Abstract:
For use with a flexible cable having a central current carrying electrical conductor, a symmetrical layer of insulation concentrically surrounding the central conductor, a symmetrical circumferential layer of shielding conductor surrounding the layer of insulation, and a symmetrical outer sheath of insulation surrounding the shielding conductor, a wiring system formed of a fitting of conductive material having a passageway therethrough that receives the flexible cable, a short length shield connector of bare conductive metal having a first portion inserted through an opening in the flexible cable outer sheath of insulation to conductively engage the cable circumferential layer of shielding conductor and having a second portion that remains exterior of the flexible cable outer sheath of insulation; and a short length electrically conductive tubular ground ring slidably received on the cable and overlying a portion of the shield connector, the ground ring being crimpable whereby when crimped it securely engages the exterior of the cable and the shield connector, the fitting being slidably positioned over the ground ring, continuity thereby being provided from the cable shielding conductor through the shield connector and the ground ring to the fitting.

Description:
REFERENCE TO PENDING APPLICATIONS 
     This is a formal application based on Provisional Application No.60/176,268, filed Jan. 14. 2000 entitled, HIGH VOLTAGE WIRING SYSTEM FOR NEON LIGHTS that is a continuation-in-part of U.S. patent application Ser. No. 09/455,185 filed on Dec. 6, 1999 entitled A SHIELDED WIRING SYSTEM FOR HIGH VOLTAGE AC CURRENT, which is a divisional of U.S. patent application Ser. No. 09/009,168 entitled A HIGH VOLTAGE WIRING SYSTEM FOR NEON LIGHTS, filed Jan. 20, 1998 and now U.S. Pat. No. 5,998,736 issued Dec. 7, 1999. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to a waterproof high voltage wiring and connector system particularly useful in wiring neon lights. 
     Luminous gaseous signs have been used for many years. While such signs can employ a variety of gases, the most popular and effective signs use neon gas and are referred to as “neon signs”. Neon signs are typically formed of glass tubing that is evacuated of substantially all of the air therein and refilled with neon gas. A conductive probe is inserted into each of the opposed ends of the tube. When high voltage energy is applied to the opposed ends of a neon filled tube, the neon gas is excited and produces visible electromagnetic radiation. The glass tubes can be of varying diameters and can easily be conformed to replicate letters, numbers and designs. The visible spectrum of light provided by excited neon gas is relatively bright and attractive; therefore the use of neon signs has become exceedingly popular in the United States and other countries of the world. 
     A serious problem that arises with the use of neon signs is the danger of fire and high voltage shock to workman who install or repair them. The typical neon sign transformer in the United States can be powered by standard household current, that is, 120V 60 Hz AC but the voltage typically supplied by the transformer and applied to neon signs is approximately 15,000V 60 Hz AC. This high voltage is dangerous to workman and any other living organism that may come in contact with the wiring for the neon sign. Further, this high voltage is also frequently the cause of building fires. Fifteen thousand volts AC readily arcs across adjacent conductors or from a conductor to a ground and such arcing can ignite combustible materials. The danger of fire as a consequence of this high voltage has become of such concern that some municipalities discourage the use of neon signs. In some cases, neon signs are being replaced by other types of signs that do not require high voltage electrical current. 
     Others have provided electrical fittings and wiring systems that are useful to supply high voltage electrical current, such as for connecting neon signs. For background information relating to other systems, reference may be made to the following United States patents: 
     
       
         
               
               
               
             
           
               
                   
               
               
                 U.S. Pat. No. 
                 INVENTOR 
                 TITLE 
               
               
                   
               
             
             
               
                 2,245,681 
                 Kenigserg 
                 Interchangeable Unit Luminous 
               
               
                   
                   
                 Gaseous Sign 
               
               
                 3,142,721 
                 Long 
                 Connector for Joining the 
               
               
                   
                   
                 Outer Conductor of a Coaxial 
               
               
                   
                   
                 Cable to a Wall 
               
               
                 4,090,029 
                 Lundeberg 
                 Liquid Tight Connector with 
               
               
                   
                   
                 Improved Ground Conductivity 
               
               
                 4,590,950 
                 Iwaszkiewicz et al. 
                 Electrical Connection 
               
