Patent Publication Number: US-8974245-B2

Title: Grounding electrical connector

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to a grounding electrical connector. More particularly, the present invention relates to a toolless and hardwareless (i.e., without separate fasteners) grounding electrical connector that is connectable to a support. Still more particularly, the present invention relates to a grounding electrical connector that receives various conductor sizes and connects to various support thicknesses. 
     BACKGROUND OF THE INVENTION 
     Grounding electrical connectors, such as lay-in lugs, are typically used for installation of a ground conductor. A fastener opening in a first portion receives a fastener to secure the connector to a support. A second fastener opening receives a set screw that extends into an opening that receives the ground conductor. The set screw engages the received ground conductor to secure the ground conductor thereto. 
     One disadvantage associated with existing grounding electrical connectors is that connecting the grounding electrical connector to the support can be a time-consuming task. A corresponding fastener hole must be formed in the support such that it can receive the fastener. Supports typically have a non-conductive coating that must be removed prior to connecting the grounding electrical connector. An installer must have the proper tools to form the fastener hole in the support and remove the non-conductive coating, as well as carrying the proper fasteners to secure the grounding electrical connector to the support. Accordingly, a need exists for a grounding electrical connector that is quickly and easily connected to a support. 
     The installer must also emply another fastener, typically a set screw, that secures the ground conductor to the grounding electrical connector. The set screw can loosen over time, which can be accelerated by movement of the conductor, thereby adversely affecting the integrity of the ground connection. Some existing grounding electrical connectors are formed from several components, some of which are movable, thereby further increasing the number of parts that the installer must have on hand during installation. Accordingly, a need exists for a grounding electrical connector having few components that is simple to install. 
     Precise torques or tools are often required to properly install existing grounding electrical connectors and secure grounding conductors thereto. The necessary tools required for installation increases the inventory of necessary parts to be carried by the installer, as well as increasing the difficulty of the installation. Accordingly, a need exists for a toolless grounding electrical connector. 
     Existing grounding electrical connectors are expensive due to machining, plating and the use of copper. Accordingly, a need exists for an inexpensive grounding electrical connector that is easily manufactured. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide an improved grounding electrical connector. 
     Another object of the present invention is to provide a grounding electrical connector that is quickly and easily connected to a support. 
     Another object of the present invention is to provide a grounding electrical connector that is inexpensive, has few parts and is easily manufactured. 
     Another object of the present invention is to provide a grounding electrical connector that is toollessly and hardwarelessly connectable to a support. 
     Another object of the present invention is to provide a grounding electrical connector that toollessly and hardwarelessly secures a ground conductor thereto. 
     The foregoing objectives are basically attained by a grounding electrical connector including a base member and first and second legs extending outwardly from the base member. A first recess is defined by the first and second legs for receiving a support. Second recesses extend inwardly from second sides of the first and second legs. A plurality of pairs of oppositely disposed grooves are formed in the second recesses. At least two pairs of the oppositely disposed grooves have different sizes for receiving various conductor sizes. 
     The foregoing objectives are also basically attained by an electrical connecting including a grounding electrical connector having a base member and first and second legs extending outwardly from the base member. First recesses extend inwardly from first sides of the first and second legs. The first recesses are connectable to a support. First pairs of upper and lower flexible tabs extend outwardly from upper and lower sides of the first recesses in the first and second legs and toward one another. Second recesses extend inwardly from second sides of the first and second legs. Second pairs of upper and lower flexible tabs extend outwardly from upper and lower sides of the second recesses in the first and second legs and toward one another. A plurality of oppositely disposed grooves are formed in free ends of the second pairs of upper and lower flexible tabs. At least two pairs of the oppositely disposed grooves have different sizes for receiving various conductor sizes. A channel member is connected to the base member and has a channel extending between each pair of oppositely disposed grooves to facilitate receiving a conductor. 
     Objects, advantages, and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the present invention. 
