Rotary electrical connector.

0001The present invention relates generally to electrical connectors for connecting a power or communication cord to an appliance or telecommunications equipment and more particularly to a rotary electrical connector for such use.

0002A rotary electrical connector is used, for example, in conjunction with a cord that connects the handset to the base of the telephone. The purpose of the rotary electrical connector is to prevent the cord from becoming tangled or twisted when used over an extended period of time, which is undesirable.

0003Rotary connectors generally comprise a spindle at least part of which is contained within a housing. Either the spindle or the housing is mounted for rotation in relation to the other, about a common axis. Male and female modular electrical connector elements are associated with one or the other of the housing and the spindle. That part of the spindle located within the housing has electrically conductive rings located around the periphery of the spindle, and these rings are connected by electrical conducting elements extending through the spindle to electrical contact members on one of the modular connector elements. The rings are engaged by other electrical contact members electrically connected to further contact members on the electrical connector element associated with the housing. There is thus formed a rotatable electrical connection between the modular male and female connector elements. The female connector element associated with the rotary connector receives a modular male connector element normally located at one end of a telephone cord, and the male modular connector element associated with the rotary connector normally plugs into a female connector element on the telephone, either the hand set or the base.

0004Most rotary electrical connectors of the type described above are relatively complicated assemblies containing a relatively large number of parts which are difficult to assemble and have operating difficulties.

Summary of the Invention

0005A rotary electrical connector in accordance with the present invention has a relatively minimal number of parts. It is relatively simple to assemble, and it has optimum operating characteristics. There are a number of improved structural features incorporated into a rotary electrical connector constructed in accordance with the present invention. Among these features are the provision of grooves in the periphery of the spindle to receive the conductive rings, and a notch in a side wall of the groove for retaining the conductive ring within the groove.

0006Another feature is structure for imparting torsion to the contact member which engages the ring, to urge the contact member against the ring.

0007A further feature is the provision of structure which permits the adjustment of a ring-­engaging contact member in an axial direction to facilitate alignment of the contact member with the particular ring it is intended to engage.

0008Another feature is the employment of a ring which is integral with the electrical conducting element connecting the ring to the modular connector element, and the provision of structure which facilitates the assembly of all the integral ring-conducting elements with the spindle.

0009Still another feature is a method for manufacturing a spindle assembly.

0010Other features and advantages are inherent in the structure and method claimed and disclosed or will become apparent to those skilled in the art from the. following detailed description in conjunction with the accompanying diagrammatic drawings.

Brief description of Drawings

0011<ul id="ul0001" list-style="none"><li>Fig. 1 is a perspective illustrating an embodiment of a rotary electrical connector in accordance with the present invention and associated telephone parts;</li><li>Fig. 2 is an exploded perspective of an embodiment of a rotary electrical connector in accordance with the present invention;</li><li>Fig. 3 is a perspective of a female electrical connector element associated with the rotary electrical connector;</li><li>Fig. 4 is a sectional view of the rotary electrical connector;</li><li>Fig. 5 is an end view as viewed from the left in Fig. 4;</li><li>Fig. 6 is a sectional view taken along line 6­-6 in Fig. 4;</li><li>Fig. 6a is a perspective of an embodiment of electrical contact member in accordance with the present invention;</li><li>Fig. 7 is an exploded perspective illustrating a spindle assembly in accordance with an embodiment of the present invention;</li><li>Fig. 8 is a plan view of one-half of a split spindle body in accordance with the present invention;</li><li>Fig. 9 is a sectional view taken along line 9­-9 in Fig. 8 but with both halves of the spindle body assembled together;</li><li>Fig. 10 illustrates a method of assembling an embodiment of a spindle assembly in accordance with the present invention;</li><li>Fig. 11 is a side elevational view of the embodiment whose assembly is depicted in Fig. 10;</li><li>Fig. 12 is a sectional view taken along line 12--12 in Fig. 10;</li><li>Fig. 13 is an exploded perspective of another embodiment of a spindle assembly in accordance with the present invention;</li><li>Fig. 14 is a side elevational view of the embodiment of Fig. 13;</li><li>Fig. 15 is an end view, as viewed from the left in Fig. 14;</li><li>Fig. 16 is a sectional view taken along line 16--16 in Fig. 15;</li><li>Fig. 17 is an exploded perspective of a further embodiment of a spindle assembly in accordance with the present invention;</li><li>Fig. 18 is a sectional view of the embodiment of Fig. 17 taken along line 18--18 in Fig. 19;</li><li>Fig. 19 is a side elevational view of the embodiment of Fig. 17;</li><li>Fig. 20 is a sectional view taken along line 20--20 in Fig. 18;</li><li>Fig. 21 is an exploded perspective of still another embodiment of a spindle assembly in accordance with the present invention;</li><li>Fig. 22 is a side elevational view of the embodiment of Fig. 21;</li><li>Fig. 23 is a sectional view, partially cut away, taken along line 23--23 in Fig. 22; and</li><li>Fig. 24 is a sectional view taken along line 24--24 in Fig. 23.</li></ul>

