Wire Nut Driver Tool

Abstract

A combination wire-nut driver tool configured with a long hollow shank with a flared tip containing two slots which securely grip a wire-nut for the purpose of positioning and tightening a pair of electrical wires. The combination wire-nut driver tool further includes an axial bore, through which an electrical wire can pass, and a removable handle-cap which can be converted to a small screwdriver.

Description

FIELD OF INVENTION

This invention relates generally to a multi-function hand tool especially suited for joining the bare ends of insulated electrical wires together with a non-insulated ground-wire using a wire-nut.

BACKGROUND

Wire-connectors are used to connect electrically exposed conductive ends of two or more electrical wires. The use of wire-connectors (or wire-nuts) has become very popular in the installation of lighting fixtures, ceiling fans, electrical switches and electrical outlets. In general, a conventional wire-nut compromises an outer cap portion of non-conductive material (e.g., plastic) and a tapered insert of conductive material (e.g., metal) carried within the cap. The cap is provided with an open lower end that permits access to the conductive insert. Typically, the insert includes an internally threaded socket adapted to receive the exposed conductive ends of two or more electrical wires that are to be conductively connected. In use, the exposed conductive ends of two or more electrical wires are aligned with one another and inserted into the open end of a wire-nut. Typically the wire-nut in manually twisted onto the ends of the wires until the internally threaded socket of the conductive metal insert tightly engages the conductive ends of the wires. The non-conductive cap of the wire-connector insulates the exposed portions of the connected electrical wires from contacting other wires or other conductive portions of the fixture. In many conventional wire-nuts, the upper end of the wire-nut includes an aperture that is adapted to allow a wire pigtail or other wire extension (e.g., a ground-wire, or a neutral conductor) to pass through the upper end of the cap.

Such conventional wire-nuts come in a variety of shapes and sizes. One type of conventional wire-nut has a generally conical and tapered shape with a ribbed outer surface that facilitates manual twisting or screwing of the wire-nut. Another type of conventional wire-nut has a generally tapered body portion with a pair of outwardly extending “wings” or fins disposed on opposite sides of the body portion to make manually twisting the wire-nut easier.

A problem with manually twisting or screwing conventional wire-nuts onto wires is that the user's fingers and thumb can become sore from engagement with the ribs and wings of the nuts, particularly after installing a large number of them. To avoid this problem, various wrenches, pliers and other tools have been developed for installing wire-nuts. However, these devices have proven to be heavy and cumbersome, difficult to use, or altogether ineffective. Thus, a need exists for a wire-nut fastening tool that facilitates manual installation of wire-nuts, yet is lighter, more compact and easier to use than existing tools.

Another problem with existing wire-nut fastening tools is that they do not allow for receiving a wire pigtail or other wire extension (e.g., a ground-wire, or a neutral conductor) to pass through the upper end of the wire-nut. While there are some wire-nut fasteners that contain a space for the extra length of wire, there exists a need for a hollow tool through which a wire can pass completely. Additionally, in both residential and commercial electrical applications, both hot and ground-wire ends are connected to posts by conventional screws. The exposed ends of the wires are looped so that they can engage a screw, which subsequently is driven and secured into a device, such as a light switch or electrical outlet. Currently, an electrician needs at least three tools to complete this task: his fingers or a wire-nut driver, a pair of pliers, and a screw driver. Thus, a need exists for a tool that has features that can quickly and easily create a loop in an exposed end of a wire, engage a wire-nut and extended ground wires, and engage a screw head.

