Abstract:
A method for converting an electrical connector to provide an insulated opening, including the steps of providing an electrical connector including a conductive block having at least one cavity having an upwardly oriented opening and a closed bottom, and an insulating outer coating at least partially surrounding the block, forming a hole through the bottom, and positioning an insulative sleeve through the cavity and the hole so as to provide an insulated passage extending through the electrical connector.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application is a Continuation-In-Part of  U.S. patent application Ser. No. 10/874,530, filed Jun. 23, 2004 now abandoned, which claims the benefit of U.S. Provisional Application Ser. No. 60/480,848, filed Jun. 23, 2003. 

   BACKGROUND OF THE INVENTION 
   Electrical or power connectors are known for connecting various different conductive elements, and  FIG. 1  shows a cross-sectional view of a conventional connector of the type in question. Connector  10  includes a conductive block  12  having a series of contact channels  14  each of which opens upwardly through a threaded opening as shown, and also opens towards the front of the device and the rear of the device as schematically illustrated by dashed lines  16 . An insulative coating or jacket  20  is positioned around block  12 . 
   In use, elements are passed into the front or back openings illustrated by dashed circles  16 , and a threaded member is screwed down through the upward opening into threads  18  so as to frictionally engage a member passed through front or back openings  16  as desired. In this manner, conductive elements can be electrically connected through fastening in connector  10 . 
   It is sometimes desirable to mount a device such as device  10  to a secure or otherwise rigid location and the like. In such instances, the most convenient form of mounting would be to use mechanical fasteners. However, device  10  does not lend itself well to such mounting, and therefore completely separate and different devices are provided having structure included for mounting of the device. Unfortunately, this leads to excessive amounts of required inventory, as well as multiple parts and other disadvantages. 
   It is the primary object of the present invention to provide an electrical connector which can readily and advantageously be converted to have one or more mountable openings. 
   It is a further object of the present invention to provide such a device whereby conversion is a simple and easily accomplished task. 
   It is a still further object of the present invention to provide an adaptor member for use in converting an electrical connector, as well as a process for converting an electrical connector, each of which presents the advantageous features of the present invention. 
   Other objects and advantages of the present invention will appear hereinbelow. 
   SUMMARY OF THE INVENTION 
   In accordance with the present invention, a method for converting an electrical connector to provide an insulated opening, comprises the steps of providing an electrical connector comprising a conductive block having at least one cavity having an upwardly oriented opening and a closed bottom, and an insulating outer coating at least partially surrounding the block, forming a hole through the bottom, and positioning an insulative sleeve through the cavity and the hole so as to provide an insulated passage extending through the electrical connector. 
   In further accordance with the present invention, an adaptor for an electrical connector comprises a sleeve of insulative material having a central passage for receiving a mechanical connector, the sleeve having a first portion with a first diameter and a second portion with a second diameter which is smaller than the first diameter. 
   In further accordance with the present invention, an electrical connector having an insulated opening is provided which comprises an electrical connector comprising a conductive block having at least one cavity having an upwardly oriented opening and a bottom, a hole passing through the bottom, an insulating outer coating at least partially surrounding the block, and an insulative sleeve extending through the cavity and the hole so as to provide an insulated passage extending through the electrical connector. 
   In accordance with a further preferred embodiment of the present invention, the insulative sleeve has a spacer or shoe which extends downwardly beyond a bottom surface of the block and insulative coating thereon. The sleeve can further preferably include a separate flange member which is movably mountable over the sleeve to securely fix the sleeve relative to the block. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A detailed description of preferred embodiments of the present invention follows, with reference to the attached drawings, wherein: 
       FIG. 1  is a sectional side view of a conventional electrical connector of the type which can be converted in accordance with the present invention; 
       FIG. 2  schematically illustrates a step in connection with conversion of the connector of  FIG. 1 , as well as an adaptor in accordance with the present invention; 
       FIG. 3  schematically illustrates a connector which has been converted in accordance with the present invention along with steps for securing the device to an underlying mounting structure; 
       FIG. 4  is a perspective view of an adaptor in accordance with the present invention; 
       FIG. 5  is an elevational view of an adaptor member in accordance with a preferred embodiment of the present invention; and 
       FIG. 6  is a side view of an electrical connector with the adaptor of  FIG. 5 . 