Detailed Description

0012Referring initially to Fig. 1, indicated generally at 30 is a rotary electrical connector constructed in accordance with an embodiment of the present invention and shown in use with a telephone. Rotary connector 30 receives a male modular connector element 31 located at one end of a telephone cord 32. Associated with rotary electrical connector 30 is a male connector element 33 received within a socket 34 in a telephone hand set 35. The other end of telephone cord 32 (not shown) is connected to the base of the telephone set.

0013The arrangement illustrated in Fig. 1 could, of course, be reversed so that the other end of cord 32 is connected to hand set 35 and so that male connector element 33, associated with the rotary electrical connector, would plug into a socket similar to 34 in the base of the telephone.

0014Referring now to Figs. 2 and 4, rotary connector 30 comprises a housing 36 having first and second opposite open ends 37, 38 respectively. Rotatably mounted within housing 36 is a spindle assembly 40 comprising a spindle body 41 which carries a plurality of electrical conducting elements 42, 42. Spindle body 41 comprises a first bearing portion 43 located between the opposite ends of the spindle body and a second bearing portion 44 located at one end of the spindle body. Extending integrally from first bearing portion 43 is a shank portion 45. When the spindle and the housing are assembled together, first bearing portion 43 is rotatably mounted within housing opening 38, and shank portion 45 extends outwardly from opening 38, to the right as viewed in Fig. 4.

0015The spindle body's second bearing portion 44 is rotatably mounted within a recess 49 located at one end of a female connector element 48 which carries a plurality of electrical contacting elements 50, 50 which, together with the engagement of the spindle's second bearing portion 44 within recess 49, attaches female connector element 48 and spindle assembly 40 together, in a manner to be subsequently described in greater detail.

0016Female connector element 48 and spindle assembly 40 are initially attached together, and they are then inserted into housing 36 through its first open end 37. When female connector element 48 and spindle assembly 42 are assembled within housing 30, they assume the positions shown in Fig. 4.

0017As assembled, female connector element 48 is contained within and supported by housing 36. Female connector element 48 in turn rotatably supports one end of spindle assembly 40, where the spindle's second bearing portion 44 is engaged within recess 49 in the female connector element. The other rotatable support for spindle assembly 40 within housing 36 is the engagement of first bearing portion 43 within second open end 38 of housing 36. As shown in Fig. 4, spindle shank 45 projects outwardly from housing 36 beyond the latter's second open end 38. Male connector element 33 is mounted on shank 45 after all of the other elements shown in Fig. 4 are assembled in the positions shown there.

0018Movement of spindle assembly 40 in an axial direction to the right as shown in Fig. 4 is prevented by the engagement of a ring-like thrust bearing 39, located on the interior of housing 36 around second open end 38, with a thrust bearing 46 on spindle body 41, located adjacent the spindle's first bearing portion 43. Movement of spindle assembly 40 in an axial direction to the left as viewed in Fig. 4 is prevented by the spindle body's engagement with female connector element 48, and movement of female connector element 48 in an axial direction to the left in housing 36 is prevented by the engagement of a pair of projections 51, 51 on the bottom of the female connector element (Figs. 2 and 3) with a pair of slots 52, 52 on the bottom of housing 36 adjacent its first open end 37 (Fig. 2).

0019When all the elements are fully assembled as shown in Fig. 4, spindle assembly 40 and male connector element 33 are rotatable together relative to female connector element 48 and housing 36, about a common axis.