SUMMARY

Aspects of the present invention are directed to a multi-purpose tool comprising an elongated shank, a hollow flared tip, a handle, and a handle-plug; wherein the elongated shank has an axial bore, a working-end, a handle-end, and a transverse aperture, wherein the aperture is dimensioned and configured to engage and bend a wire when the shank is rotated; a hollow flared tip with an axial bore in registration with the axial bore of the elongated shank, comprising a terminal working-portion and a connector-portion opposite from each other along a longitudinal axis, wherein the connector-portion is connected to the working-end of the shank, wherein the flared tip has a transverse cross-sectional area which is taped from the terminal working-portion to the connector-portion, and further comprising two slots in the working-portion dimensioned and configured to engage a wire-nut; a handle comprising a shank-engagement portion longitudinally opposite from a terminal-end, wherein the handle encases the handle-end of the elongated shank and wherein the terminal-end has an aperture positioned in registration with the axial bore of the elongated shank; and a handle-plug comprising a mushroom-shaped cap with a hollow stem and a bulbous top, wherein the hollow stem is dimensioned and configured to securely and removably engage the terminal-end of the handle and wherein the hollow stem is dimensioned and configured to removably store a driver-bit.

Aspects of the present invention are further directed to a multi-purpose tool comprising an elongated shank, a hollow flared tip, a handle, and handle-plug; wherein the elongated shank has an axial bore, a working-end, a handle-end, and a transverse aperture, wherein the aperture is dimensioned and configured to engage and bend a wire when the shank is rotated; a hollow flared tip with an axial bore in registration with the axial bore of the elongated shank, comprising a terminal working-portion and a connector-portion opposite from each other along a longitudinal axis, wherein the connector-portion is connected to the working-end of the shank, wherein the flared tip has a transverse cross-sectional area which is taped from the terminal working-portion to the connector-portion, and further comprising two slots in the working-portion dimensioned and configured to engage a wire-nut; a handle comprising a shank-engagement portion longitudinally opposite of a terminal-end, wherein the handle encases the handle-end of the elongated shank and wherein the terminal-end has an aperture positioned in registration with the axial bore of the elongated shank; a handle-plug comprising a mushroom-shaped cap with a hollow stem and a bulbous top, wherein the hollow stem is dimensioned and configured to securely and removable engage with the terminal-end of the handle and wherein the hollow stem is dimensioned and configured to removably store a driver-bit; and a driver-bit comprising two longitudinally opposite ends, wherein one end is dimensioned and configured to engage a slotted screw and the opposite end is dimensioned and configured to engage a Phillips head screw and wherein the driver-bit is stored in the stem of the handle-plug.

Aspects of the present invention are further directed to a multi-purpose tool comprising an elongated shank, a hollow flared tip, a handle, and a handle-plug; wherein the elongated shank has an axial bore, a working-end, a handle-end, and a transverse aperture, wherein the aperture is dimensioned and configured to engage and bend a wire when the shank is rotated; a hollow flared tip with an axial bore in registration with the axial bore of the elongated shank, comprising a terminal working-portion and a connector-portion opposite from each other along a longitudinal axis, wherein the connector-portion is connected to the working-end of the shank, wherein the flared tip has a transverse cross-sectional area which is tapered from the terminal working-portion to the connector-portion, and further comprising two slots in the working-portion dimensioned and configured to engage a wire-nut; a handle comprising a shank-engagement portion longitudinally opposite of the terminal-end, wherein the handle encases the handle-end of the elongated shank and wherein the terminal-end has an aperture positioned in registration with the axial bore of the elongated shank, and further comprising an inner-portion and an outer-portion wherein the inner-portion is in direct contact with the elongated shank and is dimensioned and configured to substantially resist electrical conductivity, and wherein the outer-portion is dimensioned and configured to be slip resistant; and a driver-bit comprising two longitudinally opposite ends, wherein one end is dimensioned and configured to engage a slotted screw and the opposite end is dimensioned and configured to engage to Phillips head screw and wherein the driver-bit is stored in the stem of the handle-plug.

Embodiments of the invention may include a multi-purpose tool that is especially suited for an electrician or others working with electrical wires. The working-end of the elongated shank may be flared and may include two opposing slots extending from the terminal-end close to the connector end. The terminal-end may be flared sufficiently to cover a conventional wire-nut so that the wings on a conventional wire-nut will fit into the slots of the tip. When the handle of the tool is rotated, the wire-nut may also be rotated around a central axis. Embodiments may provide for the rotation of the wire-nut to cause any wires, inserted into the wire-nut, to engage not only each other but also the internal surface of the wire-nut. Thus, a connection may be made between the wires.

