Abstract:
By providing two integrated components, an outer housing and an inner sleeve member, with the outer housing comprising a generally hollow cylindrical construction incorporating two threaded zones formed at both terminating ends, with the central portion of the hollow cylinder being formed in an arcuate curved shape, an efficient, easily manufactured and assembled cable connector is realized. Using the cable connector of the present invention, the desired metal sheath cable is quickly and easily secured to the connector and mounted in place in virtually any desired angular relationship, with complete assurance that the unwanted movement or withdrawal of the cable from the connector is virtually eliminated.

Description:
TECHNICAL FIELD 
       [0001]    This invention relates to electrical connectors, and more particularly, to electrical connectors constructed for securing metal sheath cables to junction boxes and/or outlet boxes. 
       BACKGROUND ART 
       [0002]    In the field of wiring homes and buildings, whether for new construction or for improvements or expansion, substantial development and product improvements have been made. Typically, these improvements are directed to enabling installers to securely mount any desired wiring in any desired location in the most efficient and quickest manner. 
         [0003]    In any particular installation or location, various cables must be interconnected to each other as well as connected to the primary power supply in a suitable power distributing junction box or fuse box. In each of these instances, metal sheath cables, within which the electric power carrying wires are contained, must be securely mounted to the housing of the junction box or outlet box, or connected to appropriate devices, in a protected area. 
         [0004]    In order to enable installers to securely mount metal sheath cables to any desired junction box or outlet box, numerous prior art connectors have been developed. However, in spite of the substantial effort that has been expended in developing such connectors, these prior art systems all have drawbacks or difficulties which prevent their universal adoption and use. 
         [0005]    In general, the industry has long sought to have a single cable connector which is quickly and easily secured to the end of the metal sheath cable and, once installed, is capable of preventing unwanted movement or dislodgement of the cable from the connector. In addition, the cable connector, with the cable secured therein, must be quickly mountable in secure engagement with any desired junction box or outlet box. Finally, all of these attributes must be achieved in a connector which is inexpensive, in order to enable its acceptance, use, and wide-spread adoption. 
         [0006]    One particular area in which a substantial demand exists for a cable connector, without any prior art product being produced for satisfying this need, is in the area of arcuately curved connectors. In many installations, both indoors and outdoors, installers are required to connect metal sheath cables to junction boxes and/or outlet boxes which require a curved or angular connection. Presently, several connectors are required to be mated with each other, in order to achieve the desired curved installation. However, no single, easily installed, affective, construction exists for enabling the direct connection of a metal sheath cable with a junction box and/or outlet box which requires mounted engagement about a curved area. 
         [0007]    In particular, this need is most evident in outdoor installations which require moisture proof or rain tight connections. In this regard, in a wide variety of installations, connections must be made to an outlet box and/or junction box wherein the connection must wrap around corners of the buildings, posts, housings, etc. which typically require a 90° or right angle mounted connection. In addition, other angular relationships exist which require mounted engagements at both acute angles and obtuse angles, all of which are not capable of being achieved using existing cable connectors. 
         [0008]    Although many prior art connectors have been developed which provide one or more of the attributes detailed above, no prior art connector has been developed which is capable of satisfying all of these long-sought requirements. Consequently, a long-felt need continues to exist for a cable connector meeting these requirements. 
         [0009]    Therefore, it is a principal object of the present invention to provide a connector for use with metal sheath cables which provides secure, rapid engagement and retention of the cable in the connector. 
         [0010]    Another object of the present invention is to provide a cable connector having the characteristic features described above which is also quickly and easily secured to any desired junction box or outlet box in a manner which assures secure retained engagement therewith. 
         [0011]    Another object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable, once mounted to the connector, is incapable of dislodgement or withdrawal. 
         [0012]    Another object of the present invention is to provide a cable connector having the characteristic features described above which is constructed with an arcuately curved housing for enabling any metal sheath cable to be interconnected to an outlet box and/or junction box mounted at angular relationships therewith. 
         [0013]    Another object of the present invention is to provide a cable connector having a characteristic features described above which is constructed with a housing that incorporates a right angle or 90° curved zone for enabling rapid interconnections around the corners of buildings, posts, housings, and the like. 
         [0014]    Another object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable connector is capable of being produced and assembled quickly and easily, thereby providing an inexpensive product. 
