91A is provided with an end notch 92 to define a pair of finger portions 93 for engaging and retaining a wire conductor, as hereinbefore described. In all other respects, the structure of embodiment FIG. 37 is similar to the wire retainer 83 as described.
To complete the connector assembly 80, an end ring insert 84 may be provided to protect the wire conductors 90A that extend beyond the outlet end 81B, as noted in FIG. 44. The illustrated ring inset 84 preferably formed of a suitable plastic, comprises a ring body 84A having an outwardly radially extending flange 84B. Blanked out of the plane of the ring body are opposed tangs 84C which are outwardly bent. The outer diameter of the ring body 84A is slightly smaller than the diameter of the opening 82A formed in the face portion of the external retainer ring 82. The arrangement is such that the ring insert 84 can be readily snap fitted to the opening 82A of the external retainer ring 82 and the outlet opening of the outlet end portion 81B. The insert body tangs 84C function to enable the ring insert 84 to be readily snap fitted to the outlet end portion 81A, so that the ring insert 84 is prohibited from being unintentionally separated therefrom.
Intermediate the opposed opening of the connector body, there is provided a radially outwardly projecting stop flange 95, which functions to limit the insertion of the connector assembly through a knock-out hole of an electric panel or electric box, as hereinbefore described.
FIGS. 45 to 51 illustrate a further embodiment of the invention. This embodiment of FIGS. 45 to 51 is directed to a snap-fit electrical connector assembly 100 which is particularly suitable for attaching an electric cable or conductor 101 to an electric box 102 which is disposed in a finish wall structure 103.
It is frequently necessary to upgrade, repair, or add new electric conductors or circuits to existing electric boxes concealed within the wall of an existing structure. In such instances, the installer is generally unable to access a snap-fit connector so as to apply the necessary pulling or pushing force necessary to insert and lock a snap-fit connector assembly, e.g. 100, in a knockout opening of the electric box 102. Heretofore, in such situations, the installer generally utilized a connector having a threaded outlet end which could be readily passed through a knockout hole of an electric box, which could then be secured by threading thereon a lock nut from within the box opening, which is both difficult and time consuming.
The connector assembly 100, as illustrated, includes a connector body 104 having a leading end or outlet end 105 and a trailing or inlet end 106. The connector body may be formed as a metal casting of a suitable material, e.g. a zinc alloy, having a bore 107 extending therethrough. Circumscribing the connector body 104 between the outlet end 105 and the inlet end 106 is a radially outwardly extending stop flange 108. As hereinbefore described, the outer surface S of the outlet end 105 tapers or converges inwardly toward the central axis of the connector body 104 and the outlet opening 109.
Complementing the slope or taper of the outer surface S of the outlet end 105 is a frustro-conical snap-fit retainer ring 110 which is similar in structure hereinbefore described with respect to FIGS. 1 to 4, except that the retaining slot 111 adapted to receive the retaining lug 112 is enlarged, as compared to the retaining slot 21 as hereinbefore described. As best seen in FIGS. 47 and 48, the retaining slot 111 has a width which is greater than the width of the retainer lug 112 adapted to be received in slot 111 in the assembled position, as best illustrated in FIGS. 46 and 47. In all other respects, the structure of the retainer ring 110 is similar to the construction of retainer ring 18 hereinbefore described with respect to the embodiments illustrated, for example in FIGS. 1 to 4, and which need not be repeated.
It will be understood that a conductor retainer means, similar to any of those hereinbefore described with respect to FIG. 8, FIGS. 11-18, and FIGS. 33-36 may be associated with the inlet end 106 of the connector embodiment illustrated in FIGS. 45 to 48 for receiving and retaining the wire conductor 101 to prohibit any unintentional separation of the wire conductor 101 from the connector assembly 100.
Because of the amount of force that is required to be applied to the connector assemblies as herein described, it has been noted that great difficulty has been encountered in the field when installers or electricians attempted to utilize snap-fit connectors for connecting wire conductors, cable or the like to a knock-out opening 114 of an electric box 102 seated within an established or finished wall structure 103 as shown in FIGS. 50 and 51. This is because the installer had insufficient access to the connector assembly to apply thereto the necessary pushing or pulling force required to overcome the spring tension or deflection of the locking tangs 113, required to seat the connector assembly in the knockout opening 114 of the electric box 102 in a finished wall installation.