               
                 4,690,482 
                 Chamberland et al. 
                 High Frequency, Hermetic, 
               
               
                   
                   
                 Coaxial Connector for Flexible 
               
               
                   
                   
                 Cable 
               
               
                 4,737,601 
                 Gartzke 
                 Hermetically Sealed Electrical 
               
               
                   
                   
                 Feedthrough and Method of 
               
               
                   
                   
                 Making Same 
               
               
                 4,842,535 
                 Velke, Sr. et al 
                 Gas Tube Electrode Connector 
               
               
                 5,166,477 
                 Perin, Jr. et al 
                 Cable and Termination For 
               
               
                   
                   
                 High Voltage and High 
               
               
                   
                   
                 Frequency Applications 
               
               
                 5,214,243 
                 Johnson 
                 High-Temperature, Low-Noise 
               
               
                   
                   
                 Coaxial Cable Assembly With 
               
               
                   
                   
                 High Strength Reinforcement 
               
               
                   
                   
                 Braid 
               
               
                 5,217,392 
                 Hosler, Sr. 
                 Coaxial Cable-to-Cable Splice 
               
               
                   
                   
                 Connector 
               
               
                 5,439,386 
                 Ellis et al 
                 Quick Disconnect 
               
               
                   
                   
                 Environmentally Sealed RF 
               
               
                   
                   
                 Connector For Hardline 
               
               
                   
                   
                 Coaxial Cable 
               
               
                 5,645,450 
                 Yamada et al. 
                 Shielded Connector 
               
               
                 5,773,759 
                 Hablutzel 
                 Screw-Type Conduit Fitting for 
               
               
                   
                   
                 a Shielded Cable 
               
               
                   
               
             
          
         
       
     