         [0015]    Another object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable connector automatically provides grounding and/or an electrical flow path through the junction box or outlet box when mounted thereto. 
         [0016]    A further object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable connector is self-centering when mounted in a receiving hole and provides a pre-loaded, spring biasing holding force thereto. 
         [0017]    Another object of the present invention is to provide a cable connector having the characteristic features described above wherein the cable connector is rain and/or moisture tight to enable its use outdoors or in other high moisture environments without difficulty. 
         [0018]    Other and more specific objects will in part be obvious and will in part appear hereinafter. 
       SUMMARY OF THE INVENTION 
       [0019]    By employing the present invention, all of the difficulties and drawbacks of the prior art systems have been overcome, and an efficient, easily manufactured and assembled cable connector is realized. Furthermore, using the cable connector of the present invention, the desired metal sheath cable is quickly and easily secured to the connector and mounted in place, with complete assurance that the unwanted movement or withdrawal of the cable from the connector is virtually eliminated. 
         [0020]    In the preferred embodiment, the cable connector of the present invention comprises two integrated components, an outer housing and an inner sleeve member. As detailed herein, the inner sleeve member is securely mounted to the outer housing in a manner which prevents its separation from the housing. As is more fully detailed below, the inner sleeve member is preferably press fitted into the housing in order to provide the desired secure, integrated affixation of these components. However, if desired, other securement methods well known in the industry may be used. 
         [0021]    Preferably, in this embodiment of the present invention, the outer housing comprises a generally hollow cylindrical construction incorporating two threaded zones formed at both terminating ends, with the central portion of the hollow cylinder being formed in an arcuate, curved shape. By employing this construction, the threaded terminating ends of the cable connector are effectively positioned at an angular relationship relative to each other, with an angular relationship preferably ranging between about 10° and 170°. Most typically however the terminating ends of the cable connector of the present invention are formed with an angular relationship ranging between about 750 and 105°. 
         [0022]    In addition, the first threaded end of the cable connector of the present invention incorporates a radially extending flange formed on the outer surface thereof directly adjacent the first threaded zone. In addition, the diameter of the first threaded zone is constructed for being associated with a conventional locking ring for being threadedly mounted therewith and inserted into receiving holes formed in conventional outlet boxes and/or junction boxes. In this way, the locking ring is advanced along the first threaded zone into locking abutting relationship with the wall of the outlet box or junction box and the radially extending flange. As a result, the first end of the cable connector of the present invention is quickly and easily inserted into receiving holes formed in conventional outlet boxes or junction boxes and quickly and easily securely mounted therein. 
         [0023]    Furthermore, in the preferred embodiment of the present invention, the cable connector also incorporates a sealing bushing or grommet in addition to the inner sleeve member and housing member. By employing the sealing bushing or grommet, a rain tight and/or moisture tight cable connection is attained, enabling the cable connector of this embodiment to be used in a wide variety of applications where high levels of moisture may exist. 
         [0024]    In order to assure that the desired rain tight and/or moisture tight cable connection is realized, the cable connector of the present invention is constructed for receiving the sealing bushing/grommet in the second end thereof, with the second end also being constructed for cooperative threaded mounted engagement with a gland nut or hex nut. In this construction, the sealing bushing/grommet is mounted in the cylindrical housing of the cable connector, with the gland nut or hex nut peripherally surrounding and being threadedly engaged with the threaded zone formed on the second end thereof. As a result, the gland nut/hex nut is quickly and easily threadedly mounted to the second end of the cable connector in direct association with the sealing bushing or grommet, providing the desired rain tight or moisture proof sealing construction. 
         [0025]    Furthermore, by employing the preferred embodiment of the present invention, the arcuate curved end of each arm member fully engages the outer surface of the cable throughout the entire width of the arm member. In addition, as stated above in the preferred embodiment, the distal end portion of each arm member may be split or bifurcated into two separate finger members, with each finger member preferably comprising two separate and independent angular relationships relative to the major portion of the arm member. By employing this construction, the distal end portions of the arm members are both pitched and sloped, relative to the major portion of the arm member, providing secure, locking engagement with the cable in a plurality of positions. 