     As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the exemplary embodiments of the present invention, and are not intended to limit the structure thereof to any particular position or orientation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above benefits and other advantages of the various embodiments of the present invention will be more apparent from the following detailed description of exemplary embodiments of the present invention and from the accompanying drawing figures, in which: 
         FIG. 1  is a perspective view of a grounding electrical connector in accordance with a first exemplary embodiment of the present invention; 
         FIG. 2  is a side elevational view of the electrical connector of  FIG. 1 ; 
         FIG. 3  is a rear elevational view of the electrical connector assembly of  FIG. 1 ; 
         FIG. 4  is a front elevational view of the electrical connector of  FIG. 1 ; 
         FIG. 5  is a top plan view of the electrical connector of  FIG. 1 ; 
         FIG. 6  is a bottom plan view of the electrical connector of  FIG. 1 ; 
         FIG. 7  is an upper perspective view of the electrical connector of  FIG. 1  connected to a support and receiving a conductor; 
         FIG. 8  is a lower perspective view of the electrical connector connected to the support of  FIG. 7 ; 
         FIG. 9  is a side elevational view of the electrical connector connected to the support of  FIG. 7 ; 
         FIG. 10  is a front elevational view of the electrical connector connected to the support of  FIG. 7 ; 
         FIG. 11  is a rear elevational view of the electrical connector connected to the support of  FIG. 7 ; 
         FIG. 12  is a perspective view of a grounding electrical connector in accordance with a second exemplary embodiment of the present invention; 
         FIG. 13  is a top plan view of the electrical connector of  FIG. 12 ; 
         FIG. 14  is a rear elevational view of the electrical connector of  FIG. 12 ; 
         FIG. 15  is a side elevational view of the electrical connector of  FIG. 12 ; 
         FIG. 16  is a front elevational view of the electrical connector of  FIG. 12 ; 
         FIG. 17  is a bottom plan view of the electrical connector of  FIG. 12 ; 
         FIG. 18  is a front perspective view of the electrical connector of  FIG. 12  connected to a support and receiving a conductor; 
         FIG. 19  is a rear perspective view of the electrical connector connected to the support of  FIG. 18 ; 
         FIG. 20  is a top plan view of the electrical connector connected to the support of  FIG. 18 ; 
         FIG. 21  is a rear elevational view of the electrical connector connected to the support of  FIG. 18 ; 
         FIG. 22  is a side elevational view of the electrical connector connected to the support of  FIG. 18 ; 
         FIG. 23  is a front elevational view of the electrical connector connected to the support of  FIG. 18 ; 
         FIG. 24  is a bottom plan view of the electrical connector connected to the support of  FIG. 18 ; 
         FIG. 25  is a perspective view of a grounding electrical connector in accordance with a third exemplary embodiment of the present invention; 
         FIG. 26  is a top plan view of the electrical connector of  FIG. 25 ; 
         FIG. 27  is a rear elevational view of the electrical connector of  FIG. 25 ; 
         FIG. 28  is a side elevational view of the electrical connector of  FIG. 25 ; 
         FIG. 29  is a front elevational view of the electrical connector of  FIG. 25 ; 
         FIG. 30  is a bottom plan view of the electrical connector of  FIG. 25 ; 
         FIG. 31  is a front perspective view of the electrical connector of  FIG. 25  connected to a support and receiving a conductor; 
         FIG. 32  is a rear perspective view of the electrical connector connected to the support of  FIG. 31 ; 
         FIG. 33  is a top plan view of the electrical connector connected to the support of  FIG. 31 ; 
         FIG. 34  is a rear elevational view of the electrical connector connected to the support of  FIG. 31 ; 
         FIG. 35  is a side elevational view of the electrical connector connected to the support of  FIG. 31 ; 
         FIG. 36  is a front elevational view of the electrical connector connected to the support of  FIG. 31 ; 
         FIG. 37  is a bottom plan view of the electrical connector connected to the support of  FIG. 31 ; 
         FIG. 38  is an upper perspective view of a grounding electrical connector in accordance with a fourth exemplary embodiment of the present invention; 
         FIG. 39  is a lower perspective view of the electrical connector of  FIG. 38 ; 
         FIG. 40  is a top plan view of the electrical connector of  FIG. 38 ; 
         FIG. 41  is a rear elevational view of the electrical connector of  FIG. 38 ; 
         FIG. 42  is a side elevational view of the electrical connector of  FIG. 38 ; 
         FIG. 43  is a front elevational view of the electrical connector of  FIG. 38 ; 
         FIG. 44  is a bottom plan view of the electrical connector of  FIG. 38 ; 
