The most common use for electrical conduit connectors is to facilitate the connection of a conduit or cable to a junction box. The junction box can be a variety of electrical enclosures such as an outlet box, transformer enclosure, circuit panel, lighting fixture—the list is nearly endless. Similarly, the conduit can be rigid or flexible, or could be hose, other tubing capable of routing electrical wire, or cable. Cable can be non-metallic sheathed cable, portable cord, or a variety of other types of electrical conductors. The instant application is equally successful in connecting a plurality of types of conduits, cables, and other electrical conductors to a wide variety of boxes and other enclosures. Therefore, as used in this specification, the term conduit is not limited to standard rigid electrical conduit, but shall be intended to mean any type of conduit, any type of cable, or any other type of electrical conductor. Many commercial and residential buildings have electrical installations with many types of conduit-to-junction-box connections that utilize electrical connectors.
The two most common types of electrical connectors used are a snap-in connector, and a multipart connector which can be composed of two or more components that utilizes a threaded male end in conjunction with a threaded female locknut, hereinafter referred to collectively as a two-part locknut connector. In the case of the two-part locknut connector, the male threaded end is inserted into the junction box through a knockout (e.g., a hole or other opening). A rigid connection is established by threading the lock nut onto the male end in the junction box interior. The snap-in connector is another commonly used connector, which utilizes a snap ring to quickly connect it to the junction box. Either type of connector is integrated with an adapter end, which allows the attachment of conduit, cable, or a variety of types of hollow tubing.
The installation of electrical systems is generally expensive as an electrician must first install the enclosures, route conduit between each enclosure, and install connectors and then pull all necessary electrical wiring through the conduit. In other words, installation is expensive because it is labor intensive. The commercially available electrical connectors are one factor accentuating the labor intensiveness. Locknut connectors increase the cost of installing electrical systems for a number of reasons. The current art two-part locknut connectors are plagued with labor intensive problems. First, the locknut connectors are shipped from the manufacturer preassembled. That is, the electrician must first remove the locknut from the male end before it can be installed. Once the male end of the connector is placed through the knockout, the electrician must rethread the locknut onto the connector from the interior of the junction box.
Two hands are required to disassemble and then reassemble the connectors in the knockout. Consequently, it is difficult to hold a tool or a piece of conduit while reassembling the connector. Once the locknut is threaded it must be tightened. In accordance with many building codes and safety regulations, connectors must be firmly and reliably attached to junction boxes. To properly tighten the two-part locknut connector, the electrician must use a tool, usually a set of pliers or a screwdriver. Occasionally, when the proper tool is unavailable, an electrician will use any object within reach. These situations, while rare, raise serious safety issues. In many instances, however, to “get the job done” the locknut is “finger” tightened. Those persons skilled in the art know that finger tightened two-part locknut connectors can eventually loosen, and a loose connector can cause great strain to be put onto the electrical wires and their connections resulting in an increase in the probability of an electrical fire or other electrical problems, such as poor grounding.
Secondly, when the electrician disassembles the fitting by taking the locknut off the connector, the locknut can be dropped or misplaced. This can occur when the electrician is in an elevated position, such as, on a scissor lift or on scaffolding because the electrical conduit is often installed in out-of-the-way places like in rafters and above ceilings. If the locknut cannot be found, the connector is useless. If the electrician decides to retrieve the dropped locknut, the installation time is prolonged.
A third common problem with the present locknut connectors is the locknut is easily cross threaded onto the male thread. When this occurs, the electrician must usually use a tool to remove the locknut. On occasion, cross threading the locknut will damage the male threads on the connector making it difficult or impossible to reuse the connector. Again, the electrician must spend their time either removing the defective connector or forcing the locknut through the damaged portion of the threads.
A fourth problem with the present two-part locknut connectors is the distance the male end protrudes into the junction box. In some installations, the space inside the enclosure is already minimal. The space limitation becomes an acute problem when an additional connector is installed. The male threaded end protrudes well past the depth of the locknut and may interfere with another connector, the contents of the enclosure, or wiring inside the box. Therefore, in a limited space enclosure, the excess thread must be removed. Typically, the electrician may clip off some of the receptacle or mounting screws, or completes a combination of space enlarging modifications, all of which prolong installation time and threaten the integrity of the system as designed.
