AU3009200A

AU3009200A - Electrical connector assembly

Info

Publication number: AU3009200A
Application number: AU30092/00A
Authority: AU
Inventors: Robert Julian Gretton Tomkies
Original assignee: Sales & Promotions Nz Ltd
Current assignee: Sales & Promotions (nz) Ltd
Priority date: 1999-04-09
Filing date: 2000-04-11
Publication date: 2000-10-12
Also published as: NZ335172A

Description

11/e4/20@@ 04:58 +6444965949 1 +6444965949 A PETER \IERBfJEKET COPAE4 PAGE e4 Form No.

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Application No.: a. a a a a a *taaa* a Application Date, 10 April 2000 Priority Dates: 9 April 1999 (New Zealand Patent Application No. 3351 72) Applicant: SALES PROMOTIONS (NZ) LIMITED 161 Cuba Street Petone NEW ZEALAND Address for Service: Peter Charles Robert VERBOEKET Patent Attorney Suite 904 91b Floor Hunter Street Sydney NSW 2000 Complete Specification for the invention entitled: 'Electrical Connector Assembly" The following statement is a full description of this invention, including the best method of performing it known to us: RECEIVED TIMElI. APR. 2: 59PRN IEIAR. 81 PRINT TIMEIIAPR. 8:16 A PETER VERBOEKET CO PAGE 11/04/2000 04:'5B +6444965949 +6444965949 ELECTRICAL CONNECTOR ASSEMBLY Technical Field This invention relates to electrical connector assemblies. More particularly, but not exclusively, the present invention relates to electrical connector assemblies for establishing a releasable physical and electrical connection between one electrical cable and another, or between an electrical cable and a power supply or draw off point.

Background Art Conventional electrical connector assemblies allow for cables to be fed through an aperture in, or at the part line of, the top cover of the plug and are screwed into a terminal carrier at the side adjacent the top cover. A disadvantage with this arrangement is that the wires in the cables can be easily pulled from the terminal mountings leading to loss of power or an electrical short. Some designs minimise this problem by screwing a link against the cable to prevent the cable from being pulled away from the terminal mountings. However, although this method of o*oo securement can be effective, it is time consuming, requires the use of a tool to complete the task, and involves substantial disassembly of the connector.

It is an object of the invention to provide a device for connecting electrical cables, cords and the like that overcomes at least some of the abovementioned problems, or at least to provide the public with a useful choice.

Summary of The Invention According to a first broad aspect of the invention there is provided an electrical connector, which connector includes a body portion and a front casing portion, wherein the front casing portion is releasably attachable to a front face of the body 2 RECEIVED TIME11. APR. 2:59 PRINT TIMEII. APR. 8:16 11/04/2000 ,84:58 +6444965949 PETER VERBOEKET CO PAGE 86 +6444965949 portion, the body portion having a cable entry aperture and a passageway through the body portion from that aperture to the front face of the body portion, the body portion further including one or more terminal connectors located adjacent its front face and accessible with the front casing portion removed from the body portion for, in use, establishing an electrical connection to an electrical cable to which the connector is attached, and an electrical contact means associated with each terminal connector to, in use, enable electrical connection to a further electrical connector or a power supply or draw off point while the front cover portion is attached to the body portion.

Preferably the body portion further includes cable securing means to, in use, secure a cable in to the connector.

Preferably the cable securing means comprises a clamping jaw located in the passageway of the body portion. Optionally there are a pair of clamping jaws.

o Desirably the clamping jaws are pivotally operable to clamp a said cable perpendicularly to its longitudinal axis.

Preferably the cable securing means further includes urging means to urge the clamping jaws into engagement with a said cable. Desirably the urging means is incrementally operable. Conveniently the urging means is operable by way of screw threading action on the clamping jaws, and the jaws are ramp shaped, with the ramps extending longitudinally of the passageway.

Preferably the connector further includes a secondary cable securing means adjacent the entrance to the passageway in the body portion. Desirably the secondary cable securing means provides, in use, a seal around a said cable and the passageway entrance.