         FIG. 45  is a front perspective view of the electrical connector of  FIG. 38  connected to a support and receiving a conductor; 
         FIG. 46  is a rear perspective view of the electrical connector connected to the support of  FIG. 45 ; 
         FIG. 47  is a top plan view of the electrical connector connected to the support of  FIG. 45 ; 
         FIG. 48  is a rear elevational view of the electrical connector connected to the support of  FIG. 45 ; 
         FIG. 49  is a side elevational view of the electrical connector connected to the support of  FIG. 45 ; 
         FIG. 50  is a front elevational view of the electrical connector connected to the support of  FIG. 45 ; 
         FIG. 51  is a bottom plan view of the electrical connector connected to the support of  FIG. 45 ; 
         FIG. 52  is an upper perspective view of a grounding electrical connector in accordance with a fifth exemplary embodiment of the present invention; 
         FIG. 53  is a lower perspective view of the grounding electrical connector of  FIG. 52 ; 
         FIG. 54  is a top plan view of the electrical connector of  FIG. 52 ; 
         FIG. 55  is a rear elevational view of the electrical connector of  FIG. 52 ; 
         FIG. 56  is a side elevational view of the electrical connector of  FIG. 52 ; 
         FIG. 57  is a front elevational view of the electrical connector of  FIG. 52 ; 
         FIG. 58  is a bottom plan view of the electrical connector of  FIG. 52 ; 
         FIG. 59  is a front perspective view of the electrical connector of  FIG. 52  connected to a support and receiving a conductor; 
         FIG. 60  is a rear perspective view of the electrical connector connected to the support of  FIG. 59 ; 
         FIG. 61  is a top plan view of the electrical connector connected to the support of  FIG. 59 ; 
         FIG. 62  is a rear elevational view of the electrical connector connected to the support of  FIG. 59 ; 
         FIG. 63  is a side elevational view of the electrical connector connected to the support of  FIG. 59 ; 
         FIG. 64  is a front elevational view of the electrical connector connected to the support of  FIG. 59 ; and 
         FIG. 65  is a bottom plan view of the electrical connector connected to the support of  FIG. 59 . 
     
    
    
     Throughout the drawings, like reference numerals will be understood to refer to like parts, components and structures. 
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     A grounding electrical connector in accordance with exemplary embodiments of the present invention is shown in  FIGS. 1-65 . The electrical connector is preferably unitarily formed as a single member and is made of a conductive material. The electrical connector is adapted to receive various conductor sizes and to be connected to supports having varying thicknesses. 
     A grounding electrical connector  11  in accordance with a first exemplary embodiment of the present invention connects a ground conductor  12  to a support  13 , as shown in  FIGS. 7-11 . For example, the electrical connector can be used to connect an equipment ground conductor to a solar photovoltaic (PV) module frame or module mounting structure. 
     The electrical connector  11  includes a base member  14 , as shown in  FIGS. 1-6 , and has an upper surface  15  and a lower surface  16 . A resilient channel member  17  is connected to the upper surface  15  of the base member and has a plurality of channels  18  extending between first and second opposite sides  21  and  22  of the base member  14 . As shown in  FIGS. 1 and 5 , the channel member  17  has three channels  18 ,  19  and  20 , although the channel member may have any suitable number of channels. The channel member  17  preferably does not extend the entire length of the upper surface  15  between the first and second sides  21  and  22 , as shown in  FIG. 1 . As shown in  FIGS. 1 ,  3  and  4 , the electrical connector  11  is preferably substantially U-shaped. 
     A first leg  23  extends outwardly from the first side  21  of the base member  14 . Preferably the first leg  23  is substantially perpendicular to the base member  14 , as shown in  FIGS. 3 and 4 . The first leg  23  has first and second opposite sides  24  and  25 . A first recess  26  extends inwardly from the first side  24  of the first leg  23 . A second recess  27  extends inwardly from the second side  25  of the first leg  23 . The second recess  27  is preferably disposed between the first recess  26  and the base member  14 . 
     Upper and lower flexible tabs  28  and  29  extend outwardly and toward one another from opposite sides  30  and  31  of the first recess  26 , as shown in  FIGS. 1 and 2 . The distance between the free ends of the flexible tabs  28  and  29  decreases inwardly in a direction away from the first side  21  to facilitate receiving the support  13  therein. 
     Upper and lower flexible tabs  47  and  48  extend outwardly and toward one another from opposite sides  50  and  51  of the second recess  27 , as shown in  FIGS. 1 and 2 . The distance between the free ends of the flexible tabs  47  and  48  decreases inwardly to facilitate receiving the support  13  therein. 
