Switch clamping screw

Abstract: In order to enable a switch to be shipped to a customer, ready for termination at his premises, the housing or a lid (2) thereof has a through-hole (3) for the clamping screw (1) to enter a threaded hole (4) in the terminal block (5). The threaded hole has been filled with interference material produced from an inwardly projecting annular lip (7) around the housing through-hole (3). The screw is turned fully home, then backed-off by a predicted number of turns, so that its end (9) just enables clamping wire (6) to be inserted; or alternatively is screwed in by a predicted number of turns, to achieve the same position of its end (9).

Description: This invention relates to a switch, eg. a power tool speed control switch, having a housing and a terminal block and arranged with a terminal clamping screw, which switch may possibly have to be transported from a supplier to the location of a customer where the screw is to be tightened in the terminal block in order to clamp therein on a wire or other conductor terminal. The switch and screw should preferably not be shipped separately, otherwise time is spent at the terminating location in finding and fitting the screw into the threaded hole. Also the switch should not be shipped with the screw in its fully screwed in position, tightened down to the bottom of the terminal block, because the screw then has to be loosened and somewhat withdrawn at the terminating or customer location, in order to allow the conductor terminal to be inserted in the block to its clamping position. Loosening, and partially withdrawing by the correct amount at the user location after shipping likewise takes substantial time and resources, eg. for each power tool manufactured. If, in an attempt to avoid such time losses, the switch is shipped with the screw in initially only partially screwed in to the block, a screw will tend to loosen and fall out or even be lost. A device to secure such a screw in particular positions is disclosed in DE-U-8 505 359 which defines the pre-characterizing part of Claim 1, but provides only a small number, eg two finite clamping positions, and requires an extra bifurcated pin shaped extension to provide a resilient mounting for interference knobs. According to a first aspect of the invention, an electrical switch is provided as defined in Claim 1, particular embodiments of which being set out in Claims 2 to 4. According to a second aspect of the invention a method of preparing the electrical switch is provided as defined in Claim 5. It has been proposed in US-A-3 585 332 to embed a plastics pellet, as a separate initial operation, in an external thread, to hold any position in the mating thread. This discloses also withdrawing a bolt one half turn from a fully home position. Although this reference deals with electrical terminals, it does not consider shipping a clamping screw stably installed in a pre-clamping position. Figure 7 of DE-A-2 947 193 also holds various threaded positions by entry of interference material but the whole terminal body is arranged to distort. CH-A-511 522 discloses interference by rubbing on a threaded screw, whereby only friction is relied upon for the interference and nothing enters the threaded engagement because the resilience of a bifurcation on a mounted undistorted member causes the rubbing. It has also been disclosed, in US-A-4 669 806, to use retaining projections in order to hold a clamping bolt against unwanted rotations, but not by engaging neither thread. Also, because there is a clamp bracket which is installed before shipping and abutted, there is no requirement to ship a clamping screw in a stable ready-to-clamp position, which position would be identifiable only by the counted number of turns of relative displacement of the threaded members. The inventive details will appear more clearly from the following specific description of an embodiment, given in conjunction with the drawing, in which:- Figure 1 shows a side section of the switch cover and terminal block with a screw screwed fully in (i.e. excessively by the inventive teaching); and Figure 2 shows a plan view of a lipped aperture and a threaded hole for a clamping screw not yet inserted. Referring to Figure 1, which shows a clamping screw 1 fully screwed down in a manner not following the teaching of the invention (namely partially screwing home for shipping). A switch housing portion eg. lid or cover 2 has a clearance hole 3 for screw 1 which is fully engaged as with threads 4 in a terminal block 5. The clamping screw is so far down that it more than half obscures a transverse hole 6 which may, as shown, have the same diameter as the threaded hole in the terminal block. Hole 6 is for terminal conductors such as wire, not shown, and the hole is accessible from outside the switch in some manner to feed in wire or other longitudinal conductor means. When the screw is fully home as shown, wire cannot be inserted and the screw must be withdrawn several turns, which undesirably takes time and resources in the typical production environment of a portable tool factory, or like consumer of the switch (for speed control or the like). Accordingly, one or more part annular thin distortable lips or projections 7 is designed integral with the moulded housing portion or cover, so that the first entry of the screw 1 distorts the lip(s) along the threaded cylindrical surface of the terminal block, to the position diagrammatically shown at 8, whereat it partly occupies space between the screw and terminal block, engaging both and moderately resisting the screw from turning. The screw can be unscrewed from the fully down position shown, by a finite number of turns, to a shipping position whereat it has been calculated or otherwise predicted, that the conductor could be inserted reasonably freely into hole 6. The switch can then be shipped, in the knowledge that the screw is in practice captive in the shipping position, by which for instance the free end 9 of the clamping screw shank lies just above the top 10 of the transverse hole 6 which is to accommodate the terminal conductor. Alternatively, the screw can be screwed directly in, as far as the shipping or transporting position, by a calculated number of turns or a predictable amount, without requirement to transmit through the fully-in position shown in Figure 1. Referring to Figure 2, the screw is absent and so the two lips 7 formed on cover 2 as shown in Figure 1 have not yet been distorted into the region of thread 4. There may be one, two or more lips 7, or it could be continuous, with or without radial cuts etc. It will be seen from Figure 1 and Figure 2 that the clearance hole preferably has an initial large locating region 11, then a tapering portion 12 tapering to the very thin inwardly projecting distortable lip portion 7. The invention covers the switch details as shown in Figure 1 but with the screw introduced only up to, or withdrawn up to, a pre-clamping position suitable and captive in that position for transportation, or a method of transportation, and/or clamping at the terminating station (eg. factory) with the steps described above. After screw clamping, the termination may or may not be made permanent by paint, lacquer etc as desired.

