Conduit connector and methods for making and using the same

Abstract

In one embodiment, the conduit connector can comprise: a body comprising a hollow center capable of receiving a conduit in a receiving end, wherein the hollow center extends from the receiving end to the connecting end; a spring disposed within the hollow center and extending out of the connecting end, wherein the spring comprises engagement tangs extending into the hollow center, toward the connection end, and spring tangs extending past the connection end and spaced apart a distance greater than or equal to an opening diameter in a junction box; and an antishort bush located in the connecting end of the body, retaining the spring in the body.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application the conduit connector 20 an antishort bush 12, with a conduit 18 located adjacent the receiving end 22 of a body 16. The body 16 includes a connecting end 23 and the antishort bush 12 includes a receiving end 25. From the connecting end 24 of the antishort bush 12 to the receiving end 22 of the body 16, the conduit connector 20, comprises the antishort bush 12, the spring 14, and the body 16. FIGS. 2 and 3 illustrate the assembled connector 20 attached to the junction box 10 and engaging the conduit 18. In these figures the conduit 18 extends into the body 16 wherein receiving tangs 42 engage the outer convolutions of the conduit 18, inhibiting the conduit 18 from being withdrawn from the body 20 through the receiving end 22 of the body 16. Connecting tangs 56 extend through the opening 26 in the side of the junction box 10, and engage the sides thereof to prevent the inadvertent removal or dislodging of the conduit connector 20 from the box 10. FIGS. 4-6 provide further views of the conduit connector 20 of FIG. 1.

FIGS. 7-10 illustrate embodiments of a spring that is used to engage both the conduit 18 and the box 10. The spring 14 is so sized and configured that a main portion 40 adjacent the receiving end 24 connecting end 23 of the body 16 is disposed within the body 16, when the conduit connector is assembled. The main portion 40 of the spring can be enclosed with a cavity extending therethrough or have an open side with a channel 70 extending therethrough. The overall shape is complementary to the shape of the body so as to be inserted and retained within the body 16. Some possible main portion 40 shapes include various polygonal shapes (e.g., U-shaped, rectangular, square, pentagonal, and so forth). Optionally, the body spring 14 can comprise aperture(s) 72 adjacent to the receiving end 22 25 of the antishort bush 12, e.g., can comprise a channel and an aperture 72 adjacent to each corner at the receiving end 25 of the antishort bush 12. In some embodiments the main portion 40 comprises three sides. The opposing sides are arranged substantially perpendicular to the connecting side. The corners where the sides connect can be squared corners or can be rounded.

Extending inward and toward the connecting end 24 antishort bush 12 is a plurality of receiving tangs 42. The receiving tangs 42 can form a shape that will align the conduit 18 within the connector 20. For example, the tangs can form a generally V-shaped profile that will align the conduit 18 in the channel (e.g., can align the conduit 18 in the center of the connector 20). Each tang 42, can, individually, have a shape for gripping and restraining the conduit 18 and optionally for aligning the conduit 18. For example, the spring 14 can comprise 3 receiving tangs 42. The central receiving tang 44 can angle from the sides down toward the middle (e.g., to form a V-shaped end), the first side receiving tang 46 and the second side receiving tang 48 can both have diagonal ends 50,52, respectively, that angle toward the central receiving tang 44, to attain the generally V-shaped profile (dotted line 54). Furthermore, the ends 50,52 can have an angle that is commensurate with the angle of curvature of the conduit convolutions. Optionally, each tang 44,46,48 can be oriented to extend into the body at the same distance from the receiving end 22 or can extend at different distances. For example, tang 44 can extend into the channel 70 at a distance d₁ from receiving end 22, while tang 48 can extend at a different distance d₂ from receiving end 22 as is illustrated in FIG. 8, wherein the distance is from the receiving end to the point of the tang that would engage a conduit.

Extending from the main portion 40 of the spring 14 can be connector tang(s) 56, such as at least two opposing connector tangs 56. At the base of the tang 56 can be an aperture 74 configured to receive a knob on the body 16, e.g., enhancing alignment of the spring within the body 16. Each connector tang 56 can have an optional center lug 58. This lug 58 can ease insertion through the opening in the box and can facilitate retention of the tangs 56 within the box, e.g., in case of external side forces. This tang extends outward from a surface 66 (e.g., main body portion) of the tang 56, while the connector lugs extend from opposite sides of the tangs 56. The lugs can be angled outward, e.g., to further enhance the engagement with the box (e.g., to prevent unintentional withdrawal from the knockout), and/or to enhance electrical grounding connection.