0020Housing 36, female connector element 48, spindle body 41 and male connector element 33 are all composed of electrical insulating material such as molded plastic. Electrical conducting elements 42, 42 and electrical contact elements 50, 50 are, of course, composed of a conductive metal such as copper or the like which may be gold plated to enhance corrosion resistance, or one may employ a high corrosion resistant copper-nickel-silver alloy such as 725 copper alloy.

0021Referring now to Figs. 2, 4 and 6-7, spindle body 41 has a plurality of peripheral grooves 53, 53 in the spindle body's outer surface. As best shown in Fig. 7, each electrical conducting element 42, 42 has a linear first portion 55 extending through spindle body 41 in a direction substantially parallel to the axis of the spindle, a second portion 56 extending transversely from first portion 55 through the outer surface of the spindle body and a ring portion 57 integral with second portion 56 and received in a respective peripheral groove 53 on the outer surface of the spindle body. Integral with an electrical conducting element's first portion 55 is a terminal end portion 58 shaped to conform to and engage with male connector element 33 (Fig. 4).

0022With further reference to Fig. 7, spindle body 41 comprises two halves or sections 60, 60 each having a semi-circular or convex outer surface and a respective mating or inner surface 61, 61 on which are located pins 62, 62 for engagement within holes 63, 63 on the opposite mating surface. Each mating surface also includes a peg 64 for engagement within a slot 65 on the opposite mating surface. The pins, holes, pegs and slots described in the two preceding sentences serve to hold the two spindle halves 60, 60 together. Each mating surface 61 on a spindle body half 60 contains a first slot portion 67 extending in a direction substantially parallel to the axis of the spindle. Communicating with each first slot portion 67 is a second slot portion 68 extending transversely from the first slot portion to the outer surface of the spindle where it communicates with a corresponding groove 53. When the two spindle halves 60, 60 are mated, the slot portions 67, 67 and 68, 68 on each half are similarly mated to define channels for receiving the first and second portions 55, 56 respectively of an electrical conducting element 42.

0023Referring now to Figs. 7-9, each ring portion 57 of an electrical conducting element is wrapped around the outer surface of the spindle body within a groove 53. Each groove 53 comprises a bottom 70 and a pair of side walls 71, 72. Located in side wall 71 of each groove, adjacent groove bottom 70, is a notch 73 which receives and engages the terminal end part 74 of an electrical conducting element's ring portion 57, to retain terminal end part 74 adjacent the bottom of groove 53 and maintain the entire ring portion in close engagement with the bottom of groove 53. Notch 73 prevents the ring portion from disengaging from groove bottom 70. As shown in Fig. 8, each notch 73 extends radially inwardly toward the axis of the spindle, further than does groove bottom 70. This enhances the moldability of the notch.

0024Each groove 53 has a width sufficient to accomodate two widths of the conductor material of which ring portion 57 is composed but not substantially more. The significance of this feature will be discussed below.

0025Referring now to Figs. 2-6, each electrical contact member 50 comprises a first portion 80 for engagement with an electrical contact member on male electrical connector element 31, a second portion 81 extending from first portion 80 in a direction substantially parallel with the axis of the spindle body and lying in the same plane as first portion 80, and a third portion 82 integral with second portion 81 and extending transversely to the plane of first and second portions 80, 81. First and second portions 80, 81 have a junction 83 therebetween, and second and third portions 81, 82 have a junction 84 therebetween. Third portion 30 normally abuts the spindle within a peripheral groove 53.

0026Groove 53 contains two widths of the conductor material of an electrical conducting element's ring portion 57. Third portion 82 of an electrical contact member engages the peripheral groove containing two widths of the conductor material (Fig. 4). Because the two widths of the conductor material completely fill a groove 53, a full electrical connection between electrical contact member 50 and ring portion 53 is assured. There is no danger of third contact portion 82 slipping off a ring portion into a part of the groove not occupied by the ring portion because the totality of the width of the groove is occupied by the two widths of conductor material.