To facilitate seating and locking a snap-fit connector assembly 100 in a knockout hole 114 of an electric box 102 supported in a finished or existing wall 103 as described herein, this invention contemplates an installation tool 120 which is designed to complement the circumference of the outlet end 105 of the connector assembly 100. Since the outlet end 105 and the circumscribing retainer ring 110 are frustro-conical and converge toward the outlet opening 109, the connector assembly 100, as shown in FIG. 50, can be brought into ready alignment with the knockout opening 114. However, due to the outward flare of the locking tangs and the trailing end of the frustro-conical retaining ring 110, it is prohibited from being seated or locked to the knockout hole 114, until such time that a sufficient force is applied to effect the flexing of the locking tangs 113 and to a lesser extent, the grounding tangs 115.
As access to the connector assembly 100, as shown in FIG. 50, is limited and prohibits an installer from applying the necessary force to pull or push the connector assembly 100 to seat and lock the connector assembly in the knockout opening 114, an installation tool 120 is provided to facilitate the seating and locking of the connector assembly 100 to the electric box 102. As best seen in FIGS. 52 to 55, the installation tool 120 comprised simply of an elongated flat metal plate 120A. Formed at one end of the plate 120A is a generally U-shaped cutout 121 formed with parallel edges 121A joined at the inner ends thereof by an arcuate segment 121B shaped to complement the curvature or arcuate portion of the frustro-conical retainer ring 110.
In accordance with this invention, the opposed parallel edges 121A, 121A are sized and shaped to engage the enlarged retaining slot 111 as the tool 120 in inserted through the open end of the electric box 102, as best seen in FIG. 50. It will be understood that the thickness of the plate 120A at the parallel edges 121A, 121A of the cutout portion 121 should be slightly less than the opposed open area of the enlarged retaining slots 111. In the event that the thickness of plate 120A at end 120A′ is greater than the open area of the enlarged retainer slot 111 formed in the retaining ring 110, a portion of the plate 120A adjacent the parallel edges 121A, 121A, as best seen in FIG. 52, may be machined away or removed as indicated at 121C so as to reduce the thickness of the parallel edges 121A, 121A an amount sufficient to permit the opposed parallel edges 121A, 121A to be received in the open or enlarged unoccupied area of the retainer slot 111.
FIGS. 57 and 58 illustrate a slightly modified tool embodiment 130. The tool embodiment 130 is similar to that described with respect to FIGS. 52-56 except that the thickness of the plate 130A is uniform, i.e. the thickness of the plate 130A is slightly less than the available open or unoccupied area of the enlarged retainer slot 111, which is not occupied by the retainer lug 112 when the retainer ring is assembled to the connector body. In tool embodiment 130, the parallel edges 131A, 131A of cutout 131 need not require any machining or removal of any material of the plate to size the thickness of the edges 131A, 131A, as described with respect to tool 120.
FIG. 59 illustrates another slightly modified embodiment of a tool 140. Tool 140 is similar to that hereinbefore described, except that the other end of the plate 140A is provided with a polygonic shaped cutout 142 to define an open end wrench sized and shaped to accommodate a conventional complementary polygonic lock nut (not shown) in the event a connector having an externally threaded outlet end may sometimes be used to secure a wire or cable to an electric box. Tool 140 thus has the versatility to be used to secure either a conical snap-fit connector assembly 100 as described herein, or a conventional externally threaded connector assembly secured by a lock nut, e.g. a hexagonic sided lock nut.
In operation, the connector assembly 100, with the electrical conductor 101 attached thereto as described herein, is disposed in alignment with a knockout hole 114 of an electrical box 102 installed in a finished wall 103. Since the connector assembly has a frustro-conical outlet end, it can be readily positioned in a knockout hole 114 and rest therein so that the enlarged or unoccupied portion of the retaining slot 111 is rendered accessible from within the front opening 116 of the electric box 102, as best seen in FIG. 50. Because of the outwardly bent locking tangs 113, the connector assembly 100 cannot be normally passed through the knockout hole 114 without a pulling or pushing force being imparted onto the connector assembly 100. Applying a pulling force on the individual wires 101A of the conductor 101 is not advisable, as any such pulling force may damage the insulated covering of the individual wire conductors 101A or be pulled through the connector assembly 100 depending upon the type or kind of conductor retainer that is associated in the inlet end 106 of the connector body 104.
