Electrode receptacle plug and method

Details Electrode receptacle plug and method Electrode receptacle plug and method

2000-03-22

2001-08-28

Sircus, Brian (Department: 2839)

Electrical connectors

Coupling part to receive fluorescent or neon lamp

With sealing element or material for cooperation with...

C439S232000

Reexamination Certificate

active

06280215

ABSTRACT:

FIELD OF THE INVENTION
The present invention generally relates to electrical connectors and more particularly, to an improved electrical connector for a high-voltage gas filled tube, for example, a neon tube used for signage.
BACKGROUND OF THE INVENTION
High-voltage, gas filled tubes have been widely used for signage for decades. With such tubes, it is necessary to connect a high voltage conductor with a tube electrode inside an electrode receptacle. Such an electrode receptacle is subject to degraded performance due to moisture condensing in the receptacle finding its way to a ground outside the receptacle, thereby causing damage to the gas filled tube and its associated electrical circuits and components. A known connection of a gas filled tube, for example, a neon tube to a high voltage conductor is illustrated in FIG.
4
. The neon tube
20
is mounted within a channel housing
22
, for example, an aluminum casing, that supports a face or lens
24
through which the neon tube
20
is viewed. The neon tube
20
has an electrode
26
with an electrode contact
27
to which a high-voltage potential is supplied by means of a conductor or wire, for example, a high voltage gaseous tube and oil ignition (“GTO”) cable,
28
. The voltage is in the kilovolt range; and therefore, it is important that the connection between the cable
28
and the electrode
26
be easily made and further, that the connection be reliable over a period of use. In many applications, the connection between the electrode
26
and the high-voltage cable
28
is accomplished utilizing a known electrode receptacle
30
which is often implemented with a connector P-K connector. The electrode receptacle
30
is comprised of an outer protective housing, for example, a metal tube,
32
that is connected to an inner insulator tube, for example, a glass insert,
34
by means of respective threads
36
a,
36
b.
A mounting plate
38
supporting the channel housing
22
is mounted to a structure, for example, a surface,
40
often an exterior surface, of a wall
42
. Thereafter, the insulator tube
34
is passed through a bore
44
within the mounting plate
38
and a hole
46
in the wall
42
. The metal housing
32
is then inserted through the hole
46
of the wall
42
from an opposite side
48
and over the insulator tube
34
. The metal housing
32
is then rotated with respect to the insulator tube
34
to engage the threads
36
a,
36
b
on the housing
32
and tube
34
, respectively. As the metal housing
32
is tightened, an end surface
50
of the housing
32
engages a gasket
52
located between the end surface
50
and a rear side
53
of the mounting plate
38
. In addition, a mounting flange
54
on the open end of the insulator tube
34
presses against a gasket
56
and the front surface
58
of the mounting plate
38
. Thus, the metal housing
32
and insulator tube
34
cooperate to securely mount the electrode receptacle
30
within the wall
42
to the mounting plate
38
. Thereafter, the cable
28
is passed through openings
33
,
90
, in the respective closed ends
82
,
35
of the insulator tube
34
and the metal housing
32
. A spring contact
66
is then crimped onto the end of the cable
28
in a known manner and located on a shoulder
67
within the insulator tube
34
. The cable
28
is carried within a conduit
60
mechanically connected via a conduit connector
62
to internal threads of a nut
64
on the bottom
35
of the metal housing
32
. With the cable
28
secured within the electrode receptacle
30
, the electrode
26
is inserted into the glass insulator tube
34
, and its electrode contact
27
is pushed into contact with the spring contact
66
, thereby providing a connection to the high-voltage cable
28
. One or more tube supports
68
attached to the neon tube
20
are then fastened to the mounting plate
38
by known means.
The electrode receptacle
30
normally provides a reliable, high-voltage connection between the cable
28
and the electrode
26
. However, over time, two failure conditions may arise. First, the thermal cycling of the neon tube
20
and the electrode receptacle
30
often results in the formation of condensation on the inside surface
70
of the insulator tube
34
or the metal housing
32
. If moisture weeps along the outer surface of the cable
28
, there is the potential for small current paths to be created between the spring contact
66
and ground, for example, the metal housing
32
and/or the conduit
60
and its connector
62
. Depending on the extent of moisture on the cable
28
, those current paths may be small or large, however, in any case, the current paths will cause a short circuit and failure in the lighting circuit.
A second problem with a typical electrode receptacle is that as the cable
28
passes through the bottom of the metal housing
32
, for example, through the nut
64
and into the conduit
60
, it is possible for the outer insulation of the cable
28
to be nicked or otherwise damaged by those metal components. For example, the nut
64
on the end of the metal housing
32
has internal threads that accept a threaded portion of a conduit connector
62
. Any nick or other damage to the insulation of the cable
28
reduces the integrity and effectiveness of the insulating properties and, over time, often results in a failure and short circuit condition. In addition, any nicking or degradation of the insulation of the cable
28
is magnified by the presence of condensation or moisture on the outer surface of the cable
28
that also provides a low resistance current path to the metal housing
32
or conduit
60
and connector
62
.
Therefore, there is a need for an improved connector housing a high-voltage connection between a high-voltage conductor and a gas filled tube, such as a neon tube.
SUMMARY OF THE INVENTION
The present invention provides an electrode receptacle that is less susceptible to short circuits that degrade the high voltage connection within the electrode receptacle. Thus, the present invention provides a more consistent, reliable and higher quality, high-voltage electrical connection within the electrode receptacle. The invention is especially useful in providing an electrical connection with a high-voltage, gas-filled tube used for signage in which the connection is exposed to a wide range of temperature and moisture conditions. In that regard, the invention provides an improved electrode receptacle in which moisture condensing within the electrode receptacle is prevented from contacting a ground, thereby preventing damage to the high voltage tube and its associated electrical circuits and components.
In accordance with the principles of the present invention and the described embodiments, an apparatus is provided for an insulator tube in which a high-voltage conductor and an electrode of a high-voltage tube are connected. The insulator tube has a first end receiving the electrode, and the insulator tube is received by an open first end of a housing. The insulator tube and housing are connectable to mount the insulator tube and the housing to a structure. The apparatus is a plug having a tubular body adapted to extend through the opposite end of the insulator tube, and the plug has an inner ring within the tubular body adapted to receive and sealingly engage the high-voltage conductor.
In one aspect of the invention, the inner ring is located near one end of the tubular body, and in another aspect of the invention, the inner ring is located on an end of the tubular body extending inside the insulator tube. In a further aspect of the invention, the tubular body has an opposite end extending through an opposite end of the housing.
In another embodiment, the present invention includes a method of reducing short circuits between ground and an interior of the insulator tube by preventing liquid from leaving an interior of the insulator tube through the opposite end of the insulator tube.
The sealing plug of the present invention effectively isolates moisture on the interior of the insulator tube from grou

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