Each tang 56 comprises a set of side lugs 60. The side lugs 60 can be angled toward the receiving end 25 of the antishort bush 12, e.g., have a negative angle, θ, e.g., to avoid disengagement of connector after applying pulling load. The side lugs can be angled such that the connecting tang 56 diverges from near the end 68 toward the main body 40 (e.g., the side lugs 60 can have a generally triangular shape) to allow facile insertion into the box 10.

Engaging the outside of the box when the connector is attached to the junction box are the outside lugs 62. In other words, the wall 28 of the junction box 10 is engaged on an inner surface by side lugs 60 and on an outer surface by outside lugs 62; being located in the valley 64 therebetween. The valley 64 can be sized and shaped to receive a variety of junction box wall thicknesses. For example, the outside lugs 62 can also optionally comprise a negative angle Φ that allows different size walls to be readily received and securely engaged within the valley 64. Angle Φ can be an angle of 10 to 20 degrees, specifically, 13 to 17 degrees.

Located at the receiving end connecting end 23 of the body 16 is the antishort bush 12. (See FIGS. 12-14) The antishort bush 12 is designed to connect to the body 16 at the connecting end 24 23, such that the connecting tangs 56 extend along the sides of the antishort bush 12. The antishort bush 12 comprises projections 90 for snap engagement with the body 16. The number of snap engagements is dependent upon the general shape of the body and of the antishort bush. For a generally square cross-sectional body shape, two or more projections 90 can be employed, with four or more generally used for secure engagement. Each projection can comprise a lip 92 configured to engage an opening 140 in the body 16 (see FIG. 16). The projection 90 can extend toward the receiving end 22 with the lip 92 extending outward at a complementary angle from the body to engage the opening 140, e.g., at an angle of 90° to the central axis A. (See FIG. 2) The foot 94 of the projection 90 can be angled so as to enable facile insertion into the body 16 and so as to facilitate flexing of the projection 90. For example, the foot 94 can have a generally conical (e.g., truncated conical) shape that narrows towards the receiving end 22. The angle of the foot can be different on different sides of the foot 94. For example a lower angle can extend from the end of the lip 92 to the bottom of the foot 94 than on another side of the foot 94.

In all embodiments, along one or more sides of the antishort bush 12 that will extend into the body 16 over the spring 14, can optionally be a restrictor 96. The restrictor 96 can extend toward the receiving end connecting end 23 of the body 16 at a distance that is equal to or greater than the projections 90. When the connector 20 is assembled, the restrictor 96 can restrict movement of the spring 14 in the body 16, e.g., in one axial direction. For example, the restrictor 96 can be configured to restrict the side of the spring comprising the center lug between the restrictor 96 and a side of the body 16. Extending from the restrictor 96, in a direction away from channel 98 can optionally be rib(s) 100, e.g., to assist in orientation of the antishort bush 12 in body 16. The rib 100 can extend along axis A for all or part of the length of the restrictor 96.

At the connecting end 24 of the antishort bush 12 can be a chamfer, e.g., to allow bending of the connecting tangs 56 during insertion of the connector 20 through the opening 26.

Along the sides of the antishort bush 12 can be cavity(ies) 108 each located and configured to receive a body lug 142 (See FIGS. 15 and 16). The cavity 108 has a distance between the walls 104 that is greater than or equal to the width of the body lug 142. While the connector is entering the opening in the box, the body lug 142 comes down into the channel. The lip 106 restricts the body lug movement into the channel.

Now referring to FIGS. 15-18, the body 16 comprises a shape configured to receive the spring main portion 40 within the body cavity 146 and the antishort bush 12 at the connecting end of 23 the body 16. At the receiving end connecting end 23 of the body 16 can be body lug(s) 142 that extend along the axis A from the connecting end 24 23 of the body 16. The body lug(s) 142 can be designed to have a rounded or chamfer outer body 148, e.g., to facilitate insertion into the junction box. Extending from the outer surface of the body lug 142 can be crush rib(s) 150. This rib 150 can provide a tight fit with the opening 26, crushing as necessary to enable insertion of the connecting end 24 into the box 10. On the opposite side of one or more of the body lug(s) 142 can be a groove 152 oriented and designed to receive the antishort bush rib 100. In the various embodiments, two or more body lugs 142 can be provided. The optional body lug(s) can facilitate the entry of the connector into the hole in the box and/or can establish a good contact with the body to decrease the contact resistance between the box and the connector (e.g., resulting in good grounding connection).