3 RECEIVED TIME11. APR. 2:59 PRINT TIMEII. APR. 8:16 11/04/2000 04:58 +6444965949 A PETER VERBOEKET CO PAGE 07 +6444965949 Conveniently the secondary cable securing means includes an annulus of overlapping fingers which can be urged to slidably overlap at their free ends to constrict the cross sectional size of the passageway.

Preferably the secondary cable securing means further includes an annular elastomeric gasket between the passageway and the overlapping fingers.

Conveniently the passageway is straight.

Preferably the body portion includes a back casing portion threadably connectable to the remainder. Desirably rotation in one direction of the back casing urges the overlapping fingers to constrict the passageway cross section and bear on the elastomeric gasket. Conveniently rotation of the back casing in that direction also results in the clamping jaws being urged to move inwardly towards the centre of the passsageway.

Preferably the back casing portion and the front casing portion are engageable to capture the remainder of the body portion substantially entirely therebetween.

Conveniently engagement of the front and back casing portions produces a substantially liquid tight seal.

Brief Description Of The Drawings Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1: illustrates a front end view of the body portion of a first preferred embodiment of the invention with the wiring of an electrical extension cord connected in place; and 4 RECEIVED TIME11. APR, 2:59 PRINT TIMEII. APR. 8:16 11/04/2000 04:58 +6444965949 A PETER VERBOEKET CO PAGE 08 +6444965949 Figure 2: illustrates the same view as Figure 1, but without the wiring of the extension cord; and Figure 3: illustrates a partially cut away exploded side elevational view of an electrical connector according to a first embodiment of the invention, incorporating the body portion of Figure 1; and Figure 4: illustrates a partially cut away side elevation of a fully assembled electrical connector according to Figure 3 mounted at an end of an electrical extension cord; and Figure 5: illustrates a partially cut away exploded side elevational view of an electrical connector according to a second embodiment of the invention; and Figure 6: illustrates a partially cut away side elevation of a fully assembled electrical connector according to Figure mounted at an end of an electrical extension cord; and Figure 7: illustrates a partially cut away side elevation of a fully assembled electrical connector according to Figure 4 releasably connected to, and forming an electrical union with, a fully assembled electrical connector according to Figure 6.

Description of the Preferred Embodiments Referring to figures 1 to 4, an electrical connector, as generally indicated by 1, according to a first embudiment of the invention, is illustrated.

RECEIVED TIME11. APR. 2:59 PRINT TIMEII. APR. 8:15 11/04/2008 ,04:58 +6444965949 A PETER VERBOEKET CO PAGE 09 +6444965949 The connector 1 illustrated is in a form typically referred to as an electrical plug.

The second connector embodiment, generally identified in figures 5 to 7 as 2, being the corresponding electrical socket releasably engageable with connector 1.

The connectors 1 and 2 are substantially similar, and have substantially similar features and components. In all of the figures and in the description below like components are therefore like numbered and named.

Each connector 1,2 comprises a body portion 3, a front casing portion 4, and a back casing 5. The front casing 4 is engageable with the back casing 5 to substantially fully enclose the body portion 3 therebetween and therewithin.

The body portion 3 includes a wire mounting plate 6 upstanding perpendicularly and centrally from one side of which extends a tubular wire guide means 7.

On the opposite side of the mounting plate 6 to the wire guide means 7 are provided terminal carriers 8. The number of terminal carriers 8 provided will depend on the nature of the electrical usage of the connectors 1,2. In the illustrated embodiments a single phase domestic arrangement is shown in the typical phase, neutral and earth configuration, and thus three terminal carriers 8 are shown. It will, however, be appreciated that in some instances only two terminal carriers 8 will be required, or in the case of a three phase system, the orientation and electrical function of each terminal carrier 8 will be different. Each terminal carrier 8 includes a wire securing means 9. The wire securing means may be of any known form such as, for example and as illustrated, a terminal screw screwing into a terminal post or pin (not visible).

The terminal carriers 8 are spaced around the periphery of the mounting plate 6, with the centre of the plate 6 having an aperture 11 therethrough to the wire guide means 7. As shown in figure 1, when connected to an electrical cable 40 wires 41, 42 and 43 extend through the aperture 11 from the wire guide means 7. The wires 41, 42 and 43 then radiate away from the aperture 11 following a predetermined 6 RE CEIVED T IMEI 1. APR. 2: 5 PRINT TIMEII. APR. 8:15 11/04/2000 04:58 +6444965949 A PETER \ERBGEKET CO PAGE +6444965949 pathway 12 until the wires approach the periphery of the mounting plate 6 whereupon the pathway 12 changes from radial to circumferential leading the wires 41, 42, 43 to their corresponding wire securing means 9.