   

   DETAILED DESCRIPTION 
   The invention relates to electrical connectors and, more particularly, to an electrical connector and adaptor which can readily be used to convert one or more connector ports or openings of the connector for use in mounting the connector to an underlying mounting structure. 
   As described above,  FIG. 1  illustrates a typical electrical connector  10  having a conductive block  12  with a series of connection openings  14 , each of which opens upwardly as well as to the front and rear of the device. The openings to the front and rear of the device are illustrated by dashed circles  16 , and the upwardly opening portion is the opening which has threaded walls  18 . Positioned around conductive block  12  is an insulating material  20  which is typically coated or otherwise provided onto block  12  so as to cover the entire exterior surface thereof, and further so as to define upwardly opening sleeves  22  which are aligned with each of the openings  14  in block  12 . For openings  14 ,  16  which are not to be used, a typical insulative plug member can be frictionally fit within the openings defined by sleeves  22 . It should be appreciated that insulative coating  20  is further provided so as to define sleeves such as sleeves  22  extending forward and backward from openings  16  as well. 
   In accordance with the invention, it is frequently desirable to utilize a device  10  which must be secured to an underlying mounting structure or the like. In such instances, conventionally, a new device would need to be designed which would lead to undesirable increase in cost and the amount of inventory. Turning to  FIG. 2 , the present invention is illustrated wherein an opening  14  of device  10  is converted to an insulated opening which can then be used to mount device  10  to an underlying structure utilizing conductive or conventional mechanical fasteners. 
   According to the invention, the bottom portion  24  of an opening  14  is drilled out. This hole is drilled through the bottom of conductive block  12  and through the corresponding portion of insulative layer  20 , and an insert member  26  is then advantageously disposed within opening  14  and extending through the drilled bottom portion  24 . Adaptor or insert member  26  is advantageously provided of an insulative material, and when positioned within opening  14  advantageously serves to provide an opening through which mechanical fasteners can be positioned without risk of contact or conductivity between the mechanical fastener and block  12 . Bottom portion  24  is preferably drilled to approximately the same size as adaptor  26 . 
   Adaptor  26  will be further described below, but is advantageously sized and dimensioned for secure force fitting within opening  14 . 
   It should also be appreciated that although  FIG. 2  shows adaptor  26  being positioned in one end opening  14  of device  10 , it is preferred to position as many adaptors  26  in a device  10  as are necessary to provide secure mounting of device  10  as desired, while nevertheless allowing for the necessary connections to be made through device  10  as well. In this regard, the embodiment shown illustrates a four opening device  10 . These electrical connector devices  10  can be provided having a large variety of numbers of openings, and the present invention is equally applicable to other configurations. 
   It should also be appreciated that while positioning of adaptors  26  in end openings, preferably in the pair of end openings on each end of device  10 , can in many instances provide for the most secure mounting of device  10 , it may be desirable and is certainly within the scope of the present invention to position adaptors  26  in interior openings either instead or as well. 
   Turning to  FIG. 3 , a device  10  is shown in accordance with the present invention with two adaptors  26  mounted therein, on each end opening  14 . Device  10  is mounted to underlying structures schematically illustrated at  28  using conventional fasteners  30  which can now be disposed through opening  32  of adaptors  26  and into structures  28  for use in mounting device  10  to structures  28  without risk of electrical communication or connection between fasteners  30  and block  12 . 
   In this regard, adaptors  26  are force fit into device  10 , and are preferably sized and adapted to fit snuggly into opening  14 . This in itself holds adaptor  26  securely within opening  14 . In addition, however, since mechanical fastener  30  will typically have an enlarged head which will pass over the top of adaptor  26 , the positioning of mechanical fastener  30  itself will also serve to hold adaptor  26  within opening  14  as desired. 