0027As shown in the drawings, there are four peripheral grooves 53, 53 on the spindle body. There are also four electrical contact members 50, 50 carried by female connector element 48. The third portion 82 of each contact member 50 engages a respective peripheral groove 53. In the illustrated embodiment, a pair of third portions 82, 82 engages the spindle body on each of two opposite sides, (Fig. 6), and the engagements are all tangential to the spindle body at locations on the spindle body below the axis thereof. Each of the four third portions 82, 82 is under torsion so that the two pairs of third portions 82, 82 apply between them a pinching or gripping action on the spindle body from opposite sides of the spindle body, and this helps effect the attachment between female connector element 48 and spindle body 41, an attachment which is effective outside of housing 36, as well as inside the housing. The engagement of a ring portion 57 by contact portions 82, 82 from opposite sides of a groove 53 also helps to reduce noise in the receiver. This is because noise is due to discontinuities in engagement between a ring portion 57 and a third portion 82 during rotation of one relative to the other. With two third portions 82, 82 engaging each ring, the incidence of discontinuity is reduced substantially and therefore so is the noise. Another benefit of engaging each ring portion 57 with two third portions 82, 82 is that each third portion 82 requires substantially less urging against a ring portion to avoid disengagement, and as a result, the torque required to rotate the spindle against the resistance imparted by third portions 82, 82 is substantially reduced, e.g. to about 25% of the torque required when a ring portion 57 is engaged by only one third portion 82.

0028Female connector element 48 includes structure which facilitates the alignment of each contact member's third portion 82 with a respective peripheral groove 53. More particularly, female connector element is in the form of a body having a bottom portion 86, a pair of side portions 87, 88 extending upwardly from bottom portion 86 and an end portion 89 also extending upwardly from bottom portion 86 and extending between side portions 87, 88. End portion 89 comprises a plurality of slots 90, 90 each for containing the terminal end part 85 of a first portion 80 of an electrical contact member 50. Located on the female connector element's bottom portion 86 are a plurality of slots 91, 91 each for containing a second portion 81 of electrical contact member 50.

0029Communicating with all of slots 91, 91, at an end 93 of female connector element 48, is a notch 92 for receiving junction 83 between first and second portions 80, 81 of a contact member 50. Notch 92 comprises structure for accommodating movement of contact member 50 in the plane of its portions 80, 81 toward and away from spindle body 41 along a path parallel to the axis of the spindle. This permits alignment of the contact member's third portion 82 with a predetermined peripheral groove 53 on spindle body 41. Slots 90, 90 in end portion 89 of the female connector element have a dimension, in an axial direction, sufficient to accommodate the movement described in the next to last sentence. As shown in Figs. 2-6, there is no structural restraint against contact member 50, between junction 83 and third portion 82 thereof, which prevents the above-­described movement of the contact member.

0030As noted above, third portion 82 of electrical contact member 50 is under torsion, and structure for accomplishing this will now be described. The female connector element's bottom portion 86 comprises structure including slot 91, which mounts the contact member's third portion 82 and junction 84 for rotation about the axis of second portion 81 of the contact member. Located on the upper part of the female connector element's bottom portion 86 are slots 95, 95 each for receiving and containing a part 96 of the connector member's first portion 80, adjacent junction 83 thereof. The structure described in the preceding sentence holds junction 83 against rotation about the axis of the contact member's second portion 81. In effect, the contact member's second portion 81 is restrained against rotation at an end thereof defined by junction 83, but it is not restrained against rotation at an end thereof defined by junction 84. As a result, second portion 81 of the contact member constitutes a torsion bar urging the contact member's third portion 82 against spindle body 41 toward a free state position for third portion 82. This free state position, indicated by dash dot lines at 82a in Fig. 6 is located angularly substantially inwardly of the position where third portion 82 normally abuts the spindle, the normal position being indicated in full lines at 82 in Fig. 6. Indicated by dash dot lines at 82b in Fig. 6 is the maximum torsional limit for third portion 82.

0031The amount of torsion (i.e. angle of twist) which is applied to the contact member's third portion 82 is determined by the length of the torsion bar, that is by the length of the contact member's second portion 81 between its unrestrained end at junction 84 and its restrained end at junction 83. If more torsion or angle of twist is desirable, this can be accomplished by increasing the length of the torsion bar (second portion 81). If torsion bar 81 is lengthened, then female connector element 48 must be lengthened to accommodate the increase in torsion bar length, and this can be accomplished by increasing the thickness or dimension in an axial direction of end portion 89 of the female connector element. (The distance between end 93 and end portion 89 of the female connector element is dictated by the dimension needed to accomodate male modular connector element 31. Because the size of male element 31 is fixed, female connector element 48 cannot be lengthened between end 93 and end portion 89 thereof. Hence the increase in the length of torsion bar 81 must be accommodated by increasing the thickness of the female connector element's end portion 89.)