         [0026]    By designing the slope and/or pitch angles to be substantially equivalent to the slope of the spiral juncture of the metal on the metal sheath cable, each finger of each arm member of the inner sleeve member engages the metal sheath cable directly along the juncture between the metal section, which is defined by the narrow portion or minor diameter of the cable. In this way, secure move-free engagement of the cable is realized and movement of the sheath cable relative to the sleeve member is prevented. Furthermore, by combining the slope and/or pitch angles with an arcuately curved end which matches the curvature of the cable, secure engagement of each finger of each arm member with the cable throughout the entire width of the arm member is achieved. 
         [0027]    If desired, the two arm members may be formed at different positions along the axial length of the sleeve member. In this way, the cable engaging end of each arm member interconnects with the metal sheath cable at different longitudinal spaced locations along the length of the cable. 
         [0028]    By constructing the inner sleeve member in the preferred manner, each arm member is able to engage the minor diameter of the spiral shaped juncture between the metal portions of the cable. In this way, secure engagement with the optimum area of the cable is provided and completely controlled movement-free securement of the cable by the inner sleeve is achieved. 
         [0029]    The invention accordingly comprises an article of manufacture possessing the features, properties, and the relation of elements which will be exemplified in the article herewith described, and the scope of the invention will be indicated in the claims. 
     
    
     
       THE DRAWINGS 
         [0030]    For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which: 
           [0031]      FIG. 1  is a perspective view of the fully assembled cable connector of the present invention; 
           [0032]      FIG. 2  is a front elevation view of the fully assembled cable connector of the present invention; 
           [0033]      FIG. 3  is a rear elevation view of the fully assembled cable connector of the present invention; 
           [0034]      FIG. 4  is a cross-sectional side elevation view of the cable connector of the present invention shown with the component thereof telescopically displayed; and 
           [0035]      FIG. 5  is a cross-sectional side elevation view of the cable connector of the present invention shown fully assembled. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    By referring to  FIGS. 1-5 , along with the following detailed disclosure, the construction and operation of this embodiment of electrical cable connector  20  of the present invention can best be understood. As will be evident to one having ordinary skill in the start, alternate constructions may be implemented using the teaching of the present invention without departing from the scope of this invention. However, it is to be understood that the constructions detailed herein are provided for exemplary purposes only, and are not intended as a limitation of the present invention. 
         [0037]    As shown in  FIGS. 1-5 , the principal components which form cable connector  20  of the present invention comprise housing  21 , inner sleeve member  22 , locking ring  23 , sealing bushing or grommet  24 , and gland nut or hex nut  25 . In addition, in the preferred embodiment, cable connector  20  also incorporates sealing rings  26  and  27 . By forming these component in the manner detailed below, and assembling them as shown in  FIGS. 1-5  as detailed herein, the desired unique, construction and configuration of cable connector  20  is realized. 
         [0038]    In this embodiment, cable connector  20  is constructed for enabling a shielded, metalclad, or metal sheath electrical cable  30  to be securely mounted to any desired electrical box, junction box, outlet box and/or housing in an easily achieved and quickly installed manner, with said mounted interengagement being achieved for arcuate or angular mounted installations. In addition, in the preferred embodiment, cable connector  20  of the present invention is constructed for enabling the electrical cable  30  to be mounted to the desired electrical box, junction box, outlet box, and/or housing in a moisture tight or rain tight environment. In this way, a wide variety of prior art difficulties and drawbacks are completely eliminated. 
         [0039]    As discussed above, many installations require shielded electrical cable  30  to be mounted to a junction box, outlet box, electrical box, and/or housing wherein these components are located outdoors, or in an environment where moisture is known to exist. As a result, the preferred embodiment of connector  20  of the present invention is constructed in a manner which ensures the secure affixation of electrical cable  30  to connector  20  in a completely moisture tight or rain tight manner. However, it desired, connector  20  may be constructed without the use of the moisture proof or rain tight components being employed. 
         [0040]    In order to achieve the desired mounted engagement of connector  20  in installations which require an angular connection to be made, connector  20  is constructed with housing  21  incorporating threaded zone  35  formed at one end of housing  21  and threaded zone  36  formed at the opposed end of housing  21 . 
         [0041]    In addition, housing  21  incorporates a central section  37  which is formed in an arcuately curved shape for enabling connector  20  to be mounted in locations requiring an angular connection. As shown in  FIGS. 1-5 , connector  20  is constructed with threaded end  35  angularly disposed relative to threaded end  36 . 