An advantage of the pathway 12 is that the wires 41, 42, 43 undergo two changes in direction, each of approximately 90 degrees, which decreases the direct stress on the wire securing means 10 should the free end of the cable 40 be pulled, and transfers that stress to along the length of wire 41, 42, 43 and pathway 12 thereby reducing the probability of the electrical connection between the wire and terminal *screw 10 failIi ng.

In the connector 1 which, as noted earlier, serves as a typical electrical plug, each terminal carrier 8 includes a prong 13 of known shape and configuration. The shape and configuration of each prong 13 being a feature of the electrical function its corresponding wire serves, and of the electrical system standard the plug is intended to comply with. The connector 2, being as noted earlier, a socket design, has a recess (not shown) electrically connected to the corresponding terminal carrier 8 to receive and engage physically and connect electrically with a corresponding prong 13 of a said connector 1, or of a like electrical plug.

tubular wire guide means 7 extending perpendicularly outwardly of the mounting plate 6 terminates in an annulus of gripping fingers 14 which overlap and can be urged to slidleably engage one another to increasingly constrict the cross sectional area of the internal bore 15. An elastomeric gland or gasket 16 lines the bore 15 adjacent the fingers 14 to, in use, provide an intermediary layer between the constricting fingers 14 and the wire 40 passing through the bore The gland 16 is located in position at the lower end of the fingers 14 by way of an internal step 1 7 in the bore 1 5, and is prevented from moving significantly beyond the free ends 18 of the fingers 14 by the manner of constriction of the fingers 14 under urging pressure, namely, the free ends constrict more rapidly than sections of the fingers 14 closer to the connected end 19, thereby locating the gland 16 in place in use.

7 ft L %J LI V LUi I 11I I 1 L JI L fLI OL I I 1Y1LI I, A I A U. I 11/04/2000 04:58 +6444965949 aPETER VERBOEKET CO PA' +6444965949 Immediately beneath the connected ends 19 of the fingers 14 the tubular wire guide means 7 is externally threaded for a section 20 along its length. A pair of clamping jaws 21 extend radially into the bore 15 part way along the length of the threaded portion 20 of the guide means 7.

Each of the jaws 21 is of substantially ramp like configuration, oriented parallel to the bore 1 5, with the thin end 22 of the ramp closer the free end of the guide means 7 and the thicker end 23 closer to the mounting plate 6. An aperture 24 exists in the side of the guide means 7 to accommodate each clamping jaw 21, with the thin end 22 only of the jaw 21 connected to the aperture 24. The jaw 21 has an external surface contoured to follow the threaded pattern of the guide means 7 adjacent its location, however, in moving from the thin end 22 to the thicker end 23 of the jaw 21 it and the corresponding threading increasingly sit proud of the surrounding threading on the guide means 7. Moving from the thin end 22 to the thick end 23 of the jaw 21 it also extends further and further into the bore As previously discussed, the front casing 4 is engageable with the back casing 5 to substantially fully enclose the body portion 3.

The back casing 5 is shaped and configured substantially as a cap, and has an aperture 25 centrally located in the cap sized to, in use, receive an electrical cable Depending into the cap from the aperture 25 is an internal tubular portion 26 one end of which internally screw threaded and shaped and configured to engage with the guide means 7 of the body portion 3. The other end of the tubular portion 26, adjacent the aperture 25, necks down in funnel-l ike fashion to, in use, slideably engage and co-operate with the fingers 14 of the guide means 7.

The front casing 4 is of drum-like configuration with a circumferential wall 27 and an open top 28. The base 29 has apertures therethrough, in the case of connector 1, to enable its prongs 13 to pass through or, in the case of connector 2, to in use 9 RECEIVED TIMEI I, APR. 2:59 PRINT TIMEIl.API GE 11 R. 8: 11/04/2006 64:58 +6444965949 A PETER VERBOEKET CO PAGE 12 +6444965949 enable the prongs 13 of a plug to pass through to engage with the recesses adjacent the corresponding terminal carriers 8 to establish an electrical connection.