According to this invention, the locking of the connector assembly 100 to the knockout hole 114 is achieved, without any injury to the conducting wires, simply by inserting the tool 120 through the open end 116 of the electric box 102 so that the parallel edges 121A, 121A of the cutout 121 engage the respective opposed enlarged or unoccupied portion of the retaining slot 111 immediately below the retaining lugs 112, as indicated in FIGS. 48 to 50. This can be achieved by inserting the tool 120 into the electric box slightly below the upper end of the electric box and substantially parallel thereto. With the edges of the cutout 121 engaged in the opposed enlarged or unoccupied portions of the retaining slots 111, an upward force as indicated by the force arrow A (FIG. 51) adjacent the outer end of the tool will cause the other end of the tool 120 to pull the outlet end 105 through the knockout hole 114 to seat and lock the connector assembly 100 and connected conductor or cable 101 to the electric box with a minimum of effort quickly and simply with a minimum of applied force. As noted in FIG. 51, the tool 120 functions as a lever that uses the corner or edge of the electric box at the open end thereof as a fulcrum about which the tool pivots, to pull the connector assembly downwardly with sufficient force to flex the locking tangs inwardly, permitting the connector assembly to pass through the knockout hole 114, whereby the inherent spring energy of the locking tangs causes the locking tangs to spring outwardly and lock the connector assembly 100 in place within the knockout hole.
FIGS. 60-67 are directed to another embodiment of the invention formed to enhance the grounding effect between the connector assembly 200 and the electrical box or panel 201 to which the connector assembly 200 is attached. It will be understood that the connector assembly 200 includes a connector body similar to any of the connector body forms herein described. For illustrative purposes, the connector body 202 is similar to the connector body 11 illustrated and described with respect to FIG. 1. In the embodiment illustrated in FIG. 60, the outer frustro-conical retainer ring 203 has been modified so as to enhance the grounding effect between the connector assembly 200 and the electric box or panel 201, to which the connector assembly 200 is secured. This is attained by increasing the contact area of the grounding tangs 207, 207A of the frustro-conical retaining ring with the internal periphery 201A of the knock-out hole 201, as will be hereinafter described.
In accordance with this invention, the frustro-conical retainer ring 203 is preferably formed from a blank 204 of a resilient type metallic material, e.g. spring steel, which may have a generally circular configuration as shown in FIG. 61 for illustrative purposes only. As shown, the blank 204 is provided with a center hole or opening 205, which defines the outlet opening 205A when the blank 204 is formed into a frustro-conical ring, as illustrated in FIGS. 60 and 62-64. Blanked, stamped or die cut out of the plane of the blank 204 are a pair of opposed locking tangs 206, 206A. The portions of the blank 204 disposed between the opposed locking tangs 206, 206A to either side of the locking tangs 206, 206A define the grounding tangs 207, 207A for enhancing the grounding effect when the blank is formed into a frustro-conical ring, as shown in FIGS. 65, 66.
Circumscribing the center hole 205 is a foldline f2 about which blank 204 is laterally bent, shaped or formed to define a retainer ring a shown in FIG. 60. Such forming may be accomplished by a progressive die or other forming technique. In its formed state, as best seen in FIGS. 60 and 65, the retainer ring 203 is provided at the leading end thereof with a face portion 208 which circumscribes the outlet opening 205A. The laterally outwardly sloping grounding tangs 207, 207A define a curvilinear trailing edge 209 having a diameter which is greater than that of the leading edge that defines or circumscribes the face portion 208. As shown in FIGS. 60, 63 and 65, the respective opposed locking tangs 206, 206A are angularly bent outwardly of the ring 203 at an angle or slope which is greater than the slope of the grounding tangs 207, 207A, as best seen in FIGS. 60, 63 and 65.
Formed in the plane of the respective grounding tangs 207, 207A is a retaining slot 210 arranged to receive a retaining lug 211 formed on the outlet end portion 212 of the connector body 202. It will be understood that the slot 210 may be sized as described with respect to the embodiment illustrated in FIG. 1, or as described with respect to the embodiment described with respect to FIGS. 45-49 if the use of a tool 120, as hereinbefore described, is required to secure the connector assembly to an electric box or panel.
To minimize any damage to wires that are to extend out through the outlet opening 205A, the outlet opening 205A may be formed with a protective lip 213 to provide a smooth surface about the outlet opening 205A through which the conductor wire extends. It will be understood that the. protective lip 213 may be of any shape that will form a smooth surface about the periphery of the outlet opening 205.
It is to be further understood that the frustro-conical ring as described with respect to FIGS. 60 to 67 may be utilized with any of the connector bodies herein described.