Commercial and residential electrical wiring schemes require a ground-wire as a safety device. The ground-wire is attached to an electrical switch, electrical outlet, or other electrical device to drain excess current from an electrical circuit. Wire-nuts that are specifically suited for engaging ground-wires have a hole through the top, through which extended ground-wires may pass. A wire-nut suited for ground-wires serves the purpose of connecting multiple ground wires to one grounding source. The exposed end of a hot-wire is twisted around a ground-wire by the rotation of the wire-nut. The hot-wire end remains covered within the wire-nut, while the ground wire extends through the hole in the wire-nut.

With a long enough primary ground-wire, multiple secondary ground-wires may be connected to the primary wire. In this configuration, the primary ground-wire would pass through the hole in the wire-nut and then connect to subsequent ground-wire and subsequent series of ground-wires. Aspects of the present invention may allow for this unique configuration because of the axial bore that extends through the entirety of exemplary devices, from the working-end through the handle. Such features may be particularly advantageous because the elongated shank can be produced in a length sufficient to reach deep into electrical boxes or outlets.

Another useful feature of the present subject matter is a removable handle-plug containing a driver-bit. Conventional light switches in both residential and commercial applications are connected to a power source by attaching wires to the light switch via Phillips head screws. The electrical wire (either hot or ground) is bent into a loop configuration and wrapped around the stem of a screw. When the screw is tightened into the light switch, the head of the screw squeezes the wire between the metal screw and a metal connector plate. Once the screw is tightened the wire remains in place and an electrical connection is made. A removable handle-plug as described herein may conveniently store a driver-bit. Preferably the driver-bit includes a slotted head screw end and a Phillips head screw end, however, other screw heads are possible, i.e., Allen, star, etc. A removable driver-bit may be secured into the cap of the handle-plug and function as a short or stubby screwdriver.

Embodiments may also include a transverse hole in the elongated shank. This feature can replace conventional needle-nose pliers in an electrician's toolkit. In the example of a light switch, all of the electrical wires must be bent to wrap around the screw post. Instead of using one's hands or an additional tool, the user can simply put the end of the wire into the transverse hole, hold the wire with one hand, and rotate the tool in the other hand. The aperture sufficiently grips the end of the wire and bends it into a loop. The user can then wrap the looped end of the wire around the screw post and, using the handle-plug as a screwdriver, secure the connection.

Other objects and advantages of the invention will appear more fully from the following detailed description of preferred embodiments discussed in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation of an exemplary combination wire-nut driver.

FIG. 2 is a cross-section of an exemplary combination wire-nut driver of FIG. 1 at line A.

FIG. 3 is a side elevation of an exemplary combination wire-nut driver with a hex-shape handle.

FIG. 4 is a cross-section of an exemplary handle-plug of the combination wire-nut driver of FIG. 1 at line A.

FIG. 5 is an illustration of an exemplary removable driver-bit stored in a handle-plug.

FIG. 6 illustrates an exemplary driven wire-nut.

FIG. 7A is a top plan view of an exemplary ground-wire wire-nut.

FIG. 7B is a side elevation of an exemplary ground-wire wire-nut.

FIG. 8 illustrates an exemplary driving tip of the combination wire-nut driver of FIG. 1.

DETAILED DESCRIPTION

The following detailed description is provided with reference to exemplary embodiments for the ease of description and understanding. Applicants' invention is not limited to the disclosed embodiments, and encompasses other variations that fall within the overall scope of description provided herein References will now be made to the attached drawings, where the same reference numerals are used throughout the various view.

As shown in FIG. 1, an exemplary combination wire-nut driver 10 includes an elongated shank 12. The elongated shank 12 may provide a primary structure for the wire-nut driver 10. The working end of the elongated shank 12 comprises a flared tip 14. Opposite the flared tip 14 is a handle-end 15. The flared tip 14 swells outwardly and may be configured to substantially match the taper on a conventional wire-nut 50, as shown in FIG. 7. The flared tip 14 has two opposing wing slots 26. The two wing slots 26 are located across from one another on opposite sides of the flared tip 14. The wing slots 26 may be configured to substantially match the wings 54 on a conventional wire-nut 50, as shown on FIG. 7.