     A plurality of pairs of grooves are formed in the free ends of the flexible tabs  47  and  48 , as shown in  FIGS. 1 and 2 , to facilitate receiving the conductor  12  therebetween. A first pair of grooves  32  and  33  is disposed proximal the closed end of the second recess  27 . A second pair of grooves  34  and  35  is disposed adjacent the first pair of grooves  32  and  33 . A third pair of grooves  36  and  37  is disposed proximal the open end of the second recess  27 . The groove sizes are different to facilitate receiving different conductor sizes. As shown in  FIG. 2 , the grooves increase in size from the first pair to the third pair. For example, the first pair of grooves  32  and  33  is sized to receive a 10 AWG conductor, the second pair of grooves  34  and  35  is sized to receive an 8 AWG conductor, and the third pair of grooves  36  and  37  is sized to receive a 6 AWG conductor. Accordingly, the different groove sizes facilitates receiving different conductor sizes. Any suitable combination and orientation of grooves can be used based on conductor sizes to be received by the grounding electrical connector  11 . 
     A second leg  38  is substantially similar to the first leg  23  and extends outwardly from the second side  22  of the base member  14 . Preferably the second leg  38  is substantially perpendicular to the base member  14 , as shown in  FIGS. 3 and 4 . The second leg  38  has first and second opposite sides  39  and  40 . A first recess  41  extends inwardly from the first side  39  of the second leg  38 , and is aligned with the first recess  26  in the first leg  23 . A second recess  42  extends inwardly from the second side  40  of the second leg  38 , and is aligned with the second recess  27  in the first leg  23 . The second recess  42  is preferably disposed between the first recess  41  of the second leg  38  and the base member  14 . 
     Upper and lower flexible tabs  43  and  44  extend outwardly and toward one another from opposite sides  45  and  46  of the first recess  41 , as shown in  FIG. 1 . The distance between the free ends of the flexible tabs  43  and  44  decreases inwardly to facilitate receiving the support  13  therein. 
     Upper and lower flexible tabs  52  and  53  extend outwardly and toward one another from opposite sides  54  and  55  of the second recess  42 , as shown in  FIG. 1 . The distance between the free ends of the flexible tabs  43  and  44  decreases inwardly to facilitate receiving the support  13  therein. 
     A plurality of pairs of grooves are formed in the free ends of the flexible tabs  52  and  53 , as shown in  FIGS. 1 and 11 , to facilitate receiving the conductor  12  therebetween. A first pair of grooves  56  and  57  is disposed proximal the closed end of the second recess  42 . A second pair of grooves  58  and  59  is disposed adjacent the first pair of grooves  56  and  57 . A third pair of grooves  60  and  61  is disposed proximal the open end of the second recess  42 . The groove sizes are different to facilitate receiving different conductor sizes. As shown in  FIG. 11 , the grooves increase in size from the first pair to the third pair. For example, the first pair of grooves  56  and  57  is sized to receive a 10 AWG conductor, the second pair of grooves  58  and  59  is sized to receive an 8 AWG conductor, and the third pair of grooves  60  and  61  is sized to receive a 6 AWG conductor. Accordingly, the different groove sizes facilitate receiving different conductor sizes. Any suitable combination and orientation of grooves can be used based on conductor sizes to be received by the grounding electrical connector  11 . 
     The channel member  17  is connected to an upper surface  15  of the base member  14 , as shown in FIGS.  1  and  3 - 5 . Preferably, a rear wall  66  connects the channel member  17  to the base member  14 , thereby providing flexibility to the channel member  17  such that the channel member  17  extends from a fixed end  67  connected to the rear wall to a free end  68  spaced from the rear wall  66 . The channels  18 ,  19  and  20  extend from a first side  62  to a second side  63  of the channel member  17 , as shown in  FIG. 1 . Preferably, the first side  62  is spaced inwardly from the first leg  23  and the second side  63  is spaced inwardly from the second leg  38 , as shown in  FIGS. 3 and 4 . A lower surface  64  of the channel member  17  is spaced upwardly from the base member  14 , as shown in  FIGS. 7 and 8 . A recess  65  is formed in the base member  14  corresponding to the channel member  17 . The free front end  66  of the channel member  17  is resilient such that various diameter conductors can be quickly and easily inserted in the second recesses  27  and  42  of the first and second legs  23  and  38  and securely held therein by the flexible tabs pressing against the inserted conductor. 