In the preferred embodiments illustrated the front casing 4 is attached to the body portion 3 using screws (not shown) passing through the base 29 into corresponding receiving pegs 30 on the mounting plate 6.

The peripheral edge of the cap 5 comprises an annular ring 31 which is gently tapered inwardly towards the ultimate edge. As the cap 5 and front casing 4 are brought together the gently tapering annular ring 31 increasingly engages the interior of the circumferential wall 27, thereby encasing the body portion 3, with an annular overlap occurring between the front casing 4 and cap 5 at that point.

To fit a connector 1 (or 2) to an electrical cable 40 the front casing 4 is first removed by removing the locating screws. The cap 5 is then partially unscrewed from the guide means 7 of the body portion 3. It must be unscrewed sufficiently so that the jaws 21 are free to flex outwardly.

Next a free end of the cable 40 is passed through the aperture 25 in the cap down the bore 15 of the guide means 7. The free end of the cable 40 is forced passed the ramped faces of the jaws 21 which, depending on the cable diameter, flex outwardly slightly to accommodate the cable.

The cable 40 is pushed further through until its free end exits the aperture 11 in the mounting plate 6 of the body portion 3, and extends some way there beyond. The individual insulated wires 41, 42, 43 are then pared out, connected to corresponding and correct wire securing means 9, and then laid in the corresponding pathway 12. Excess cable is then pulled gently back through the bore The cap 5 is then screwed onto the threaded guide means 7 as far as is possible.

As the cap 5 is screwed on two things happen. Firstly, the clamping jaws 21 are 9 RECEIVED TIMEII, APR, 2:59 PRINT TIME11. APR. 8:15 11/04/2000 04:58 +6444965949 PETER VERBOEUKEI COUr +6444965949 forced inwardly on the bore 15 to bite into the cable 40, thereby preventing any further longitudinal cable movement relative to the body portion 3. Secondly, the fingers 14 are urged by the necked end of the tubular portion of the cap 5 to constrict the elastomeric gland 16 around the cable 40 locating against it and forming a substantially liquid tight seal.

An advantage of the preferred embodiment as described is that the cable 40 is firmly gripped internally of the connector 1,2. The elastomeric seal formed at the aperture 25 in the cap 5 through which the cable 40 enters the connector 1,2 provides a measure of protection against insulation wear at the point of entry, which can be a problem with prior art connectors.

A further advantage of the preferred design is that the elastomeric seal provided at the entry point of the cable 40 into the connector 1,2 is liquid tight. In situations where, for example, an extension cord is being used outside and may have been subject to water the seal prevents water running down the cable if it is picked up and entering the connector where it could otherwise cause a short circuit.

A still further advantage of the invention is that the cap 5 does not have to be completely removed before a cable 40 can be attached to the connector 1,2. This means that there is less chance of pieces of the connector 1,2 being lost and provides a convenient gripping point to enable the attachment operation to be quickly and properly completed.

To further enhance the liquid proofing of the connector 1,2 an annular elastomeric seal (not shown) could be included where the cap 5 engages the front casing 4 resulting in a liquid tight seal being effected once the cap 5 and front casing 4 were properly in place.

The connector 1(2, when assembled, will represent an electrical plug (socket) that can be mated with any corresponding electrical socket (plug). It will be seen that this connector 1(2) has the advantage of being capable of being disassembled to to ~E 13 RECEIVED TIMEILAPR, 2:59 PRINT TIMEIIAPR. 8:15 11/e I4/280 04: 58 +6444965949 A PETER VERBOEKET CO PAGE 14 +6444965949 remove or replace the cable 40 within, as required. Further, the connector is potentially reasonably impervious to moisture and other undesirable environmental hazards to the proper working of electrical components. Where the connector 1 is mated with a connector 2, as illustrated in figure 7, the liquid imperviousness of the coupling can be enhanced by providing an annular sleeve extension 32 to the wall 27 of the front casing on the connector 2 so that in use, with the connectors 1 and 2 engaged the annular sleeve 32 covers the part line between the bases 29. This liquid imperviousness can be still further enhanced through use of an annular :elastomeric seal means (not shown) on the inside edge of the annular extension 32 so that the engagement between the connectors 1 and 2 is an interference fit.