Also located at the connecting end 24 23 of the body 16 can be a stop protrusion extending outward from the body 16 and configured to limit the insertion of the connector 20 into the opening 26. In addition to the stop protrusions 154, the body 16 can comprise extensions 156 that angle outward from the main body portion 158. The extensions 156 can also limit the amount of that the connector 20 at extends into the box 10. In many embodiments, the body comprises two extensions 156 on opposite sides, with two body lugs 142 on the other two opposing sides. The extensions 156 flare away from the main body portion 158 so as to receive the tangs 56 in their relaxed state. Therefore, the extension 156 can have a diverging area 160 that diverges at an angle complementary to the outward flare 72 of the spring 14. Within the extension 156 can be a knob 162 that has a size and shape to extend into aperture 74 of the spring 14 when the connector 20 is assembled.

The main body portion 158 can comprise grips 164 on one or more sides thereof. The grips 164 can be any combination of elements that facilitates gripping of the main body portion 158, e.g., serrations, depressions, protrusions (e.g., bumps), holes, as well as combinations comprising at least one of the foregoing.

The shape of the main body portion 158 is complementary to the spring shape. The main body portion can be polygonal (e.g., square, rectangular, and so forth). For example, three sides can form a U-shape (e.g., sides 166,168,170), with the fourth side (172) merely covering the opening (e.g., see the cross-sectional view of FIG. 11), e.g., forming a generally square shape. As can be seen, the sides can meet in a rounded corner (174,176) or a squared corner (178,180). The forth side 172 can comprise guide rib(s) 144 extending adjacent to the sides 166,170 to guide the edges 76 of the spring 14 when inserting the spring into the body 16, and to prevent the edges from bending inward, into body cavity 146.

At the connecting end 23 of the main body portion 158 are the openings 140 each sized and configured to receive one of the antishort bush projections 90. At the receiving end 22 of the body 16 can be a collar 182 that prevents the spring from being forced out of the receiving end of the body 22 body 16; e.g., the collar can restrict the spring in one of the axial directions. Also at the receiving end 22 of the main body portion 158 can be a slot 184 in one or more sides (e.g., in opposite sides 166, 170) sides and located to allow the corners 78,80 of the spring 14 to extend through the slot 184 such that the jut 186 extends into window 82, e.g., to further secure the spring within the body.

The main body portion 158 can also optionally comprise pocket(s) 190 configured to receive lug 90/92 from the antishort bush 12, e.g., to retain the spring in the body.

The conduit connector can be formed of various materials as appropriate for the particular element. For example, the body can comprise a metal or metal alloy, such as zinc, aluminum, steel, as well as combinations comprising at least one of the foregoing (e.g., zinc alloy, aluminum alloy, and/or steel alloy). The spring can comprise a material such as steel, (e.g., spring steel and/or stainless steel), as well as combinations comprising at least one of the foregoing. The antishort bush can be formed of a plastic, such as engineering plastics.

In use, a conduit 18 (e.g., an electrical conduit) is inserted through the body 16 until the conduit is accessible at a connecting end 24 of that will be inserted into the enclosure 10. As the conduit 18 is inserted into the body 16, the coils (peaks) 30 of the conduit 18 cause the receiving tangs 42 cantilever outward towards the walls of the body 16 and spring inward as the valleys 32 of the conduit 18 reaches the ends of the receiving tangs 42. As the conduit 18 is inserted into the body 16, the center lug 58 guides the conduit into the desired location within the body.

In one embodiment, the conduit connector can comprise: a body comprising a hollow center capable of receiving a conduit in a receiving end, wherein the hollow center extends from the receiving end to the connecting end; a spring disposed within the hollow center and extending out of the connecting end, wherein the spring comprises engagement tangs extending into the hollow center, toward the connection end, and spring tangs extending past the connection end and spaced apart a distance greater than or equal to an opening diameter in a junction box; and an antishort bush located in the connecting end of the body, retaining the spring in the body.

