Single fastener electrical connector

Abstract

A one-piece metallic connector is configured to receive a fastener and has features that grip and electrically bond two conductors as they are clamped together when the fastener is tightened. The connector's generally U-shaped body has first and second legs, a bight portion joining the legs and an opening in each leg through which a single mounting fastener can extend. When installed with the outside of one leg abutting one conductor, another conductor is clamped between the legs. At least one outer projection (tooth) on the outer face of one leg engages the conductor to which the connector is mounted. At least one inner projection (tooth) on the same leg engages the conductor clamped between the legs. A recess on the inner face of the distal portion of the other leg is configured to cradle the clamped conductor.

Claims

1. An electrical connector for connecting a first conductor to a second conductor when secured by a fastener, comprising: a one-piece, generally U-shaped metal body having a first leg, a second leg and a bight portion joining said legs, each of said legs having a proximal portion near said bight portion and a distal portion remote from said bight portion, spaced apart to receive the first conductor therebetween; a first opening in said first leg; a second opening in said second leg, said first and second openings being substantially aligned to permit a fastener to extend therethrough; said second leg having a first thickness at said proximal portion and a second thickness at said distal portion, wherein said second thickness is greater than said first thickness; at least one outer projection formed on said second leg extending outward from the outer face thereof for engaging the second conductor; a recess on the inner face of the distal portion of said first leg configured to cradle the first conductor; and at least one internal projection formed on the distal portion of said second leg and extending inward from the inner face thereof for engaging the first conductor, whereby, when a fastener extending through said openings is tightened with the second conductor abutting the outer face of said second leg and the first conductor in said recess, said at least one outer projection is forcibly pressed against the second conductor and the first conductor is clamped by said legs to forcibly press said at least one internal projection against the first conductor.

2. The electrical connector of claim 1, wherein the distal portion of said first leg is outwardly convex, and said recess comprises the concave inside of said outwardly convex distal portion.

3. The electrical connector of claim 1, wherein said recess comprises a knurled surface.

4. The electrical connector of claim 1, wherein said at least one internal projection and said recess are substantially opposed.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) Preferred embodiments of the disclosed invention are described in detail below purely as examples, with reference to the accompanying drawing, in which:

(2) FIG. 1 is a perspective view of a first embodiment of the electrical connector of the invention shown assembled on a portion of a flat conductor and almost fully clamping a round conductor to the flat conductor;

(3) FIG. 2 is a side elevational view of the assembly of FIG. 1;

(4) FIG. 3 is a side elevational view of the first embodiment of FIG. 1 per se;

(5) FIG. 4 is a bottom plan view of the first embodiment of FIG. 3;

(6) FIG. 5 is a perspective view of a second embodiment of the electrical connector of the invention shown assembled on a portion of a flat conductor and almost fully clamping a round conductor to the flat conductor;

(7) FIG. 6 is a side elevational view of the assembly of FIG. 5;

(8) FIG. 7 is a side elevational view of the second embodiment of FIG. 4 per se;

(9) FIG. 8 is a bottom plan view of the second embodiment of FIG. 7; and

(10) FIG. 9 is a detail plan view of an optional knurled clamping surface suitable for inclusion in any embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

(11) Referring to FIGS. 1-4, a first embodiment of the electrical connector of the invention comprises a one-piece, generally U-shaped body 2 preferably made of stainless steel. Body 2 has a first leg 4, a second leg 6 and a bight portion 8 joining the legs. First leg 4 has an inner face 10, an outer face 12 and a distal portion 14 remote from bight portion 8. Second leg 6 has an inner face 16, an outer face 18 and a distal portion 20 remote from bight portion 8. Inner faces 10, 16 oppose one another and distal portions 14, 20 are spaced or can be urged apart to receive a first conductor C1 between them. Legs 4, 6 have respective holes 22, 24 that are aligned to accommodate a fastener F, such as a threaded bolt, for securing the body to a second conductor C2 with conductor Ci clamped between the legs.

(12) The distal portion 14 of first leg 4 preferably is curved outward as shown to provide an arcuate recess 26 on its inner face that cradles round conductor C1. Distal portion 14 may be configured to provide a cradling recess of a different shape, for example, a V-shaped recess (not shown). Knurls 27 (see FIG. 9) optionally may be formed on the inner surface of recess 26 to enhance the grip on and bond with conductor C1. Bonding with conductor Ci primarily occurs at the distal portion 20 of second leg 6 by means of two inner teeth 28 that project from the leg's inner face 16. One tooth would suffice if it makes a good electrical bond; however, at least two teeth are preferred and all teeth directly oppose the longitudinal center of recess 26, i.e., the centers of teeth 28 and the center of recess 26 lie in a common plane P1 (see FIGS. 2-4).

(13) Bonding with conductor C2 occurs at the distal portion 20 of second leg 6 by means of two outer teeth 30 that project from the leg's outer face 18. Teeth 30 are formed on a terminal portion 32 of leg 6 that is folded outward 180 substantially flat against the remainder of distal portion 20. Here, too, one tooth 30 would suffice if it makes a good electrical bond; however, at least two teeth 30 are preferred, the number being equal to the number of inner teeth 28. Each outer tooth 30 preferably is aligned with a respective inner tooth 28 so as to form sets of aligned, oppositely directed teeth, all of which lie in common plane P1. Thus, when fastener F is installed and tightened, the clamping force exerted by the connector on conductors C1 and C2 acts directly along common plane P1, maximizing the penetrating effect of the teeth on their respective conductors.

(14) Referring to FIG. 2, the outwardly folded terminal portion 32 of second leg 6 results in a thicker distal portion 20 and thus causes second leg 6 to be slightly inclined relative to conductor C2. As shown, this geometry initially focuses the clamping force of teeth 30 through a smaller area, resulting in an enhanced ability to break anodic coatings. When the fastener is tightened further for full clamping effect (not shown) the sharp distal edge of terminal portion 32 may also penetrate the coating. The damping force is optimized by keeping the distance from common plane P1 to bight portion 8 as short as practicable and locating holes 22, 24 (and hence fastener F) fairly dose to common plane P1, preferably not more than about half the distance from common plane P1 to bight portion 8.

(15) Teeth 28 and 30 may be any of the types of teeth disclosed in the aforesaid U.S. Pat. No. 8,092,129 to Wiley, et al., such as those shown in FIGS. 3-8 and described at col. 7, lines 14-31 thereof. The preferred tooth form is circular and the connector may have a thin coating of a material such as chromium or titanium nitride in order to achieve the desired tooth hardness so that the teeth can penetrate anodic coatings and become embedded in the underlying metal.

(16) Referring to FIGS. 5-8, a second embodiment of the electrical connector of the invention similarly comprises a one-piece, generally U-shaped body 42, preferably made of stainless steel, having a first leg 44, a second leg 46 and a bight portion 48 joining the legs. First leg 44 has an inner face 50, an outer face 52 and a distal portion 54 remote from bight portion 48. Second leg 46 has an inner face 56, an outer face 58 and a distal portion 60 remote from bight portion 48. Inner faces 50, 56 oppose one another and distal portions 54, 60 are spaced or can be urged apart to receive a first conductor C1 between them. Legs 44, 46 have respective holes 62, 64 that are aligned and located to accommodate a fastener F as described above in connection with the first embodiment. The distal portion 54 of first leg 44 similarly is preferably curved outward as shown to provide an arcuate recess 66 on its inner face that cradles round conductor C1. Knurls 27 (see FIG. 9) and other recess shapes may be used as described above.

(17) Bonding with conductor C1 in this embodiment is similarly accomplished by means of two inner teeth 68 at the distal portion 60 of second leg 46 that project from the leg's inner face 56. Here, too, one tooth would suffice if it makes a good electrical bond; how, at least two teeth 68 are preferred and all teeth directly oppose the longitudinal center of recess 66, i.e., the centers of teeth 68 and the center of recess 66 lie in a common plane P2 (see FIGS. 6-8). Bonding with conductor C2 also occurs at the distal portion 60 of second leg 46 by means of two outer teeth 70 that project from the leg's outer face 58. In contrast to the first embodiment, however, the distal portion of second leg 46 is not folded; and outer teeth 70 are offset from plane P2 and are centered along a plane PJ that is perpendicular to plane P2 (see FIG. 6). Tooth design options are preferably the same as those described in connection with the first embodiment.

(18) The one-piece construction and configuration of the above embodiments make installation of these electrical connectors fast and easy: (1) a bolt is placed through the holes in the legs, (2) the legs are spread slightly to embrace conductor C1, and (3) the bolt is inserted in a predrilled hole in conductor C2 and driven home to clamp the parts together. Some installers may find it more convenient to reverse steps 1 and 2. Either way, the result is a quick and effective electrical bond.

(19) While preferred embodiments have been chosen to illustrate the electrical connector of the invention, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined by the appended claims.