     The grounding electrical connector  11  is preferably unitarily formed as a single member and is made of a conductive material, such as stainless steel. The grounding electrical connector  11  can be stamped out of a single piece of conductive material. 
     Assembly and Operation 
     As shown in  FIGS. 7-11 , an electrical connector  11  in accordance with an exemplary embodiment of the present invention is connected to the support  13 , such as a solar PV module frame or module mounting structure. The electrical connector  11  receives the conductor  12 , such as an equipment ground conductor, to mechanically and electrically connect the conductor  12  to the support  13 . 
     The first recesses  26  and  41  in the first and second legs  23  and  38  receive a substantially planar member  69  of the support  13 . The decreased distance between the first ends of the flexible tabs  28  and  29  of the first leg  23  and the flexible tabs  43  and  44  of the second leg  38  facilitate inserting the planar member  69  in the first recesses  26  and  41 . The flexible tabs extend toward one another such that movement of the electrical connector  11  causes the flexible tabs to tighten their grip on the planar member  69 . The flexibility of the tabs facilitates connecting the electrical connector  11  to supports having various thicknesses. 
     The second recesses  27  and  42  in the first and second legs  23  and  38  receive the conductor  12 . The decreased distance between the first ends of the flexible tabs  47  and  48  of the first leg  23  and the flexible tabs  52  and  53  of the second leg  38  facilitate inserting the conductor  12  in the second recesses  27  and  42 . The flexible tabs extend toward one another such that movement of the conductor  12  causes the flexible tabs to tighten their grip on the conductor  13 . 
     The oppositely disposed pairs of grooves in the flexible tabs of the second recesses  27  and  42  have different sizes to accommodate various conductor sizes. As shown in  FIGS. 10 and 11 , three pairs of grooves are shown sized to receive 6, 8 and 10 AWG conductors. The channels  18 ,  19  and  20  in the channel member  17  have sizes corresponding to the pair of grooves between which the channels extend, thereby facilitating receiving the conductor  12 . The free end  68  of the channel member  17  facilitates flexing of the channel member  17  to more easily receive the inserted conductor  12  and to increase conductive surface area contact between the conductor  12  and the connector  11 . 
     Second Exemplary Embodiment 
     A grounding electrical connector  111  in accordance with a second exemplary embodiment of the present invention is shown in  FIGS. 12-17 . The electrical connector  111  is shown connected to a support  113  and receiving a ground conductor  112  in  FIGS. 18-24 . The electrical connector  111  is substantially similar to the electrical connector  11  of the first exemplary embodiment shown in  FIGS. 1-11 . Similar features are indicated with the same reference numeral, except in the 100 series, e.g., 1xx. 
     The electrical connector  111  includes third and fourth legs  171  and  172  that extend inwardly from ends of the first and second legs  123  and  138 , as shown in  FIGS. 12-17 . The third and fourth legs  171  and  172  are substantially planar to the base member  114  from which the first and second legs  123  and  138  extend, respectively. The third and fourth legs  171  and  172  are preferably substantially perpendicular to the first and second legs  123  and  138 . 
     A recess or gap  173  is formed between free ends  174  and  175  of the third and fourth legs  171  and  172 , as shown in  FIGS. 12 and 13 . The gap  173  tapers or narrows from a first end  176  to a second end  177  of the gap. The gap  173  receives the substantially planar member  169  of the support  113 , as shown in  FIGS. 18-24 . Inserting the planar member  169  of the support  113  in the gap  173  between the third and fourth legs  171  and  172  of the electrical connector  111  causes the conductor  112  to be more tightly gripped. 
     Third Exemplary Embodiment 
     A grounding electrical connector  211  in accordance with a third exemplary embodiment of the present invention is shown in  FIGS. 25-30 . The electrical connector  211  is shown connected to a support  213  and receiving a ground conductor  212  in  FIGS. 31-37 . The electrical connector  211  is substantially similar to the electrical connector  11  of the first exemplary embodiment shown in  FIGS. 1-11 . Similar features are indicated with the same reference numeral, except in the 200 series, e.g., 2xx. 