A method of using the conduit connector can comprise inserting a conduit into the channel so that the engagement tangs physically contact grooves along the outer surface of the conduit; and inserting the spring tangs into an opening (e.g., in a junction box), until the side lugs engage the inner surface of the box.

In the various embodiments, (i) each spring tang can comprise an aperture that receives a knob on the body; and/or (ii) each spring tang can comprise a center lug extending outward from a spring main portion, away from the spring and toward the receiving end; and/or (iii) each spring tang can comprise side lugs angled toward the receiving end at an angle so that, once the connector is attached to an opening, the lugs avoid disengagement after applying a pulling load; and/or (iv) the side lugs form wings on opposite sides of each spring tang and have a shape that diverges from near an end of the spring tang toward the receiving end; and/or (v) a spring main portion can have three sides, with the spring tangs extending from two opposite sides, and the engagement tangs extend into the channel from all three sides; and/or (vi) the engagement tangs form a generally V-shaped profile that is configured to align a conduit in the channel; and/or (vii) the engagement tangs can comprise a central receiving tang that is angled from the sides into the channel and having a generally V-shaped end, and a first side receiving tang having a diagonal ends that angles toward the central receiving tang and a second side receiving tang having a diagonal end angled toward the central receiving tang forming a generally V-shaped profile of the engagement tangs; and/or (viii) each engagement tang can extend into the body at a different distance than another engagement tang; and/or (ix) the antishort bush can further comprise a restrictor extending toward the receiving end, wherein the restrictor restricts movement of the spring; and/or (x) the antishort bush can comprise projections that extend toward the body and through an opening such that a foot on the projection snapfits the antishort bush onto the body; and/or (xi) near the receiving end, the body can comprise a slot such that a corner at the receiving end of the spring passes through the slot and a window near the corner engages a jut on the body; and/or (xii) the body can have a polygonal shape.

Before or after the conduit 18 is disposed within the body 16, the conduit connector 20 can be connected to the junction box 10. Connection to the box 10 comprises exerting force on the conduit connector 20 in the direction of the opening 26. As the connector tangs enter the opening 26, they pivot (cantilever), decreasing the outer diameter of the spring 14, and enabling the side lugs 60 to pass into the box 10. Once the lugs 60 have passed through the opening 26, the connector tang springs outward causing the wall 28 to be located in the valley 64, the side lugs to be located within the box 10, and the outside lugs to be located outside the box 10, thereby grasping the box opening 26 and holding the connector 20 to the box 10. If the center lug(s) 58 are present along the connector tang(s) 56, they facilitate the inward flexing of the connector tang 56 as it passes through the opening 26.

Claims

1. A conduit connector, comprising:

a body comprising a hollow center capable of receiving a conduit in a receiving end, wherein the hollow center extends from the receiving end to the a connecting end;

a spring disposed within the hollow center and extending out of the connecting end body, wherein the spring comprises engagement tangs extending into the hollow center, toward the connection end wherein the engagement tangs are configured to physically contact grooves along an outer surface of a conduit when the conduit is inserted into the body, and spring tangs extending past the connection connecting end and spaced apart a distance greater than or equal to an opening diameter in a junction box; and

an antishort bush located in the connecting end of the body, retaining the spring in the body.

2. The conduit connector of claim 1, wherein each spring tang comprises an aperature aperture that receives a knob on the body.

3. The conduit connector of claim 1, wherein each spring tang comprises a center lug extending outward from a spring main portion, away from the spring and toward the receiving end.

4. The conduit connector of claim 1, wherein each spring tang comprises side lugs angled toward the receiving end at an angle so that, once the connector is attached to an opening, the lugs avoid disengagement after applying a pulling load.

5. The conduit connector of claim 4, wherein the side lugs form wings on opposite sides of each spring tang and have a shape that diverges from near an end of the spring tang toward the receiving end of the antishort bush.

6. The conduit connector of claim 1, wherein a spring main portion can have three sides, with the spring tangs extending from two opposite sides, and the engagement tangs extend into the channel from all three sides.

7. The conduit connector of claim 6, wherein the engagement tangs angle toward each other to form a generally v-shaped profile that is configured to align a the conduit in the channel center of the connector.

8. The conduit connector of claim 6, wherein the engagement tangs comprise a central receiving tang that is angled from the sides into the channel and having a generally v-shaped end, and a first side receiving tang having a diagonal ends end that angles toward the central receiving tang and a second side receiving tang having a diagonal end angled toward the central receiving tang forming a generally v-shaped profile of the engagement tangs.

9. The conduit connector of claim 6, wherein each engagement tang extends into the body at a different distance than another engagement tang.

10. The conduit connector of claim 1, wherein the antishort bush further comprises a restrictor extending toward the receiving end connecting end of the body, wherein the restrictor restricts movement of the spring.

11. The conduit connector of claim 1, wherein the antishort bush comprises projections that extend toward the body and through an opening such that a foot on the projection snapfits the antishort bush onto the body.

12. The conduit connector of claim 1, wherein, near the receiving end, the body comprises a slot such that a corner at the receiving end of the spring passes through the slot and a window near the corner engages a jut on the body.

13. The conduit connector of claim 1, wherein the body has a polygonal shape.

14. A conduit connector, comprising:

a body comprising a hollow center capable of receiving a conduit in a receiving end and a knob, wherein the hollow center extends from the receiving end to the a connecting end;

a spring disposed within into the hollow center and extending out of the connecting end body, wherein the spring comprises

engagement tangs extend into the hollow center, toward the connection connecting end, wherein the engagement tangs angle toward each other to form a generally v-shaped profile that is configured to align a conduit in the channel,

spring tangs comprise a center lug extending outward from a spring main portion, away from the spring and toward the receiving end, wherein the spring tangs extend past the connection end and are spaced apart a distance greater than or equal to an opening diameter in a junction box, and wherein each spring tang comprises side lugs angled toward the receiving end at an angle so that, once the connector is attached to an opening, the lugs avoid disengagement after applying a pulling load; and

an aperture that received the knob; and

an antishort bush located in the connecting end of the body, retaining the spring in the body.

15. The conduit connector of claim 14, wherein the side lugs form wings on opposite sides of each spring tang and have a shape that diverges from near an end of the spring tang toward the receiving end of the antishort bush.

16. The conduit connector of claim 14, wherein a spring main portion can have three sides, with the spring tangs extending from two opposite sides, and the engagement tangs extend into the channel from all three sides.

17. The conduit connector of claim 16, wherein the engagement tangs comprise a central receiving tang that is angled from the sides into the channel and having a generally v-shaped end, and a first side receiving tang having a diagonal ends that angles toward the central receiving tang and a second side receiving tang having a diagonal end angled toward the central receiving tang forming a generally v-shaped profile of the engagement tangs.

18. The conduit connector of claim 16, wherein each engagement tang extends into the body at a different distance than another engagement tang.

19. The conduit connector of claim 14, wherein antishort bush further comprises a restrictor extending toward the receiving connecting end of the body, wherein the restrictor restricts movement of the spring, and comprises projections that extend toward the body and through an opening such that a foot on the projection snapfits the antishort bush onto the body.

20. The conduit connector of claim 14, wherein, near the receiving end, the body comprises a slot such that a corner at the receiving end of the spring passes through the slot and a window near the corner engages a jut on the body.

21. A conduit connector, comprising:

a hollow body capable of receiving a conduit in a receiving end, wherein the body has a rectangular body shape, wherein the body extends from the receiving end to a connecting end;

a spring inserted into the body, wherein the spring comprises engagement tangs extending into the body capable of engaging a conduit, and at least two spring tangs capable of engaging an opening in a junction box; and wherein the body is configured to receive the spring; and

an antishort bush located at the connecting end of the body.

22. The conduit connector of claim 21, wherein the spring has a rectangular shape that is complementary to the rectangular body shape.

23. The conduit connector of claim 21, wherein the antishort bush extends into the spring, between the spring tangs.

24. The conduit connector of claim 21, wherein the spring tangs are capable of removably engaging the opening in the junction box.

25. A method of securing a conduit to a junction box, comprising:

disposing a conduit into a conduit connector and engaging the conduit with engagement tangs that extend into the conduit connector, wherein the conduit connector comprises

a hollow body having a rectangular body shape, wherein the conduit extends into the body;

a spring disposed within the hollow body and comprising the engagement tangs and spring tangs extending out of the hollow body; and

an antishort bush, wherein the antishort bush extends through the opening in the junction box;

inserting a connecting end of the conduit connector into an opening in a junction box such that the spring tangs engage the opening.