     BRIEF SUMMARY OF THE INVENTION 
     The invention is concerned with a waterproof high voltage wiring and connector system for transferring high voltage electrical AC current from a high voltage power source to an apparatus, such as a neon sign. When the apparatus is a neon sign, the typical high voltage transformer may, as an example, employ a primary winding activated by 120V 60 Hz AC as is commonly used in the United States. The transformer converts the 120V 60 Hz AC electrical energy into high voltage 60 Hz electrical energy typical in a range of about 15,000 volts. This disclosure provides a waterproof connector useful in systems for safely conducting high voltage to individual segments of a neon sign. 
     This invention is basically concerned with a wiring and connector system by which a high voltage AC current is transported from a two pole high voltage transformer to a neon sign, one pole of the transformer being at ground potential and the other pole of the transformer being at a high AC voltage relative to ground. The system employs a flexible cable having in cross-section: (a) a central current carrying electrical conductor; (b) a symmetrical layer of insulation concentrically surrounding the central conductor; and (c) a symmetrical circumferential layer of metallic woven shielding conductor surrounding the layer of insulation. The cable usually also has an outer layer of plastic or rubber insulation. 
     An important application of the connector to be described is for passing high voltage through a metal wall having an opening therethrough. A short length cylindrical pass-through body has a nominal external diameter less than that of the opening. The pass-through body has a first end and second end. Spaced between the first and second ends of the pass-through body is an integral enlarged external diameter flange. An integral tubular first portion extends from the flange to the body second end and a tubular second portion extends from the flange to the body second end. External threads are provided on the exterior of the pass-through body first portion. A coaxially insulated conductor extends through the pass-through body. A ground conducting lug is centered within the pass-through body. The tubular second portion of the pass-through body is then crimped (compressed) to make permanent contact with the ground shield connection and also to form strain relief for the completed cable system. 
     The first tubular portion of the pass-through body that is externally threaded receives a nut by which the pass-through fitting can be secured in an opening in a device. 
     The ground conducting lug provides continuity between the metallic woven shielding conductor of the cable and the pass-through body. The ground conducting lug is formed of an elongated thin strip of highly conductive material, such as copper. An opening is cut into the cable outer insulation sheathing. A U-shaped bent inner portion of the ground conducting lug is inserted through the opening so as to lie against the outer surface of the cable metallic woven shielding conductor to thereby provide electrical communication between the cable shielding conductor and the pass-through connector. 
     Positioned over an outer portion of the ground conducting lug and surrounding the cable is a ground ring, that is, a ring of conductive material dimensioned to be easily slid over the exterior of the cable. The ground ring, after being positioned over the external part of the ground conducting lug and over the U-shaped inner part of the lug that is within the outer insulation sheathing of the cable is mechanically crimped to shrink it in diameter around the exterior of the cable and to secure electrical contact with the ground conducting lug. After the ground ring is crimped the pass-through fitting is slid over it so that the ground ring is positioned within the pass-through fitting. 
     After the pass-through fitting is slid over the installed crimped ground ring the thin wall integral second tubular portion of the pass-through body is itself crimped against the exterior of the cable. The crimped portion engages the ground conducting lug so that the pass-through body is then in electrical continuity with the metallic woven jacket of the cable. 
     The combination of a crimped ground ring and a crimped pass-through body provides an improved fitting for the neon sign industry. The cable resists pull from the pass-through body. Further, a waterproof closure is obtained around the cable. 
     A better understanding of the invention will be obtained from the following description of the preferred embodiments taken in conjunction with the attached drawings. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevational cross-sectional enlarged view of a pass-through fitting showing its use in passing a high voltage cable through an opening in a metal wall. 
     FIG. 2 is an elevational cross-sectional view of the pass-through fitting as taken along the line  2 — 2  of FIG.  1 . 
     FIG. 3 is an elevational cross-sectional view of the pass-through fitting as taken along the line  3 — 3  of FIG.  1 . 
     FIG. 4 is an elevational cross-sectional view of am improved pass-through fitting having a high voltage cable received therein. 
     FIG. 5 is a cross-sectional view of the fitting and cable taken along the line  5 — 5  of FIG.  4 . 
     FIG. 6 is an elevational view of a ground conducting lug as employed in the fitting of FIGS. 4 and 5. 
     FIG. 7 is a top plan view of the ground conducting lug taken along the line  7 — 7  of FIG.  6 . 