   Turning to  FIG. 4 , adaptor  26  is further illustrated and preferably is a substantially elongate and tubular member having a head portion  34  preferably defining a flange  36  which is sized to extend and overlap over the top edge  38  ( FIG. 3 ) of openings  14 . Adaptor  26  also has an intermediate portion  40  which is preferably provided having an outside diameter sized to frictionally engage with threads  18  of opening  14 . Adaptor  26  further has a lower portion  42  extending to an edge  44  of adaptor  16  which is sized, preferably, to match the size of the hole to be drilled through drilled bottom portion  24 . This preferred embodiment of adaptor  26  advantageously serves to allow for converting an unmountable opening  14  such as is illustrated in  FIG. 1  to a mountable opening such as is illustrated in  FIG. 3  for use with mechanical fasteners  30  and underlying mounting structures  28  as desired. 
   As set forth above, adaptors  26  can advantageously be provided from any suitable non-conductive material, many examples of which are well known to a person of ordinary skill in the art. 
   Further, adaptor  26  is preferably provided having a length from flange portion  36  to edge  44  which substantially corresponds to the length of opening  14  after drilling of drilled portion  24  such that adaptor  26  can be positioned with flange  36  resting on the top surface of block  12 , and with bottom edge  44  substantially flush with a bottom surface of insulative coating  20 . 
   It should be appreciated that adaptor  26  as illustrated in  FIGS. 2 ,  3  and  4  is a preferred embodiment, and it is well within the broad scope of the present invention to provide adaptor  26  having a different shape or structure, particularly, a different outer shape or structure, for use in engaging interior portions of opening  14 . For example, the stepped down size of adaptor  26  allows for a smaller hole to be drilled through bottom portion  24 , which is desirable so as to reduce impact upon the structural strength of the connector. Of course, it is well within the broad scope of the present invention to have an adaptor having a substantially straight outer wall. 
   It should also be noted that interior opening  32  of adaptor  26  is advantageously sized and dimensioned to receive a typical mechanical fastener, and this dimension can be adjusted as necessary or desired. It is preferable that opening  32  be of a size sufficient to receive the largest of any suitable size mechanical fastener which may be desired for use in connection with mounting device  10  as desired. 
   It should also be noted that conversion of an opening  14  to a mountable opening in accordance with the present invention and as described above serves to block the front and back opening  16  of device  10  for use in securement of conductive members. Front and back opening  16  for a converted opening  14  are advantageously filled with insulative plug members as described above. 
   It should further be noted that the drilling of bottom portion  24  is preferably done in a factory setting, where machining tolerances and requirements of uniformity can readily be met, as can regulatory codes for the manufacture of such articles. Of course, it is within the broad scope of the invention to modify a connector by drilling and positioning of an insert in other settings, or even on an as used basis, although in such settings other steps may be needed to ensure conformance of the converted part. 
     FIG. 5  shows a sleeve or adaptor  100  in accordance with a preferred embodiment of the present invention. Adaptor  100  advantageously includes a shoe  102  which is positioned at one end  104  of adaptor  100 . Shoe  102  extends radially relative to a diameter of the sleeve portion  106  of adaptor  100 , and thereby extends radially over a bottom surface of the converted block as will be illustrated in  FIG. 6 . 
   Still referring to  FIG. 5 , adaptor  100  in this embodiment can further advantageously include a sleeve collar  108  which is advantageously positioned and spaced along a longitudinal axis of adaptor  100 , relative to shoe  102 , which engages against a block which is converted using adaptor  100  so as to firmly secure adaptor  100  relative to the block as desired. In this regard, collar  108  advantageously engages the block. This is also further illustrated in  FIG. 6  discussed below. 
   Still referring to  FIG. 5 , adaptor  100  in this embodiment is advantageously provided in the form of two sleeve members  110 ,  112 , and shoe  102  is advantageously defined on one member  110 , while collar  108  is advantageously defined on the other member  112 . Members  110 ,  112  are further engagable one, relative to the other, for example through telescoping or force fit as in the embodiment of  FIG. 5 . More specifically, first sleeve portion  110  advantageously has a male or reduced-diameter portion  114 , and sleeve portion  112  advantageously has a corresponding female or receiving portion  116  which is sized to receive portion  114  of sleeve portion  110 . 