The cap5 and front casing 4 are preferably made of any suitable non-conductive 5 durable and resilient material such as a plastics material. The body portion 3 may be made from similar materials, except for those components that allow the desired electrical connection.

It will be appreciated that the inventive features described are not limited by pin shape, and thus can be applied to any type of electrical plug and socket arrangement known internationally having the necessary fundamental features.

Wherein the foregoing description reference has been made to integers or components having known equivalents then such equivalents are herein incorporated as if individually set forth.

Although this invention has been described by a way of example of possible embodiments, it is to be appreciated that improvements and/or modifications may be made thereto without departing from the scope of the invention as claimed.

RECEIVED TIMEII.APR. 2:59 PRINT TIMEIIAPR. 8:15

Claims

1. An electrical connector, which connector includes a body portion and a front casing portion, wherein the front casing portion is releasably attachable to a front face of the body portion, the body portion having a cable entry aperture and a passageway through the body portion from that aperture to the front face of the body portion, the body portion further including one or more terminal connectors located adjacent its front face and accessible with the front casing portion removed from the body portion for, in use, establishing an electrical connection to an electrical cable to which the connector is attached, and an electrical contact means associated with each terminal connector to, in use, enable electrical connection to a e.e. further electrical connector or a power supply or draw off point while the front cover portion is attached to the body portion. S-

2. A connector according to claim 1 wherein the body portion further includes cable securing means to, in use, secure a cable in to the connector.

3. A connector according to claim 1 or 2 wherein the cable securing means comprises a clamping jaw located in the passageway of the body portion.

4. A connector according to claim 3 wherein there are at least a pair of clamping jaws.

A connector according to claim 4 wherein the clamping jaws are pivotally operable to clamp a said cable perpendicularly to its longitudinal axis.

6. A connector according to claim 4 or 5 wherein the cable securing means further includes urging means to urge the clamping jaws into engagement with a said cable.

7. A connector according to claim 6 wherein the urging means is incrementally operable. 12 jE RECEIIVED T IMEIi. AP R. 2:59 PRINT TIMEII. APR.

8:15 11/04/2000 04:58 +6444965949 A PETER VERBOEKET CO PAGE~ lb +6444965949 B. A Connector according to Claim 7 wherein the urging means is operable by way of screw threading action on the clamping jaws, and the jaws are ramp shaped, with the ramps extending longitudinally of the passageway.

9. A connector according to any one of claims 3 to 8 wherein the connector further includes a secondary cable securing means adjacent the entrance to the passageway in the body portion.

10. A connector according to claim 9 wherein the secondary cable securing means provides, in use, a seal around a said cable and the passageway entrance.

*11. A connector according to claim 10 wherein the secondary cable securing includes an annulus of overlapping fingers which can be urged to slidably overlap at their free ends to constrict the cross sectional size of the passageway.

12. A connector according t claim 11 wherein the secondary cable securing means further includes an annular elastomeric gasket between the passageway and the overlapping fingers.

13. A connector according to any one of the preceding claims wherein the passageway is straight.

14. A connector according to any one of the preceding claims wherein the body portion includes a back casing portion threadably connectable to the remainder. Desirably rotation in one direction of the back casing urges the overlapping fingers to constrict the passageway cross section and bear on the elastomeric gasket. Conveniently rotation of the back casing in that direction also results in the clamping jaws being urged to move inwardly towards the Centre of the passsageway. 13 RECEIVED TIMEl I. APR. 2:59 PRINT TIMEIl.

APR. 8:15 11/84/2000 04:58 +6444965949 A PETER VERBOEKET CO PAGE 17 +6444965949 A connector according to claim 414 wherein the back casing portion and the front casing portion are engageable to capture the remainder of the body portion substantially entirely therebetween.

16. A connector according to clam 15 wherein the engagement of the front and back casing portions produces a substantially liquid tight seal.

17. A connector substantially as herein described or exemplified with reference to the accompanying drawings. a a a 14 RECEIVED TIMEll. APR. 2:59 PRINT TIME1l. APR. 8:15