     The electrical connector  211  includes third and fourth legs  271  and  272  that extend inwardly from ends of the first and second legs  223  and  238 , as shown in  FIGS. 25 ,  27  and  29 . The third and fourth legs  271  and  272  are substantially planar to the base member  214  from which the first and second legs  223  and  238  extend, respectively. The third and fourth legs  271  and  272  are preferably substantially perpendicular to the first and second legs  223  and  238 . 
     Fifth and sixth legs  273  and  274  extend downwardly toward the base member  214  from the third and fourth legs  271  and  272 , as shown in  FIGS. 25 ,  27  and  29 . The fifth and sixth legs  273  and  274  are preferably substantially parallel to the first and second legs  223  and  238 . 
     Upper openings  275  and  276  in the fifth and sixth legs  273  and  274  are aligned with the openings  226  and  241  in the first and second legs  223  and  238  to receive the substantially planar member  269  of the support  213 , as shown in  FIGS. 31-37 . The upper openings  275  and  276  extend forwardly from a rear end of the fifth and sixth legs  273  and  274 . 
     Lower openings  277  and  278  in the fifth and sixth legs  273  and  274  are aligned with the openings  227  and  242  in the first and second legs  223  and  238  to receive the conductor  212 , as shown in  FIGS. 31-37 . The lower openings  277  and  278  extend rearwardly from a front end of the fifth and sixth legs  273  and  274 . A plurality of grooves are formed in the lower openings  277  and  278  that correspond to the grooves formed in the openings  227  and  242  to accommodate various conductor sizes. Accordingly, each of the grooves in the lower openings  277  and  278  is a different size. 
     As shown in  FIG. 30 , the base member  214  is preferably a substantially planar and continuous member. The lower openings  277  and  278  in the fifth and sixth legs  273  and  274  support the conductor  212  such that a channel member  17  ( FIG. 1 ) is not required. The free ends of the fifth and sixth legs  273  and  274  are preferably spaced above the base member  214 , as shown in  FIGS. 27 and 29 . The fifth and sixth legs  273  and  274  provide additional openings to receive the planar support member  269  and the conductor  212 , thereby improving the retention and electrical connection of the grounding electrical connector  211 . 
     Fourth Exemplary Embodiment 
     A grounding electrical connector  311  in accordance with a fourth exemplary embodiment of the present invention is shown in  FIGS. 38-44 . The electrical connector  311  is shown connected to a support  313  and receiving a ground conductor  312  in  FIGS. 45-51 . The electrical connector  311  is substantially similar to the electrical connector  211  of the third exemplary embodiment shown in  FIGS. 25-37 . Similar features are indicated with the same reference numeral, except in the 300 series, e.g., 3xx. 
     Tabs  379  and  380  extend from free ends of the fifth and sixth legs  373  and  374  toward the first and second legs  323  and  338 , respectively, as shown in  FIGS. 38 ,  39 ,  41  and  43 . A plurality of grooves  381  are formed in the free ends of the fifth and sixth legs  373  and  374 , corresponding to the grooves in the openings  327  and  342  in the first and second legs  323  and  338 , to facilitate receiving different diameter conductors. The tabs  379  and  380  facilitate retaining the conductor  312  and creating an electrical connection thereto. 
     Fifth Exemplary Embodiment 
     A grounding electrical connector  411  in accordance with a fifth exemplary embodiment of the present invention is shown in  FIGS. 52-58 . The electrical connector  411  is shown connected to a support  413  and receiving a ground conductor  412  in  FIGS. 59-65 . The electrical connector  411  is substantially similar to the electrical connector  11  of the first exemplary embodiment shown in  FIGS. 1-11 . Similar features are indicated with the same reference numeral, except in the 400 series, e.g., 4xx. 
     The electrical connector  411  is preferably made from a rectangular tube. The electrical connector  411  has an upper planar member  491  substantially parallel to the base member  414 , as shown in  FIGS. 52 ,  55  and  57 . The upper planar member  491  extends between the first and second legs  323  and  338 . Manufacturing the electrical connector  411  from a tube provides rigidity to the resulting electrical connector, in addition to providing manufacturing options. 
     The foregoing embodiments and advantages are merely exemplary and are not to be construed as limiting the scope of the present invention. The description of exemplary embodiments of the present invention is intended to be illustrative, and not to limit the scope of the present invention. Various modifications, alternatives and variations will be apparent to those of ordinary skill in the art, and are intended to fall within the scope of the invention as defined in the appended claims and their equivalents.