Lead wire strain relief connector and switch mount

Details Lead wire strain relief connector and switch mount Lead wire strain relief connector and switch mount

1995-10-06

2001-06-26

Gaffin, Jeffrey (Department: 2841)

Electricity: conductors and insulators

Conduits, cables or conductors

Accessories

C174S13800J, C200S294000

Reexamination Certificate

active

06252174

ABSTRACT:

BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention pertains to an apparatus that is attached to a surface of an electrical device that secures lead wires of a switch employed in the device, resisting the lead wires from being pulled from the device. The apparatus also includes clasps that securely hold the switch to the apparatus without adhesives or separate fasteners.
(2) Description of the Related Art
Various types of electrical devices, ranging from home appliances to industrial electric motors, employ electric switches that are operative to selectively open and close electric circuits between the devices and their external power sources. Typically, the switch in the electric circuit is mounted stationary on a casing or housing of the device and communicates with the external power source through lead wires that extend from the switch and exit the interior of the device housing through an aperture.
It is common that some sort of strain relief connector be employed in an electrical device to secure lead wires exiting the housing of the device. The strain relief connector is provided to prevent a pulling force exerted on the lead wires from being transmitted to the electrical connections of the lead wires within the device housing and possibly separating the connections. Frequently, an electrical device is provided with a hole in its housing through which the lead wires extend. A resilient grommet is attached around the lead wires and press fit into the housing hole to function as the strain relief connector for the lead wires. An example of this type of strain relief connector is disclosed in the Bizoe U.S. Pat. No. 3,502,917. However, with this type of strain relief connector, the device housing must be manufactured with an aperture that is specifically shaped and sized to receive and securely hold the particular grommet attached around the lead wires and inserted into the aperture. The particular grommet is limited in its use to a device housing manufactured with the particular sized and shaped aperture to receive the grommet.
Frequently, the housings of electrical devices are specifically designed to incorporate a strain relief connector for the lead wires entering the housing. Examples of housings incorporating strain relief connectors are disclosed in the Schwaneke U.S. Pat. No. 2,707,623 and Daniels U.S. Pat. No. 4,719,379. However, as can be appreciated, to specifically design some portion of a device's housing structure to include a strain relief connector for lead wires entering the housing, or to provide a housing surface that mates with a strain relief connector formed on another housing surface such as that shown in Schwaneke, adds to the cost of manufacturing the housing.
It is an object of the present invention to provide a strain relief connector for an electrical device that can be conveniently attached to most any casing or housing surface of the device to securely hold lead wires communicating the device with an external power source and thereby provide a strain relief connection to the lead wires. It is also an object of the present invention to provide a lead wire strain relief connector that is configured to be employed in various different types of electrical devices without requiring the casings or housings of the devices to be modified so that they also contribute to the strain relief functioning of the connector or accommodate the attachment of the connector to the housings, the connector of the invention only requiring a small surface area of a device casing or housing for attachment of the connector. It is a further object of the invention to provide a strain relief connector that may be employed in various different types of electrical devices more inexpensively than prior art connectors due to the elimination of specifically shaped and sized apertures and housing or casing structures required to accommodate or work with prior art strain relief connectors. To further enhance the economy of the lead wire strain relief connector of the invention, it includes an integrally formed mounting for an electrical switch that attaches the switch in a stationary position relative to the device housing without the need for separate fasteners or adhesives or other methods of attachment.
SUMMARY OF THE INVENTION
The lead wire strain relief connector and switch mount of the present invention is basically comprised of a base that supports both a lead wire anchor and a switch mount at fixed positions relative to the electrical device casing or housing to which it is attached. In the preferred embodiment, the base, lead wire anchor and switch mount are all constructed integrally as a single unit. Preferably, they are constructed of a nonconductive plastic material by any conventional molding process. However, the materials and process employed in constructing the apparatus are not critical to its operation, and other materials and manufacturing processes may be employed.
In the preferred embodiment, the base has a columnar configuration with longitudinally opposite top and bottom ends. A center bore extends axially through the base between its ends. The bottom end of the base is shaped with a generally planar surface perpendicular to the base center axis.
The lead wire strain relief anchor is comprised of an arm that cantilevers laterally from a side of the base between the base top and bottom ends. The arm is configured as a narrow, planar web that extends longitudinally downwardly from adjacent the base top end to a bottom edge of the arm adjacent the base bottom end. A beveled edge is formed along the bottom of the arm. The beveled edge is longitudinally spaced a set distance from the bottom end of the base, the set distance being predetermined to crimp switch lead wires between the arm beveled edge and the surface of the casing or housing to which the base is attached.
The switch mount is connected to the base above the arm. The switch mount is comprised of a pair of mutually opposed clamps that project laterally from the base. The clamps have barbs at their distal ends that are spaced a sufficient distance to enable insertion of an electrical switch therebetween. The clamps extend over opposite sides of the switch and their barbs engage around the sides of the switch inserted between the clamps to securely attach the switch to the base without the need for separate fasteners, adhesives or other methods of attachment. The switch mount in the preferred embodiment is also provided with a pair of laterally projecting posts that engage in holes provided in the electrical switch to further secure the switch to the base.
In securing the lead wire strain relief connector and switch mount to the casing of the device with which it is used, a surface of the device casing or housing is chosen which will result in the desired positioning on the device of the switch held by the switch mount. If necessary, the longitudinal length and/or shape of the base may be varied to properly position the switch held in the switch mount. A hole is then made through the device casing surface chosen, and a threaded fastener is then inserted through the center bore of the base and the hole in the casing surface. The lead wires of the switch are positioned between the beveled edge of the arm and the casing surface prior to the fastener being tightened. As the fastener is tightened, the bevel edge crimps the lead wires between the beveled edge and the casing surface, thereby providing a strain relief connection of the lead wires to the device casing. The lead wires are then passed through any convenient opening of the casing to its exterior, or through an aperture provided in the casing for the lead wires. Because the strain relief connector of the invention is not secured in the aperture for the lead wires, it is not necessary to provide the aperture with any specific shape or size.
The lead wire strain relief connector and switch mount of the invention may be employed in most any type of electrical device to inexpensively provide a strain relief connection fo

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