As described, it will be noted the trailing edge 209 of the frustro-conical retaining ring 203 defines a curvilinear trailing edge that approximates at least three quarters or 270° of the circumference of the trailing end of the frustro-conical retainer ring 203. As the diameter of the trailing edge 209 is formed slightly greater than the diameter of the knock-out hole adapted to receive the same and together with the inherent resiliency of the spring metal grounding tangs, there is produced an inherent spring bias whereby the grounding tangs are normally biased outwardly to ensure positive engagement of the grounding tangs 207, 207A with the internal periphery 201A of the knock-out hole 201. Because of the approximately 270° or extended contacting surface of the grounding tangs with the internal peripheral surface of the knock-out hole and coupled with inherent spring force or bias of the grounding tangs to maintain the grounding tangs 207, 207A in positive contact with the internal periphery of the hole 205, the electrical grounding effect therebetween is substantially enhanced and assured. In all other respects, the connector assembly 200 functions as hereinbefore described.
FIGS. 68 to 72 illustrate a further modified embodiment of a frustro-conical retainer ring 220 which is capable of further enhancing the grounding effect between a connector assembly 221 and a knock-out hole 222 in an electric box or panel 223. In this form of the invention, the connector body 224 may be similar to any of the various connector bodies hereinbefore described. Generally, the connector body includes an inlet end portion 224A and a frustro-conical outlet end portion 224B similar to that hereinbefore described.
In this form of the invention, the connector body 224 is provided with a further modified frustro-conical retainer ring 225. The frustro-conical ring 225 is formed with a grounding tang 226 that has a circumference of 360° that defines the trailing end 225A of the frustro-conical ring 225. The modified retaining ring 225 may be formed from a blank 230 of a resilient or spring metal, e.g. spring steel, as shown in FIG. 68. The blank 230 includes an outer circumference that defines the trailing edge 225A of the retaining ring 225 in its fully formed state as shown in FIGS. 69-72. A center hole 230 is formed in the blank 226 which defines the outlet opening 227A through which a wire conductor may be extended. As shown in FIG. 68, a pair of opposed locking tangs 228, 228 are formed in the plane of the blank 230, which are arranged to be outwardly bent from the plane of the blank as the blank 230 is progressively worked to form the retainer ring into its finally formed state as shown in FIGS. 69 to 70.
In this form of the invention, the outer free ends 228A of the locking tangs 228 are disposed inwardly of the outer edge 225A of the blank 225. As a result, the trailing outer edge 225A of the fully formed frustro-conical retaining ring 225 defines a grounding surface about the entire circumference of the frustro-conical retaining ring 225 at its trailing edge.
Oppositely disposed and off-set approximately 90° from the respective locking tangs 228, 228, the blank 230 is formed with opposed slots 229, 229, which are sized and arranged to receive the retaining lugs formed on the outlet end portion 224B as hereinbefore described with respect to FIG. 1 or as described with respect to FIGS. 45-51 for accommodating a tool 120.
It will be understood that the blank 230 is transformed into a ring shape by subjecting the blank 230 through progressive dies whereby the portion of the blank 230 circumscribing the central opening or hole 227 is laterally and outwardly sloped, bent, or formed into a frustro-conical ring as illustrated in FIGS. 69-71. In its formed state, the frustro-conical ring includes a face portion 225B which defines the leading end of the retainer ring 225 having a diameter which is less than the diameter defined by the trailing edge 225A.
In this form of the invention, it will be noted that the grounding tang is defined by the sloping surface S1 of the frustro-conical ring 225 which, at the trailing edge 225A, defines a contact surface about the entire circumference of the retainer ring 225, i.e. 360°.
As noted in FIG. 72, the entire circumference of 360° is biased in direct contact with the internal periphery of the knock-out hole 222 of the electric box or panel 223. The inherent spring bias of the sloping surface S1 that defines a grounding tang assures a positive electrical grounding between the retainer ring 225 and the electric box or panel 223. In all other respects, the embodiment of FIGS. 68-72 functions as hereinbefore described.
The enhanced contact surface at the trailing edge of the respective frustro-conical retainer rings 203 and 225 with the inner periphery surface of a knock-out hole of an electric box or panel assures that the desired grounding effect is achieved when used with thin walled boxes or panels.
While the present invention has been described with respect to several embodiments, it will be understood that various modifications may be made without departing from the spirit or scope of the invention.

## Claims

1. An electric connector assembly comprising:
a connector body having an inlet end portion, and an outlet end portion, said outlet end portion defining an outlet opening, a radially outward extending stop flange formed about an intermediate portion of said connector body, and a snap fit retaining ring having a leading end and a trailing end, and having a frustro-conical configuration wherein the diameter of the trailing end of said frustro-conical configuration is greater than the diameter of said leading end thereof, said frustro-conical retaining ring having at least one locking tang and grounding tang formed out of the surface of said retaining ring, and means for securing said retaining ring onto said outlet end portion of said connector body, wherein said grounding tang includes a free end defining a curvilinear contact area extending over a range of at least 270° to 360° of the circumference of said trailing end.

2. An electrical connector assembly as defined in claim 1 wherein said grounding tang includes a free end defining a curvilinear contact area that extends over at least 270° of the circumference of said trailing end.

3. An electrical connector assembly as defined in claim 1 wherein said grounding tang includes a free end defining a curvilinear contact area that extends about the entire circumference of said trailing end.

4. An electrical connector assembly as defined in claim 1 wherein said locking tang is outwardly bent at an angle which is greater than the angle of said grounding tang.

5. An electrical assembly comprising:
an electrical box having a knock-out hole and an electrical connector assembly adapted to be secured to said knock-out hole, said connector assembly including a connector body having an inlet end, an outlet end and a bore connecting said inlet end to said outlet end, a radially outwardly extending stop flange circumscribing said connector body between said inlet and outlet end, said outlet end defining an outlet opening, and said outlet end having an outer sloping surface between said stop flange and said outlet opening, that slopes downwardly toward said outlet opening, a snap fit retaining ring having a leading end and a trailing end defining a frustro-conical surface therebetween wherein the diameter of said trailing end is greater than the diameter of said leading end, means for securing said retaining ring on said outer sloping surface of said outlet end, a pair of opposed tangs formed out of said frustro-conical surface, said opposed tangs being outwardly bent at an angle relative to the surface of said frustro-conical surface, and the remainder of said frustro-conical surface between said leading end and trailing end forming a grounding tang for effecting an electrical grounding effect between said connector assembly and said electrical box when said connector assembly is secured to said knock-out hole of said electrical box, wherein said grounding tang includes said trailing end of said retaining ring for engaging at least 270° of said inner periphery of said knock-out hole.

6. An electrical assembly as defined in claim 5 wherein said knock-out hole is circular.

7. A electrical assembly as defined in claim 6 wherein said grounding tang includes said trailing end of said retaining ring forming a curvilinear contact area for engaging an arcuate portion of the inner periphery of said knock-out hole extending between 270° to 360° thereof when said connector assembly is secured in said knock-out hole.

8. An electrical assembly as defined in claim 6 wherein said grounding tang includes said trailing end of said retaining ring arranged to engage the entire inner periphery of said knock-out hole when said connector assembly is secured in said knock-out hole.

9. An electrical assembly comprising:
an electrical box having a knock-out hole and an electrical connector assembly,
said electrical connector assembly including a connector body having an outlet end portion and an inlet end portion whereby said outlet end portion is adapted to be received within said knock-out hole,
said outlet end portion defining an outlet opening,
a snap fit retaining ring having a leading end, a trailing end and an outer sloping surface therebetween defining a frustro-conical configuration wherein said trailing end has a diameter greater than that of said leading end,
means for securing said snap fit retaining ring on said outlet end portion,
a pair of locking tangs formed out of said ring on said outlet end portion,
said locking tangs being outwardly bent at a angle greater than said sloping surface of said retaining ring,
and said sloping surface of said retaining ring extending between said locking tangs defining a grounding tang that includes a circumferential portion of said trailing end that extends through at least an arcuate portion thereof ranging between 270° to 360°.

10. An electrical assembly as defined in claim 9 wherein said grounding tang defines a curvilinear contact area at said trailing end for engaging a corresponding portion of the inner periphery of said knock-out hole when said electrical connector assembly is secured in said knock-out hole.