     FIG. 8 is an isometric view of a ground ring as employed in the fitting of FIGS. 4 and 5. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     This invention is concerned with a waterproof high voltage connector that is particularly useful in neon power cabling for transferring high voltage electrical energy from a high voltage source, typically a transformer, to one or more electrical energy consuming devices, such as neon light tubes. FIGS. 1,  2  and  3  illustrates one embodiment of the system that employs a pass-through assembly or a pass-through connector that is useful for passing high voltage electrical energy through a wall and illustrates a means of providing electrical continuity and electromagnetic field shield continuity through the wall. The device when installed as shown in FIGS. 1,  2  and  3  also insures that a positive ground path is established with the wall. These Figures show a metallic wall  10  of an energy producing or consuming device. Wall  10  has an opening  12  therein. The objective is to pass through opening  12  a cable  14  in a way to maintain a substantially uniform electromagnetic field and insure a positive ground path from a ground conductor within the cable to wall  10 . 
     Received within opening  12  is a pass-through fitting  16  having a first end  18 , a second end  20 , an intermediate flange section  22  and a central opening  24  extending therethrough. Integral outwardly extending flange  22  separates the first end portion and the second end portion of the fitting. External threads  26  are formed on the fitting body extending from flange  22  to first end  18 . Integrally extending from flange  22  to second end  20  is a reduced external diameter tubular portion  28 . To retain pass-through fitting  16  within opening  12 , nut  30  is employed. Wall  10  is captured between flange  22  and nut  30 . 
     Cable  14  includes a central conductor  32  having inner insulation  34  thereon, the insulation being surrounded by a metallic woven jacket  36 . An outer insulating sheathing  38  surrounds the metallic woven jacket. 
     Extending through a small slit in the cable outer insulating sheathing  38  is an inner portion of a ground/shield connection  40 . Ground/shield connection  40  has an external portion that is positioned within fitting tubular portion  28 . After cable  14  and ground/shield connection  40  are placed in the fitting  16  as shown in FIG. 1, tubular portion  28  is externally compressed, that is, crimped. Crimping of tubular portion  28  of fitting  16  provides a positive electrical connection between the fitting and cable ground/shield  40  and provides positive strain relief for the cable relative to wall  10 . 
     Further, and of most significance, ground shield connection  40  electrically grounds metallic jacket  36  of cable  14  to pass-through fitting  16  and thereby to wall  10 . 
     By arranging a high voltage wiring system for neon signs wherein the electric field is maintained concentric to the high voltage conductor throughout the system and wherein the possibility of a point of concentration of the electric field is eliminated or at least substantially minimized, the possibility of failure of the wiring system is greatly reduced. The pass-through connector of FIGS. 1,  2  and  3  demonstrate how a system can be constructed so that throughout the entire system, including connections, pass-throughs and so forth, lines of electric field force are concentrically maintained. Thus, the possibility of failure of the high voltage wiring system for a neon sign is substantially reduced. 
     FIGS. 4-8 illustrate an improved embodiment of the invention as shown in FIGS. 1-3 in which the same numerals are employed for comparable elements. A portion of a wall of a piece of equipment is illustrated by numeral  10 , the wall being of metal and having an opening  12  therein. The invention provides a connector for passing a high voltage cable  14  through wall  10  by way of opening  12 . Cable  14  includes a primary conductor  32  that is surrounded by inner insulation  34 . Around inner insulation  34  is a metallic woven jacket  36  that serves as a shielding conductor. On the exterior of woven jacket  36  an outer insulation, usually plastic sheathing, is formed. Cable  14  including elements  32 ,  34 ,  36  and  38  as has been previously described with reference to FIGS. 1,  2  and  3 , is a typical high voltage conductor and is characteristic of high voltage conductors employed, in the neon sign industry. The cable  14  is a single conductor that typically includes only one primary conductor  32  as compared with a type of wiring utilized for transmitting a low voltage electrical current of the type employed for wiring buildings, including homes. In the typical wiring for neon lights, one pole of a high voltage circuit is connected to central conductor  32  while the other pole is connected to ground. That is, the return path of an electrical circuit employing cable  14  is by ground. Further, the metallic woven jacket  36  of cable  14  is typically connected to ground and provides one return ground path for current flow. 
     The connector used to extend cable  14  through wall  10  is a pass-through tubular fitting  16  that has a first end  18  and a second end  20 . Intermediate the ends is a radially extending flange  22 . Between flange  22  and first end  18  is a tubular body portion  17  that is provided with external threads  26 . 
     Received on tubular body portion  17  is a nut  30  that holds the fitting flange  16  in electrical and physical contact with wall  10  and thereby secures cable  14  in relationship to wall  10 . 
     Extending between flange  22  and second end  20  of fitting  16  is a tubular portion  28  that has a wall thickness less than that of the tubular body portion  17 . The tubular portion  28  is configured to be mechanically crimped to the exterior of cable  14 . The mechanical crimping of tubular portion  28  can take place before or after fitting  16  is installed in opening  12  of wall  10 . In one way of practicing the invention, the weatherproof high voltage connector as shown in FIG. 4 is attached to the length of cable  14  at a factory, or a shop, before the cable with the attached connector is brought to a job site. In another way of practicing the invention, the cable can be secured within the fitting and the tubular portion  28  crimped at the job site. There are advantages in providing an assembly that is, a length of cable having secured to it a fitting in a factory or shop rather than the assembly operation taking place on the job since in a factory or shop the quality control can be more carefully monitored. 