   As with the embodiment of  FIGS. 1-4 , adaptor  100  is advantageously adapted to force-fit within the opening in the block, and further to have a force-fit between elements  114  and  116 . This advantageously provides for reliable and secure engagement of the elements of adaptor  100 , and further of secure engagement of adaptor  100  with the block. 
   Shoe  102  is advantageous as will be further illustrated in  FIG. 6  described below because shoe  102  extends over a bottom surface of the insulated block and serves to space the entire connector assembly from the mounting structure. This advantageously serves to prevent undesirable arcing and/or to prevent spark from jumping between the block and mounting surface, particularly when exposed to rigorous testing conditions and the like. 
   Still referring to  FIG. 5 , a sleeve extension  118  can advantageously be provided and extending further upwardly or away from shoe  102  past collar  108 . This extending portion  118  advantageously allows the adaptor  100  to be securely engaged by a cap, also as will be discussed below. Extension  118  preferably extends at least about ⅜- 7/16″ past collar  108  for a typical-sized connector, and this length of extension  118  has been found to be advantageous in reliably insulating block  122  from a fastener positioned through adaptor  100 . 
   While the embodiment of  FIG. 5  shows elements  110 ,  112  as telescopingly engagable sleeves, it should be appreciated that the entire length of the sleeve could be defined as a single element, for example extending from shoe  102 , and collar  108  could be securable relative to this extended length sleeve. Conversely, the entire sleeve could be mounted relative to collar  108  and movably engagable with shoe  102  as well. Further, elements  110 ,  112  can be engagable in other ways, for example with threads or other securing structure, well within the broad scope of the invention. 
   Adaptor  100  in all other respects works in similar fashion to the adaptor discussed in connection with  FIGS. 1-4  and provides an insulative opening through the block for use in mounting the block to an underlying structure with a conventional fastener such as a bolt. 
   Turning now to  FIG. 6 , a connector assembly  120  is illustrated which includes an adaptor  100  in accordance with the present invention which is positioned within a block  122  which has been drilled to provide a hole passing therethrough in similar fashion to the embodiment of  FIGS. 1-4 . As shown, first sleeve portion  110  is positioned into this opening through a bottom opening  124  in block  122 , and second sleeve portion  112  is positioned into the opening from the upper opening  126  in block  122 . Portions  114 ,  116  of adaptor  100  are slidably engaged as shown, with sleeve collar  108  engaging an upper portion of block  122  and with shoe  102  extending over a bottom surface  128  of the insulative coating surrounding block  122 . As shown, shoe  102  advantageously serves to define or provide a gap between bottom surface  128  and the underlying mounting surface  130  as desired. 
   A fastener  132  is shown positioned through adaptor  100  and into mounting surface  130 , which advantageously results in mounting of connector assembly  120  relative to mounting surface  130  as desired. 
   After securing connector  132  as shown, a cap  134  can advantageously be positioned over the head of connector  132  and have an extending sleeve member  136  which is slidably engaged with sleeve extension  118  as discussed above. 
   The provision of shoe  102  and collar  108  advantageously serves to insure against arcing and other undesirable result when particularly large voltages are passed through the connector. This can be particularly helpful when subjected to conditions such as those required for UI rating. 
   It should be appreciated that adaptor  100  can advantageously be provided from any suitable material which is sufficiently insulative, and preferably which allows for a good force fit relative to block  122  and between the elements  110 ,  112  thereof. For example, these elements can be made of nylon as one non-limiting example. 
   Referring to both  FIGS. 5 and 6  together, and in similar fashion to the embodiments of  FIGS. 1-4 , adaptor  100  has an internal passage  138  which in this embodiment extends from shoe  102  along first portion  110  and including portion  114 , and which then continues in second portion  112 , and this embodiment from the top of portion  116  through collar  108  and sleeve extension  118 . When first and second portions  110 ,  112  are assembled, this passage  138  extends continuously through the entire adaptor  100  for receiving a connector as shown in  FIG. 6  and as desired. 
   It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, arrangement of parts and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope.