Patent Publication Number: US-7585180-B2

Title: Method and apparatus for containing a conductor carrier in an electrical connector

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to modular panels, and, more particularly, to an electrical assembly which electrically connects modular wall panels, the electrical assembly including an electrical connector which contains an end of a conductor carrier. 
     2. Description of the Related Art 
     Modular wall panels are often used in office settings to separate workspaces. These workspaces are provided with electric power. To provide the electric power to the workspaces, electrical assemblies, such as jumper assemblies or power feed cable assemblies, are often used to provide connection within the line from the power source to the electric load. 
     Electrical assemblies can include a conductor carrier, conductors running within the conductor carrier, and electrical connectors coupled with each end of the conductor carrier and with each end of the conductors. Ends of the conductor carrier must be coupled securely to the electrical connectors. That is, upon pulling the conductor carrier in a direction away from the electrical connector with a predetermined force (applying the “pull test”), the conductor carrier should not separate from the electrical connector. To pass the pull test, a certain type and number of conductors are required. For example, if any wires are removed from the electrical assembly, the electrical assembly will not pass the pull test. A different electrical connector would be needed to accommodate the fewer number of wires, so as to pass the pull test. 
     What is needed in the art is an electrical connector having a post which positively retains within the electrical connector an end of a conductor carrier without regard for the type and number of conductors. 
     SUMMARY OF THE INVENTION 
     The present invention provides an electrical connector having a post which positively retains within the electrical connector an end of a conductor carrier without regard for the type and number of conductors. 
     The invention in one form is directed to an electrical connector configured for connecting with a conductor carrier and a plurality of conductors at least partially within the conductor carrier. The electrical connector includes a housing member and at least one post. The housing member includes a first wall and a second wall. The post is connected to the first wall, extends toward the second wall, and terminates at least near the second wall. The post is configured for extending through the conductor carrier and retaining within the housing member an end of the conductor carrier. In an embodiment of the present invention, the post can be configured for piercing the conductor carrier. 
     The invention in another form is directed to an electrical assembly including a conductor carrier, a plurality of conductors at least partially within the conductor carrier, and an electrical connector coupled with the plurality of conductors. The electrical connector includes a housing member and at least one post. The housing member includes a first wall and a second wall. The post is connected to the first wall, extends toward the second wall, extends through the conductor carrier, and terminates at least near the second wall, the post being disposed between at least two of the plurality of conductors. In an embodiment of the present invention, the post transversely pierces the conductor carrier. 
     The invention in yet another form is directed to a method of assembling an electrical assembly, including the steps of providing, coupling, and retaining. The step of providing includes providing a conductor carrier, a plurality of conductors at least partially within the conductor carrier, and an electrical connector coupled with the plurality of conductors and including a housing member, the housing member including a first wall and a second wall. The step of coupling includes coupling the conductor carrier with at least one post, wherein the post is connected to the first wall, extends toward the second wall, extends through the conductor carrier, and terminates at least near the second wall, the post being disposed between at least two of the plurality of conductors. The step of retaining includes retaining within the housing member an end of the conductor carrier. In an embodiment of the present invention, the coupling step includes the post transversely piercing the conductor carrier. 
     An advantage of the present invention is that it provides a simple mechanism for retaining an end of a conductor carrier, such as a mesh sleeve, within an electrical connector. 
     Another advantage is that the present invention provides an electrical connector which retains the mesh sleeve end while accommodating various types and numbers of conductors. 
     Yet another advantage is that the present invention provides a more economical electrical assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: 
         FIG. 1  is a sectional, bottom interior view of an electrical assembly according to the present invention showing a mesh sleeve surrounding wires; 
         FIG. 2  is a sectional, bottom interior view of the electrical assembly in  FIG. 1  without the mesh sleeve completely surrounding the wires; 
         FIG. 3  is a sectional, bottom interior view of the electrical assembly in  FIG. 1  taken along line A-A in  FIG. 1  showing the post of the present invention, the mesh sleeve, and the wires; 
         FIG. 4  is a perspective view of an electrical connector; 
         FIG. 5  is a side view of the electrical connector in  FIG. 4 ; 
         FIG. 6  is a bottom-side exterior view of the electrical connector in  FIG. 4 ; 
         FIG. 7  is a front view of the electrical connector in  FIG. 4  showing the post of the present invention; 
         FIG. 8  is an exploded, perspective view of the electrical connector in  FIG. 4  showing the post of the present invention; 
         FIG. 9  is a perspective, cross-sectional view of the electrical connector in  FIG. 4  taken along line B-B in  FIG. 6  showing one embodiment of the present invention; 
         FIG. 10  is a side, cross-sectional view of the electrical connector in  FIG. 4  taken along line B-B in  FIG. 6  showing the embodiment of the present invention of  FIG. 9 ; 
         FIG. 11  is a side, cross-sectional view of the electrical connector in  FIG. 4  taken along line B-B in  FIG. 6  showing another embodiment of the present invention; 
         FIG. 12  is a perspective, sectional, bottom interior view of an electrical connector showing the post of the present invention; 
         FIG. 13  is a sectional, bottom interior view of the electrical connector in  FIG. 12 ; and 
         FIG. 14  is a sectional, back, cross-sectional view of the electrical connector in  FIG. 12  taken along line C-C in  FIG. 13 . 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention, in more than one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, and more particularly to  FIGS. 1-3 , there is shown an electrical assembly  20  which generally includes a conductor carrier  22 , a plurality of conductors (i.e., wires)  24 , and at least one electrical connector  26 . Electrical assembly  20  can be, but is not limited to, a power feed assembly with a power feed connector or a jumper assembly. 
     Conductor carrier  22  can be a mesh sleeve which is pulled over wires  24 . Conductor carrier  22  includes a bottom portion  46 , a top portion  48 , and an end  62 . Conductor carrier  22  can include one or more pre-fabricated holes (not shown) in bottom and top portions  46 ,  48 . 
     Wires  24  are located at least partially within mesh sleeve  22  and include ends  64 . Additionally, while  FIGS. 1-2  show seven wires, more or less wires and various types of wires can be accommodated by conductor carrier  22  and electrical connector  26  depending upon the application. 
     Electrical connector  26  is configured for connecting with conductor carrier  22  and conductors  24 . As shown in  FIGS. 1-8 , electrical connector  26  includes a housing  28 . Housing  28  includes two opposing ends, a first end  30  having terminals and a second end  32 . The terminals of first end  30  couple with ends  64  of wires  24 . Housing  28  is entered through second end  32  by conductor carrier  22  and wires  24 . Housing  28  also includes a bottom wall  34 , a top wall  36 , and at least one post  38 ; housing  28  can, thus, include a single post  38  or a plurality of posts  38 . Bottom and top walls  34 ,  36  of housing  28  are respectively adjacent to bottom and top portions  46 ,  48  of mesh sleeve  22 . Bottom and top walls  34 ,  36  can be detachable relative to one another, as shown in  FIG. 8 . As shown in  FIGS. 9-10 , housing top wall  36  includes an inner surface  52 . Inner surface  52  can be level as shown in  FIGS. 9-10 , can define a recess  54  as shown in  FIG. 11 , or can define a hole (not shown). Housing  28  can include a plurality of teeth  40  arranged in a plurality of rows within housing  28  in a region of housing second end  32 . Additionally, various types and shapes of housing  28  can be used according to the present invention. 
     As shown in  FIG. 9 , post  38  has a first end  42  and a second end  44 . Post first end  42  is connected to bottom wall  34  in the region of second end  32  of housing  28 . From bottom wall  34 , post  38  extends toward top wall  36  in a longitudinal direction  58  of post  38 , as also shown in  FIG. 14 . Post second end  44  terminates at least near top wall  36 . Post second end  44  can contact top wall  36 . In so extending between bottom and top walls  34 ,  36 , post  38  extends through mesh sleeve  22  in a direction transverse to a running direction of mesh sleeve  22 , as shown in  FIGS. 1-3 . In extending transversely through mesh sleeve  22 , post  38  is disposed between at least two wires  24 , as shown in  FIGS. 1-2 . 
     In extending transversely through mesh sleeve  22 , post  38  enters bottom portion  46  of mesh sleeve  22 , passes by wires  24 , and exits mesh sleeve  22  through top portion  48  of mesh sleeve  22 . In entering and exiting bottom and top portions  46 ,  48  of mesh sleeve  22 , post  38  can transversely pierce bottom and top portions  46 ,  48 . Alternatively, post  38  (or the plurality of posts  38 ) can slidably enter and/or exit the one or more pre-fabricated holes (not shown) in bottom and/or top portions  46 ,  48  of conductor carrier  22 . Post  38  does not necessarily exit top portion  48  of mesh sleeve  22 . Post  38  can be mounted to top wall  36  of housing  28 , rather than bottom wall  34 . 
     As shown in  FIGS. 9-10 , post second end  44  terminates at—that is, contacts—inner surface  52  of top wall  36  at a place of contact between post second end  44  and inner surface  52 , inner surface  52  of the place of contact being substantially level with inner surface  52  which surrounds the place of contact. Alternatively, post second end  44  can terminate near but not contact inner surface  52 , inner surface  52  being substantially level in a region of inner surface  52  near post second end  44 . Alternatively, as shown in the embodiment of the present invention in  FIG. 11 , post second end  44  can enter and terminate in recess  54 , recess  54  being complementary in shape to post second end  44 . Alternatively, post second end can enter and terminate in the hole (not shown) in top wall inner surface  52 , the hole being complementary in shape to post second end  44 . 
     Post  38  has a transverse cross-section in a direction  56  transverse to longitudinal direction  58  of post  38 , as shown in  FIG. 14 . Thus, post  38  has a transverse cross-section at post first end  42  and a transverse cross-section at post second end  44 . Post first end  42 , which is connected to bottom wall  34 , can have a greater transverse cross-sectional extent than post second end  44 , which terminates at least near top wall  36 . Post  38  transverse cross-sectional extent can taper evenly running in longitudinal direction  58  from first end  42  to second end  44 , as a cone. Alternatively, post  38  transverse cross-sectional extent can taper unevenly running in longitudinal direction  58  from first end  42  to second end  44 . Alternatively, post  38  transverse cross-sectional extent can be substantially the same running in longitudinal direction  58  of post  38 , as a cylinder. 
     Post  38  transverse cross-section can take on a variety of shapes. These shapes include, but are not limited to, a circle, a triangle, a square, an ellipse, and a rectangle. 
     In another embodiment of post  38  as shown in  FIGS. 13-14 , post second end  44  can taper at an angle suitable for piercing mesh sleeve  22 . For example, post second end  44  can include a tip  60  which forms a relatively sharp point at approximately a center of transverse cross-section of post second end  44 . 
     Post  38  serves, alone or in combination with teeth  40 , to retain within housing  28  end  62  of mesh sleeve  22 . Post  38  can be made integral with housing  28  or be made detachable from housing  28 . 
     To assemble electrical assembly  20 , post  38  couples with mesh sleeve  22 , and mesh sleeve end  62  is retained within housing  28 . In coupling post  38  with mesh sleeve  22 , post  38  is connected to bottom wall  34  and extends toward top wall  36 . In so extending between bottom and top walls  34 ,  36 , post  38  extends transversely through mesh sleeve  22 . Post  38  terminates at least near top wall  36 . In extending through mesh sleeve  22 , post  38  is disposed between at least two wires  24 . Additionally, in coupling post  38  with mesh sleeve  22 , post  38  can transversely pierce mesh sleeve  22  through bottom and top portions  46 ,  48  of mesh sleeve  22 . Furthermore, electrical assembly  20  can include two opposing ends (only one end shown in drawings), each end including electrical connector  26  coupled with mesh sleeve  22  and wires  24 . Each electrical connector  26  includes at least one post  38  which retains within housing  28  ends  62  of mesh sleeve  22 . 
     While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.