     A feature of pass-through fitting  16  that forms the waterproof high voltage connector is that it is grounded or has continuity with metallic woven jacket  36  of cable  14 . This is accomplished by cutting a small slit at a location identified by the numeral  29  in FIG. 4 in the outer insulation sheathing  38  of cable  14 . The small slit cuts the outer insulation  38  but does not cut woven metal jacket  36 . A ground conducting lug  40 A is employed to provide a conducting path between metal woven jacket  36  of cable  14  and fitting  16 . A ground conducting lug  40 A, as shown in FIGS. 6 and 7, is a unitary length of relatively thin elongated electrically conducting metallic strip, typically formed of copper. The ground conducting lug  40 A can initially be in the shape of an elongated narrow relatively thin piece of copper or similar metal that is bent into a U-shaped or hook arrangement as shown in FIG. 6 to have a long leg  41  and a short leg  43  that is bent back parallel to leg  41 , with an integral bight portion  45  therebetween. 
     After the small slit  29  is cut in cable outer insulation sheathing  38  the short leg portion  43  of grounding lug  40 A is inserted through the slit and the ground conducting lug is positioned so that the bight portion  45  extends through the slit with the short leg portion  43  lying in contact with an external surface of woven metal jacket  36  and with the long leg portion  41  lying in contact with the external surface of the cable outer insulation sheathing  38 . 
     The embodiment of FIGS. 4-8 employs an additional element that is not used in the embodiment of FIGS. 1,  2  and  3  and that is, a ground ring  46  that is illustrated isometrically in FIG.  8 . The ground ring is a short length tubular member that normally has an internal diameter greater than the external diameter of cable  14  so that the ground ring can be slid over the cable  14 . The ground ring  46  is a tubular member of relatively thin highly conductive metal such as copper. After the ground conducting lug  40 A is installed through a slit cut at  29  in the outer installation sheathing  38  of cable  14  the ground ring  46  is slid into position to overlay short leg  43  and a portion of the long leg  41  of ground conducting lug  40 A. The ground ring  46  is then crimped that is, it is circumferentially compressed and distorted to cause it to conform tightly about cable  14  and about ground conducting lug  40 A. 
     After the ground conducting lug  40 A is installed on cable  14  and the ground ring crimped in position as indicated, fitting  16  can then be slid in position as shown in FIG. 4 so that the tubular body portion  17  of the fitting overlays ground ring  46 . Fitting tubular portion  28  overlays a portion of the long leg  41  of the ground conducting lug. 
     While fitting  16  can be formed with a constant internal diameter, in the preferred embodiment, as illustrated, the fitting has two concentric internal diameters that is, the tubular portion  28  has a central opening  24  with a given internal diameter while the fitting tubular body portion  17  has a slightly enlarged internal diameter  47 . The slightly enlarged diameter  47  allows the fitting to be slid over the crimped ground ring  46 . The internal diameter of central opening  24  is such as to be snug but slidable on cable  14  with sufficient clearance to receive the outer end of the ground lug long leg  41  as shown in FIG.  4 . 
     When ground conducting lug  40 A has been installed in cable  14  and ground ring  46  is positioned and crimped, fitting  16  is slidably positioned in place as shown in FIG.  4  and then fitting tubular portion  28  is crimped by application of a crimping tool to its exterior surface. Crimping of fitting tubular portion  28  securely locks it in place on cable  14  and securely establishes electrical continuity between ground conducting lug  40 A and the fitting  16 . Thus the continuity between the metal woven jacket  36  of cable  14  and fitting  16  is positively established by ground paths augmented by crimped ground ring  46  and crimped tubular portion  28  of the fitting. Further, the crimping of tubular portion  28  forms a watertight compression of the fitting tubular portion  28  against the external surface of cable  14 . The fitting, when installed in the method described, is securely attached to the external surface of cable  14  in a way that resists slidable displacement of the fitting relative to the cable that is, the fitting when installed has a high pull resistance load and at the same time a waterproof contact is made between the central opening  24  of the fitting and the exterior of cable  14 . 
     Thus the waterproof high voltage connector system as shown in FIGS. 4-8 is an improvement to the basic high voltage wiring system as shown in FIGS. 1-3. The differences between the embodiment of FIGS. 1-3 and that of FIGS. 4-8 is that the latter embodiment provides an increased load resistance that is, the fitting can tolerate a higher force tending to pull cable  14  out of connector  16  and at the same time, the resistance against the passage of water through the connector is substantially increased. 
     The claims and the specification describe the invention presented and the terms that are employed in the claims draw their meaning from the use of such terms in the specification. The same terms employed in the prior art may be broader in meaning than specifically employed herein. Whenever there is a question between the broader definition of such terms used in the prior art and the more specific use of the terms herein, the more specific meaning is meant. 
     While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled.