Electrical connectors – With circuit conductors and safety grounding provision – Grounding to connector container or housing
Reexamination Certificate
2000-06-20
2001-05-15
Paumen, Gary F. (Department: 2833)
Electrical connectors
With circuit conductors and safety grounding provision
Grounding to connector container or housing
C174S054000
Reexamination Certificate
active
06231357
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to a waterproof high voltage wiring and connector system particularly useful in wiring neon lights.
Luminous gaseous signs have been used for many years. While such signs can employ a variety of gases, the most popular and effective signs use neon gas and are referred to as “neon signs”. Neon signs are typically formed of glass tubing that is evacuated of substantially all of the air therein and refilled with neon gas. A conductive probe is inserted into each of the opposed ends of the tube. When high voltage energy is applied to the opposed ends of a neon filled tube, the neon gas is excited and produces visible electromagnetic radiation. The glass tubes can be of varying diameters and can easily be conformed to replicate letters, numbers and designs. The visible spectrum of light provided by excited neon gas is relatively bright and attractive; therefore the use of neon signs has become exceedingly popular in the United States and other countries of the world.
A serious problem that arises with the use of neon signs is the danger of fire and high voltage shock to workman who install or repair them. The typical neon sign transformer in the United States can be powered by standard household current, that is, 120V 60 Hz AC but the voltage typically supplied by the transformer and applied to neon signs is approximately 15,000V 60 Hz AC. This high voltage is dangerous to workman and any other living organism that may come in contact with the wiring for the neon sign. Further, this high voltage is also frequently the cause of building fires. Fifteen thousand volts AC readily arcs across adjacent conductors or from a conductor to a ground and such arcing can ignite combustible materials. The danger of fire as a consequence of this high voltage has become of such concern that some municipalities discourage the use of neon signs. In some cases, neon signs are being replaced by other types of signs that do not require high voltage electrical current.
Others have provided electrical fittings and wiring systems that are useful to supply high voltage electrical current, such as for connecting neon signs. For background information relating to other systems, reference may be made to the following United States patents:
U.S. Pat. No.
INVENTOR
TITLE
2,245,681
Kenigserg
Interchangeable Unit Luminous
Gaseous Sign
3,142,721
Long
Connector for Joining the
Outer Conductor of a Coaxial
Cable to a Wall
4,090,029
Lundeberg
Liquid Tight Connector with
Improved Ground Conductivity
4,590,950
Iwaszkiewicz et al.
Electrical Connection
4,690,482
Chamberland et al.
High Frequency, Hermetic,
Coaxial Connector for Flexible
Cable
4,737,601
Gartzke
Hermetically Sealed Electrical
Feedthrough and Method of
Making Same
4,842,535
Velke, Sr. et al
Gas Tube Electrode Connector
5,166,477
Perin, Jr. et al
Cable and Termination For
High Voltage and High
Frequency Applications
5,214,243
Johnson
High-Temperature, Low-Noise
Coaxial Cable Assembly With
High Strength Reinforcement
Braid
5,217,392
Hosler, Sr.
Coaxial Cable-to-Cable Splice
Connector
5,439,386
Ellis et al
Quick Disconnect
Environmentally Sealed RF
Connector For Hardline
Coaxial Cable
5,645,450
Yamada et al.
Shielded Connector
5,773,759
Hablutzel
Screw-Type Conduit Fitting for
a Shielded Cable
BRIEF SUMMARY OF THE INVENTION
The invention is concerned with a waterproof high voltage wiring and connector system for transferring high voltage electrical AC current from a high voltage power source to an apparatus, such as a neon sign. When the apparatus is a neon sign, the typical high voltage transformer may, as an example, employ a primary winding activated by 120V 60 Hz AC as is commonly used in the United States. The transformer converts the 120V 60 Hz AC electrical energy into high voltage 60 Hz electrical energy typical in a range of about 15,000 volts. This disclosure provides a waterproof connector useful in systems for safely conducting high voltage to individual segments of a neon sign.
This invention is basically concerned with a wiring and connector system by which a high voltage AC current is transported from a two pole high voltage transformer to a neon sign, one pole of the transformer being at ground potential and the other pole of the transformer being at a high AC voltage relative to ground. The system employs a flexible cable having in cross-section: (a) a central current carrying electrical conductor; (b) a symmetrical layer of insulation concentrically surrounding the central conductor; and (c) a symmetrical circumferential layer of metallic woven shielding conductor surrounding the layer of insulation. The cable usually also has an outer layer of plastic or rubber insulation.
An important application of the connector to be described is for passing high voltage through a metal wall having an opening therethrough. A short length cylindrical pass-through body has a nominal external diameter less than that of the opening. The pass-through body has a first end and second end. Spaced between the first and second ends of the pass-through body is an integral enlarged external diameter flange. An integral tubular first portion extends from the flange to the body second end and a tubular second portion extends from the flange to the body second end. External threads are provided on the exterior of the pass-through body first portion. A coaxially insulated conductor extends through the pass-through body. A ground conducting lug is centered within the pass-through body. The tubular second portion of the pass-through body is then crimped (compressed) to make permanent contact with the ground shield connection and also to form strain relief for the completed cable system.
The first tubular portion of the pass-through body that is externally threaded receives a nut by which the pass-through fitting can be secured in an opening in a device.
The ground conducting lug provides continuity between the metallic woven shielding conductor of the cable and the pass-through body. The ground conducting lug is formed of an elongated thin strip of highly conductive material, such as copper. An opening is cut into the cable outer insulation sheathing. A U-shaped bent inner portion of the ground conducting lug is inserted through the opening so as to lie against the outer surface of the cable metallic woven shielding conductor to thereby provide electrical communication between the cable shielding conductor and the pass-through connector.
Positioned over an outer portion of the ground conducting lug and surrounding the cable is a ground ring, that is, a ring of conductive material dimensioned to be easily slid over the exterior of the cable. The ground ring, after being positioned over the external part of the ground conducting lug and over the U-shaped inner part of the lug that is within the outer insulation sheathing of the cable is mechanically crimped to shrink it in diameter around the exterior of the cable and to secure electrical contact with the ground conducting lug. After the ground ring is crimped the pass-through fitting is slid over it so that the ground ring is positioned within the pass-through fitting.
After the pass-through fitting is slid over the installed crimped ground ring the thin wall integral second tubular portion of the pass-through body is itself crimped against the exterior of the cable. The crimped portion engages the ground conducting lug so that the pass-through body is then in electrical continuity with the metallic woven jacket of the cable.
The combination of a crimped ground ring and a crimped pass-through body provides an improved fitting for the neon sign industry. The cable resists pull from the pass-through body. Further, a waterproof closure is obtained around the cable.
A better understanding of the invention will be obtained from the following description of the preferred embodiments taken in conjunction with the attached drawings.
REFERENCES:
patent: 2245681 (1941-06-01), Kenigsberg
patent: 2904619 (1959-09-01), Forney, Jr.
patent: 3142721 (1964-07-01), Long
patent: 4090029 (1
Head Johnson & Kachigian
Nguyen Phuongchi
Paumen Gary F.
Relight America, Inc.
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