A fifth common problem with the present two-part locknut connectors occurs during disassembly of the connector from the enclosure. Electricians may disassemble an installation for a variety of reasons. The disassembly of the locknut connector is more time consuming than the installation. If the locknut was installed properly, that is, by tightening it with a tool, then the locknut must be removed with a tool. Similar to the installation, if the threads are damaged during disassembly, the connector is useless. Also similar to the installation problems, if the locknut is lost, it must be replaced if the connector is to be used again. The snap-in connector presents similar problems. However, the most significant problem is that these connectors, in most cases, do not create a rigid connection. Because the snap ring is sized to accept a variety of box wall thickness, it does not rigidly attach to many boxes. The loose fit may cause electrical continuity problems, a highly dangerous situation, since the box, the conduit, and the connector are intended to be part of the electrical grounding system in some applications.
A sixth problem with present two-part locknut connectors occurs when a conduit must be attached to a junction box at an angle. For example, if the only available hole in a junction box is in a direction that is not consistent with the direction the conduit runs. In this situation, the conduit will have to bend sharply in order to insert the connector into the hole. In instances where space is limited, this may not be possible.
There remains an unfulfilled need to provide a generally universal connector that is easy to use; e.g., which can be installed quickly and easily without tools, does not require access to the interior of the junction box, can be installed at an angle, and/or can be easily removed and reused in the box.
Disclosed herein are conduit connectors and methods for making and using the same.
In one embodiment, the conduit connector can comprise a body comprising with an open side capable of receiving a conduit in a receiving end. The open side can extend from a receiving end to a connecting end. A back component can be configured to engage and close a portion of the open side, and the back component can be moveable from an open to a closed position. A spring can be disposed around the connecting end. The spring can comprises one or more engagement tangs protruding away from the body and away from the connection end and spaced apart a distance greater than or equal to an opening diameter in a junction box. The body can also include an antishort bush located in and extending from the connecting end of the body.
These and other features of the conduit connector and method will be understood from the drawings and description below.
Refer now to the figures, which are merely exemplary, not limiting, and wherein like elements are numbered alike.
Disclosed herein are conduit connectors capable of connecting to an enclosure, e.g., capable of connecting an electrical conduit to a junction box. The conduit connector comprises a body, a spring, and an antishort bush. The spring is situated around the connecting end of the body and can be held in place with a lip or protrusion at the end of the connecting end. The spring can include one or more tangs that extend away from the body and toward a receiving end of the body (i.e., away from the connecting end). The antishort bush can be located within the connecting end of the body. The antishort bush can include threads that correspond with threads located within the connecting end of the body. The conduit connector can also include a back component or clamp, which closes the body around a conduit. The back component can pivot to close, or can be removable. In addition, the back component can be locked onto the body through one or more tabs and corresponding openings. During use, the tangs of the spring extend into and hold the connector to a junction box, while the back component engages and retains the conduit inside the body.
The conduit connector answers a long felt need for an electrical connector which can be installed quickly and easily without tools and does not require access to the interior of a junction box. In addition, the conduit connector enables a connection to an enclosure (e.g., to an electrical junction box) at an angle. The conduit connector can also accommodate multiple conduits. The electrical connector has utility, among other uses, in the connection of a conduit to an enclosure through an opening in the side of the box commonly referred to as a knockout. Additionally, although this connector securely engages the enclosure and is not easily dislodged due to bumping or otherwise, it can be easily removed if desired. The conduit engagement region can cooperate with a variety of conduit, cables, and other electrical conductors.
Referring now to
A back component (or clamp) 300 is pivotally mounted on body 200 to close at least a portion of open side 210. Back component 300 can comprise a free end 380 and a pivot end 390. Back component 300 can close the entirety of open side 210. As illustrated in
As discussed above, clip 340 can be configured to engage conduit 1. For example, as shown in
Spring 400 is mounted around connecting end 220. Spring 400 can include one or more tangs 440 that extend away from body 200 and connecting end 220. As shown in
As shown in
In operation, the connector shown in
As shown in
As shown in
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.
The embodiments described above are interchangeable. For example, the conduit connector can comprise a combination of any of the springs, back components, bodies, or antishort bushes described above. For example, the double conduit connector described above in reference to
Set forth below are some embodiments of the conduit connector and methods of using the same.
A conduit connector, comprising: a body comprising an open side, wherein the body is capable of receiving a conduit in a receiving end, wherein the open side extends from a receiving end to a connecting end; a back component configured to engage and close a portion of the open side, wherein the back is moveable from an open to a closed position; a spring disposed around the connecting end, wherein the spring comprises one or more engagement tangs protruding away from the body and away from the connection end, wherein the tangs are spaced apart a distance greater than or equal to an opening diameter in a junction box; and an antishort bush located in and extending from the connecting end of the body.
The conduit connector of Embodiment 1, wherein the body comprises apertures configured to receive tabs on the back component and prevent movement of the back component.
The conduit connector of Embodiments 1 or 2, wherein the back component comprises a free end and a pivoting end, wherein the pivoting end comprises apertures configured to receive tabs on the body.
The conduit connector of Embodiment 3, wherein the apertures are formed in protrusions that extend from a pivoting end of the back component, wherein the tabs are angled toward a centerline of the back that runs from the pivoting end to a free end, and wherein the apertures are configured to slide on the tabs on the body from a pivoting position to a locked position.
The conduit connector of any of Embodiments 1-3, wherein the back component comprises an engagement member configured to engage the conduit.
The conduit connector of Embodiment 5, wherein the engagement member retains the conduit within the body.
The conduit connector of any of Embodiments 1-6, wherein a first portion of the body comprising the receiving end is angled with respect to a second portion of the body comprising the connecting end.
The conduit connector of Embodiment 7, wherein the first portion is angled 90 degrees from the second portion.
The conduit connector of any of Embodiments 1-8, wherein the antishort bush comprises a first portion with a diameter smaller than the connecting end of the body, wherein the first portion comprises grooves that correspond to grooves located within the connecting end of the body.
The conduit connector of Embodiment 9, wherein the antishort bush comprises a second portion extending from the connecting end with a diameter greater than the diameter of the connecting end.
The conduit connector of any of Embodiments 1-10, wherein the connecting end comprises a lip with a diameter greater than an opening diameter in a junction box.
The conduit connector of any of Embodiments 1-11, wherein the body comprises a divider that separates the receiving end into at least two portions, wherein each portion is capable of receiving a conduit.
The conduit connector of any of Embodiments 1-12, wherein the connecting end comprises a second lip with a diameter greater than or equal to the diameter of the spring.
The conduit connector of Embodiment 13, wherein the second lip prevents the spring from dislodging from the connecting end.
The conduit connector of any of Embodiments 1-14, wherein the antishort bush further comprises threads configures to engage threads on an interior surface of the body.
The conduit connector of any of Embodiments 1-15, wherein the antishort bush further comprises grip extending around a periphery of an end of antishort bush, opposite the end that extends into the body.
The conduit connector of any of claims 1-16, wherein the body has two parallel channels such that different conduits can be located in each channel, and wherein the back component comprises an engagement member configured to engage each of the conduits.
A method of connecting a conduit to a junction box, comprising: extending an end of the conduit through a receiving end, through a body, and through a connecting end of a conduit connector; closing a back component to engage the conduit in the body with a clip protrusion extending from a clip arm on a back component, wherein the back component connects to the body with a tab; introducing the connecting end to an opening in the junction box such that the conduit and the connecting end extend through the opening, into the junction box; an dengaging an inner surface of the junction box with locking tabs on a spring that extends around the outer surface of the connecting end.
The method of claim 18, wherein the conduit end extends out of the connecting end at an angle of about 90° compared to the angle the conduit end entered the receiving end.
The method of any of claims 18-19, wherein, after engaging the inner surface of the junction box, further comprising unscrewing an antishort bush from the connecting end, removing the spring, and removing the connecting end from the opening.
The method of claim 20, further comprising reattaching the conduit connector to the junction box by placing the spring onto the connecting end, screwing the antishort bush into the connecting end, and inserting the connecting end through the opening.
All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other (e.g., ranges of “up to 25 wt. %, or, more specifically, 5 wt. % to 20 wt. %”, is inclusive of the endpoints and all intermediate values of the ranges of “5 wt. % to 25 wt. %,” etc.). The terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to denote one element from another. The terms “a” and “an” and “the” herein do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including one or more of that term (e.g., the film(s) includes one or more films). Reference throughout the specification to “one embodiment”, “another embodiment”, “an embodiment”, and so forth, means that a particular element (e.g., feature, structure, and/or characteristic) described in connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.
While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.
This application is a U.S. Non-Provisional application which claims Priority to U.S. Provisional Application Ser. No. 61/832,352, entitled “CONDUIT CONNECTORS AND METHODS FOR MAKING AND USING THE SAME”, filed Jun. 7, 2013, which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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61832352 | Jun 2013 | US |