The handle-end 15 of the elongated shank 12 is encased by the handle 19. In a preferred embodiment, the handle-end 15 of the elongated shank 12 does not extend entirely through the handle 19; rather the handle extends past the terminal end of the handle-end 15 of the elongated shank 12.

A handle-plug 20 may be removably securable to the end of the handle 19. A wire-bending hole 18 is shown positioned transverse to the longitudinal axis of the combination wire-nut driver 10. As shown in FIG. 1, the wire-bending hole 18 may be located in the handle 19. In an alternate embodiment, the wire-bending hole 18 may be positioned at a point in the elongated shank 12 or the handle-plug 20. The elongated shank 12 is shown with a hollow inner shaft 22 which extends completely through the longitudinal axis of the elongated shank 12. Because the handle 19 and the handle-plug 20 also have a hollow inner shaft, an axial bore extends through the entirety of the exemplary combination wire-nut driver 10.

FIG. 2 is a cross-sectional view of FIG. 1 at line A. A ground-wire 24 is illustrated extending through the hollow inner shaft 22 beginning at the flared tip 14 of the elongated shank 12, through the handle-end 15 and the handle 19 and extending outward from the handle-plug 20. FIG. 2 also illustrates a preferred construction of the handle 19. The handle 19 includes an insulating inner handle 17 and a finished outer handle 16. The insulating inner handle 17 prevents the passage of any electrical current from the elongated shank 12 to the hand of the user. A preferred material of the insulating inner handle 17 is, for example, cellulose acetate; however, other substantially insulating materials could be used, such as rubber, wood, ceramic, or other insulating material. The finished outer handle 16 surrounds the insulating inner handle 17 and may provide a slip resistant surface for the user. A preferred construction of the finished outer handle 16 may include a ribbed or ridged rubber material. However, the outer handle 16 can be made of any other slip resistant and comfortable material. The handle-plug 20 may be preferably made of a similar material to the finished outer handle 16. The elongated shank 12 may be preferably made of a material capable of withstanding great torsion or pressure.

FIG. 3 illustrates an alternate embodiment of the elongated shank 12. The elongated shank 12 has a flared tip 14 and opposing wing-slots 26 as well as a hollow inner shaft 22. On the opposite longitudinal end from the flared tip 14 is the alternative hex-shape handle 28. The hex-shape handle 28 is configured to be gripped by a conventional rotary drill or mechanical tool (not shown) with a three-jaw chuck. It is also within the scope of the invention, that the hex-shape handle 28 can be used manually with a crescent wrench (not shown) or a suitably sized open jaw wrench. It is also within the scope of this invention that the handle 19 (shown in FIGS. 1 and 2) can securely fit over the alternative hex-shape handle 28. It is also within the scope of this invention that the wire-bending hole 18 may be positioned as part of the elongated shank 12 or the hex-shape handle 28, and not in the handle 19.

FIG. 4 illustrates an exemplary handle-plug 20. The handle-plug 20 is mushroom-shaped with a bulbous cap 21 and a stem 23, both of which have an axial bore in registration with the hollow shaft 22 of the elongated shank 12. The stem 23 may be configured to securely fit in the handle 19. FIG. 5 illustrates a driver-bit 30 which can be securely stored inside the handle-plug 20. The handle-plug 20 has a securing protrusion 32 which engages a notch 33 on the driver-bit 30. The securing protrusion 32 is rigid enough to keep the driver-bit 30 securely in place, yet flexible enough to allow the removal of the driver-bit 30 from the handle-plug 20. A preferred embodiment of the driver-bit 30 is illustrated in FIG. 5 with a slotted screw end 34 and a Phillips head end 36. Slotted and Phillips head screws are the most common used in electrical wiring; however, alternative embodiments of the driver-bit 30 may engage other types of screw heads, e.g., star or Allen. The handle-plug 20 can be used as a short or stubby screwdriver when necessary. When a handle-plug 20 is removed from the handle 19, an end of the driver-bit 30 may extend past the stem 23. If another of the driver-bit 30 is desired, the user may apply enough pressure on the driver-bit 30 to urge the notch 33 off the securing protrusion 32. The user then inverts the driver-bit 30 and replaces it into the stem 23 with enough pressure to urge the notch 33 back onto the securing protrusion 32. Once the user has finished using the handle-plug 20, it may be securely placed back into the handle 19.

FIG. 6 illustrates an example of how the combination wire-nit driver 10 may be used. For example, in a typical residential or commercial application, ground-wire 24 and other ground wires 40 are combined 42 in an electrical box 38. The ground-wires 24, 40 are brought close together and a wire-nut 50 is placed over the top so that (as shown) only a single ground-wire 24 extends through the hole 52 in the wire-nut 50. FIG. 7A is a top plan view of a conventional ground-wire-nut 50 illustrating the hole 52 and the wings 54. FIG. 7B is a side elevation view of a conventional ground-wire-nut 50. FIG. 8 is a side plan view of just the flared tip 14 and the opposing wing slots 26. After the wire-nut 50 is placed onto the ground-wires 24, 40 with one ground-wire 24 extending through the hole 52 of the wire-nut 50, the flared tip 14 can be slid onto the wire-nut 50. The wings 54 slide into the slots 26 and the extended ground-wire 24 extends into the flared tip 14 and further into the hollow inner shaft 22 of the elongated shank 12. The user can then rotate the handle 19, which rotationally urges the wire-nut 50. The wire-nut 50 engages, twists and subsequently connects the ground-wires 24, 40.

It is understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims.

Claims

1. A multi-purpose tool comprising: an elongated shank defining an axial bore, comprising a working-end and a handle-end, and further having a transverse aperture defined therein, wherein the aperture is dimensioned and configured to engage and bend a wire when the shank is rotated;a hollow flared tip defining an axial bore in registration with the axial bore of the elongated shank, comprising a terminal working-portion and a connector-portion opposite from each other along a longitudinal axis, wherein the connector-portion is connected to the working-end of the shank, wherein the flared tip has a transverse cross-sectional area which is tapered from the terminal working-portion to the connector-portion, and further comprising two slots in the working-portion dimensioned and configured to engage a wire-nut;a handle, comprising a shank-engagement portion longitudinally opposite of a terminal-end, wherein the handle encases the handle-end of the elongated shank and wherein the terminal-end has an aperture positioned in registration with the axial bore of the elongated shank;a handle-plug, comprising a mushroom-shaped cap with a hollow stem and a bulbous top, wherein the hollow stem is dimensioned and configured to removably engage the terminal-end of the handle, wherein the hollow stem is dimensioned and configured to store a driver-bit.

2. The tool in claim 1, the handle further comprising an inner-portion and an outer-portion, wherein the inner-portion is in direct contact the elongated shank and is dimensioned and configured to substantially resist electrical conductivity, and wherein the outer-portion is dimensioned and configured to be slip-resistant.

3. The tool in claim 1, wherein the handle is removable from the elongated shank.

4. The tool in claim 1, wherein the handle-end of the elongated shank has a hexagonal cross-section, dimensioned and configured to be engaged by power tools having at least one of locking jaws and chucks.

5. The tool in claim 1, further comprising a driver-bit, wherein the driver-bit is stored in the stem of the handle-plug.

6. The tool in claim 5, wherein the driver-bit further comprises two longitudinally opposite ends, wherein one end is dimensioned and configured to engage a slotted screw and the opposite end is dimensioned and configured to engage to Phillips head screw.

7. The tool in claim 1, wherein the bulbous top of the handle-plug having an axial aperture defined therein, is dimensioned and configured to rotationally secure the driver-bit and function as a screwdriver.

8. A multi-purpose tool comprising: an elongated shank defining an axial bore, comprising a working-end and a handle-end, and further having a transverse aperture defined therein, wherein the aperture is dimensioned and configured to engage and bend a wire when the shank is rotated;a hollow flared tip defining an axial bore in registration with the axial bore of the elongated shank, comprising a terminal working-portion and a connector-portion opposite from each other along a longitudinal axis, wherein the connector-portion is connected to the working-end of the shank, wherein the flared tip has a transverse cross-sectional area which is tapered from the terminal working-portion to the connector-portion, and further comprising two slots in the working-portion dimensioned and configured to engage a wire-nut;a handle, comprising a shank engagement portion longitudinally opposite of a terminal-end, wherein the handle encases the handle-end of the elongated shank and wherein the terminal-end has an aperture positioned in registration with the axial bore of the elongated shank;a handle-plug, comprising a mushroom-shaped cap with a hollow stem and a bulbous top, wherein the hollow stem is dimensioned and configured to securely and removably engage with the terminal-end of the handle, wherein the hollow stem is dimensioned and configured to removably store a driver-bit; anda driver-bit, comprising two longitudinally opposite ends, wherein one end is dimensioned and configured to engage a slotted screw and the opposite end is dimensioned and configured to engage a Phillips head screw, and wherein the driver-bit is stored in the stem of the handle-plug.

9. The tool in claim 8, the handle further comprising an inner-portion and an outer-portion, wherein the inner-portion is in direct contact with the elongated shank and is dimensioned and configured to substantially resist electrical conductivity, and wherein the outer-portion is dimensioned and configured to be slip-resistant.

10. The tool in claim 8, wherein the handle is removable from the elongated shank.

11. The tool in claim 8, wherein the handle-end of the elongated shank has a hexagonal cross-section, dimensioned and configured to be engaged by power tools having at least one of locking jaws and chucks.

12. The tool in claim 8, wherein the bulbous top of the handle-plug having an axial aperture defined therein, is dimensioned and configured to rotationally secure the driver-bit and function as a screwdriver.

13. A multi-purpose tool comprising: an elongated shank defining an axial bore, comprising a working-end and a handle-end, and further having a transverse aperture defined therein, wherein the aperture is dimensioned and configured to engage and a bend wire when the shank is rotated;a hollow flared tip defining an axial bore in registration with the axial bore of the elongated shank, comprising a terminal working-portion and a connector-portion opposite from each other along a longitudinal axis, wherein the connector-portion is connected to the working-end of the shank, wherein the flared tip has a transverse cross-sectional area which is tapered from the terminal working-portion to the connector-portion, and further comprising two slots in the working-portion dimensioned and configured to engage a wire-nut;a handle, comprising a shank-engagement portion longitudinally opposite of a terminal-end, wherein the handle encases the handle-end of the elongated shank and wherein the terminal-end has an aperture positioned in registration with the axial bore of the elongated shank, and further comprising an inner-portion and an outer-portion, wherein the inner-portion is in direct contact with the elongated shank and is dimensioned and configured to substantially resist electrical conductivity, and wherein the outer-portion is dimensioned and configured to be slip-resistant;a handle-plug, comprising a mushroom-shaped cap with a hollow stem and a bulbous top, wherein the hollow stem is dimensioned and configured to securely and removably engage with the terminal-end of the handle, wherein the hollow stem is dimensioned and configured to removably store a driver-bit; anda driver-bit, comprising two longitudinally opposite ends, wherein one end is dimensioned and configured to engage a slotted screw and the opposite end is dimensioned and configured to engage a Phillips head screw, and wherein the driver-bit is stored in the stem of the handle-plug.

14. The tool is claim 13, wherein the handle is removable from the elongated shank.

15. The tool in claim 13, wherein the handle-end of the elongated shank has a hexagonal cross-section, dimensioned and configured to be engaged by power tools having at least one of locking jaws and chucks.

16. The tool in claim 13, wherein the bulbous top of the handle-plug having an axial aperture defined therein, is dimensioned and configured to rotationally secure the driver bit and function as a screw driver.