Claims: An electrical switch comprising a housing, which contains a terminal block member (5) having a threaded hole (4); a clamping screw (1) screwed into the hole and holdable at a depth within the hole (4), by means of material (7) interfering with the clamping screw (1); a lid or cover portion (2) of the housing having an aperture (3) for arranging over the threaded hole (4) in the terminal block member (5), and a portion (2) of the housing having a projection which is abutted by said introduced screw, thereby causing a distortion of said latter portion of the housing, to form the interference material (7), characterized in that the latter portion of the housing is the lid or cover portion (2); the material (7) interferes with the threaded engagement; the projection being an inward projection from the periphery of the said aperture (3) which is distortable by the threaded engagement of the screw (1) whereby the screw is holdable at whatever depth it is screwed into the hole (4); the inward projection comprises one or more part-annular distortable lips moulded integrally with said lid or cover portion (2), so that a first entry of the clamping screw (1) distorts the lip(s) (7) along the threaded cylindrical surface of the terminal block (5), whereat it forms said interfering material (7), which partly occupies space between the screw and the terminal block, engaging both, and moderately resisting the screw from turning. An electrical switch according to Claim 1 characterized in that a transverse orifice (6) intersects the threaded hole which is accessible from outside the housing for introduction of an elongated conductor to be terminatingly clamped; and in that the intermediate position is defined by the end (9) of the screw being located just clear of the periphery (10) of the transverse orifice (6). An electrical switch according to Claim 2 wherein the lid or cover portion aperture (3) has in axial order, an initial large diameter locating region (11) for a screw (1) to be introduced, a tapering region (12), and then said distortable inward projection providing said interfering material (7). An electrical switch according to any of Claims 2 or 3, characterized in that a power tool speed control switch, eg. with the termination made permanent by paint or lacquer, is terminated by said termination housing. A method of preparing the electrical switch of Claim 2, 3 or 4 for installation of terminal wire in the transverse orifice (6) in the block, characterized in that, for ready installation, the clamping screw (1) has first been screwed fully home into the screw hole (4) with said interference material (7) between the threads, and has then been withdrawn from the fully home position by a number of turns or part-turns previously predicted, thereby enabling the extreme periphery (10) of the transverse orifice (6) at the intersection to be just cleared by the free end (9) of the screw (1).

Inventors: HANSEL NORBERT, HANSEL, NORBERT
Applicants: EATON CORP, EATON CORPORATION
Application year: 1989
Main classification: H01R4
IPC codes: H01R4, H01H1