         [0042]    In this most typical construction, threaded end  35  is positioned substantially 90° relative to threaded end  36 . However, threaded ends  36  formed in connector  20  can be constructed with any desired angular relationship typically ranging between about 10° and 170°, with 75° to 105° being most typical. 
         [0043]    By employing the construction detailed above, connector  20  is able to be installed in locations in which no prior art connector is capable of being used. In this regard, connector  20  provides a single component which enables electrical cable  30  to be quickly and easily directly mounted to any desired junction box, outlet box, electrical box or housing wherein components are positioned at an angular relationship to each other. 
         [0044]    In the preferred embodiment, cable connector  20  of the present invention incorporates sealing bushing/grommet  24 , and sealing rings  26  and  27  in order to provide the desired rain tight or moisture proof construction. However, if desired, these components can be eliminated if a rain tight or moisture proof configuration is not required. 
         [0045]    Furthermore, in order to securely affix metalclad or metal sheath cable  30  to cable connector  20 , for enabling the electrical wires contained therein to be secured in the desired position in the outlet box, junction box, electrical box, or housing, cable connector  20  incorporates sleeve member  22  which is constructed for providing the desired mounted, interlocking interengagement of cable  30  with connector  20 . In a preferred construction, sleeve member  22  comprises a generally cylindrical shape which is configured for being advanced onto cable  30 , peripherally surrounding and lockingly engaging with the metalclad or metal sheath surface thereof. 
         [0046]    In this regard, sleeve member  22  comprises a generally hollow cylindrical shape having a diameter greater than the diameter of the outer surface of cable  30  while also incorporating arms  41  and  42  which are constructed for radially extending inwardly. In addition, arms  41  and  42  incorporate engaging tabs  43  and  44  formed at the terminating ends thereof and constructed for secure locking interengagement with the convolutions forming the outer surface of metalclad or metal sheath cable  30 . 
         [0047]    By employing this construction, or any other equivalent construction, sleeve member  22  is quickly and easily telescopically advanced onto cable  30  and lockingly engaged therewith, with arm members  41  and  42  peripherally surrounding and engaging the outer surface of cable  30 . Once in this position, sleeve member  22  is incapable of being removed from cable  30  using normal forces. 
         [0048]    In addition, in the preferred construction, sleeve member  22  is constructed for being press fitted into the receiving zone  38  of housing  21 . In this way, inner sleeve member  22  is inserted into receiving zone  38  of the housing  21  and advanced therein until frictional engagement is established between inner sleeve member  22  and housing  21 . Once in this position, sleeve member  22  and cable  30  are engaged and securely mounted to housing  21 . 
         [0049]    Once cable  30  and sleeve member  22  are securely mounted to housing  21  of cable connector  20 , and threaded zone  35  is secured to the desired cable box, outlet box, electrical box, or housing, the final installation of cable connector  20  is achieved. In this regard, in the preferred embodiment wherein a moisture proof or rain tight connection is desired, cylindrically shaped sealing bushing/grommet  24 , gland nut/hex nut  25 , and sealing ring  27  are mounted in place. Preferably, sealing bushing/grommet  24 , locking ring  26 , and gland nut/hex nut  25  are mounted on electrical cable  30  prior to inserting cable  30  into sleeve member  22  and mounting sleeve member  22  in housing  21 . 
         [0050]    In this way, as shown in  FIG. 5 , with these components mounted in position, cable  30  and sleeve member  22  are inserted into receiving zone  38  of housing  21  of connector  20 , causing sleeve member  22  to be frictionally mounted within receiving zone  38 . In addition, sealing bushing/grommet  24  is forced into the opening of receiving zone  38  for being compressed therein. Finally, in order to complete the installation, sealing ring  26  abuts the outer surface of sealing bushing/grommet  24 , and gland nut/hex nut  25  is threadedly mounted on threaded zone  36 . In this regard, as is evident from the foregoing detailed discussion, the outer diameter of threaded zone  36  and the inner diameter of gland nut/hex nut  25  are constructed for being threadedly interengaged with each other for assuring a secure mounted interconnection therebetween. 
         [0051]    With gland nut/hex nut  25  and sealing bushing/grommet  24  securely mounted in place, sealing bushing/grommet  24  is compressed into frictional engagement with cable  30 , peripherally surrounding cable  30  and effectively sealing the outer peripheral surface of cable  30  with the entry portal of receiving zone  38 . As a result, any moisture or rain which otherwise could enter through the portal of receiving zone  38  is substantially reduced or effectively eliminated. In this way, the desired moisture tight or rain tight securement of cable  30  with connector  20  is realized. If desired, added protection is provided by incorporating sealing ring  27  between gushing/grommet  24  and gland/hex nut  25 . In this way, an additional moisture or rain barrier is provided. 
         [0052]    In order to assure the sealing engagement of cable  30  with connector  20 , sealing bushing/grommet  24  is preferably formed for material suitable for providing deformation, compressibility, and sealing cooperation with cable  30 . In this regard, it has been found that nonconductive, elastomeric materials such as rubber-based products or thermoplastic elastomers can be effectively employed to achieve the desired results. As is evident from this disclosure, the actual material employed for sealing bushing/grommet  24  may be selected from a wide variety of alternate compositions, with the only limitation being the use of a material which is capable of compressively surrounding cable  30  and cooperating with cable  30  to effectively seal the entry portal of receiving zone  38 . 
         [0053]    Once cable  30  has been sealingly mounted to connector  20  in the manner detailed above, the assembly is completed by mounting connector  20  to the desired junction box, outlet box, electrical box, or housing. If desired, connector  20  may be mounted to the desired box or housing prior to the installation of cable  30 . 
         [0054]    Typically, in order to enable cable connector  20  of the present invention to be quickly and easily inserted into and lockingly engaged with the desired junction box, outlet box, electrical box or housing, threaded zone  35  of connector  20  is constructed with an overall diameter dimensioned for insertion into conventionally sized receiving holes formed in typical junction boxes, outlet boxes, electrical boxes, and housings. In this regard, these receiving holes are generally formed with a protective or knock-out plug or plate mounted therewith which enables the pre-formed holes to be quickly and easily opened for receiving connector  20 . 
         [0055]    Once threaded zone  35  of connector  20  is inserted through the desired hole of the outlet box, junction box, electrical box, and/or housing, locking ring or nut  23  is advanced along the threads of threaded zone  35  until locking ring/nut  23  is brought into abutting contact with the wall of the box or housing. Once secured in place, connector  20  is affixed to the desired box or housing, and the electrical wires contained in metalclad or metal sheath cable  30  can be secured in the desired positions. 
         [0056]    In the preferred construction, housing  21  of connector  20  incorporates radially extending flange  39  which peripherally surrounds threaded zone  35  and extends outwardly therefrom. In order to assure the desired cooperative interengagement, radially extending flange  39  comprises a diameter greater than the diameter of the aperture of the junction box, outlet box, electrical box, or housing into which connector  20  is secure. In this way, flange  39  prevents connector  20  from advancing into the aperture beyond the desired point by abutting the side wall of the junction box, outlet box, or housing, thereby assuring cable connector  20  is mounted in a precisely desired position. 
         [0057]    In order to securely affix connector  22  in the desired junction box, outlet box, electrical box, or housing, locking ring or nut  23  is employed. With connector  20  mounted in the desired position, as detailed above, locking ring/nut  23  is threadedly advanced onto threaded zone  35  of housing  21  by engaging the threads of the locking ring/nut therewith. Then, ring/nut  23  is advanced into secure engagement with the inside wall of the junction box, outlet box, electrical box, or housing, securely mounting connector  20  in the desired position. In addition, by employing the construction detailed above, connector is secured in a manner which provides rain tight or moisture proof mounting of cable  30 . 
         [0058]    In order to further enhance the rain tight or moisture proof construction, sealing ring  26  may be mounted between locking ring/nut  23  and the wall of the housing. In this way, added moisture protection is provided. 
         [0059]    As is evident from the foregoing detailed disclosure, the present invention is capable of being manufactured in numerous alternate embodiments, with each alternate embodiment incorporating a wide variety of alternate constructions. However, as is clearly evident to one having ordinary skill in the art, the various constructions can be freely employed with any embodiment, thereby further increasing the possible alternate constructions for the present invention which come within the scope of this discovery. Consequently, it is to be understood that the various embodiments detailed herein along with the construction details thereof, are provided for exemplary purposes and the alternate combinations of features, elements, and arrangement of parts and components can be achieved without departing from the scope of this invention. 
         [0060]    It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above article without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
         [0061]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.