0032In the embodiments discussed above, there is a single contact member 50 and a single third portion 82 for each peripheral spindle groove 53. In another embodiment, there can be a pair of contact members 50, 50 for each peripheral spindle groove 53, with the third portion 82 of each contact member in the pair engaging groove 53 from a respective opposite side. In such an embodiment each contact member in the pair has first and second portions 80, 81 each disposed in close side-by-­side relation with the first and second portions of the other contact member in the pair, and portions 80, 81 of each contact member in the pair lie in the same slot 90, 91, 95. The third portion 82 of each contact member in the pair diverges from the third portion of the other contact member in the pair. This can be accomplished by making each contact member from a separate wire or from one wire doubled to form the portions 80, 81, 82 of the two contact members, as shown in Fig. 6a.

0033The slots 90, 91, 95 etc. should be wide enough to accommodate both members 50, 50 or the members 50, 50 should be narrow enough to both fit in the same slot. Each contact member 50 in the pair has the torsion bar characteristics described above for an unpaired contact member 50, so that there is a double torsion bar effect urging each of the third portions 82, 82 in a pair toward each other from opposite sides of the same peripheral spindle groove.

0034As noted above, each first portion 80, 80 in a pair lies in the same slot 90, and each first portion 80, 80 in a pair is engaged by the same contact member 97 in male modular connector element 31 (Fig. 1).

0035There will now be described various embodiments for facilitating the assembly of electrical conducting elements 42, 42 with spindle body 41 and for maintaining the electrical conducting elements in insulated relation to each other.

0036Referring to Figs. 13-16, spindle body 41 has a pair of opposite ends 100, 101 and an outer surface 102. In this embodiment, shank 45 would also function as a bearing portion, like portion 43 in the embodiment of Figs. 2 and 4. Spindle body 41 also comprises an axial opening 103 extending between opposite ends 100, 101. Axial opening 103 slidably receives an elongated holding member 104 having an outer surface 107 containing a plurality of peripheral grooves 108, 108. Holding member 104 comprises a key 105 extending radially outwardly therefrom, and spindle body 41 comprises a key way 106 at axial opening 103 for receiving key 105 to fix holding member 104 against rotation about the axis of spindle body 41 when the holding member is slidably received within axial opening 103.

0037An electrical conducting element 42 is received in each groove 108 on holding member 104, before the holding member is slidably inserted into the spindle body's axial opening 103. Holding member 104 is composed of electrical insulating material, and when the holding member is received within the spindle body, the holding member and the spindle body cooperate to maintain electrical conducting elements 42, 42 in insulated relation to each other.

0038When holding member 104 is assembled within spindle body 41, the holding member's elongated grooves 108, 108 each extend in a direction parallel to the axis of the spindle body, and each comprises structure for holding the first portion 55 of a respective electrical conducting element 42 (Fig. 16).

0039The spindle body comprises structure for facilitating the fabrication of electrical conducting element 42 into its component portions 56, 57, and such structure will now be described. Extending radially inwardly from outer surface 102 of spindle body 41 are a plurality of slots 110, 111, 112, 113 each extending from spindle body end 100 toward the other end 101 in a direction parallel to the spindle body's axis, and each slot 110-113 terminates at a respective one of the spindle body's peripheral grooves 53, 53. Grooves 53, 53 are separated by dividers integral with spindle body 41, and each slot 110-113 terminates between a pair of adjacent dividers. Each slot 110-113 extends in a different respective radial direction transverse to the axis of spindle body 41, and when holding member 104 has been slidably inserted within spindle body 41, each of the elongated grooves 108, 108 on the holding member is radially aligned with a respective slot 110-113 in spindle body 41. Each of slots 110-113 is angularly spaced from the other, and each of the elongated grooves 108, 108 in the holding member is angularly spaced from the other at a spacing corresponding to the angular spacing of slots 110-113.

0040When holding member 104 is initially inserted within spindle body 41, holding member end 115 is aligned with spindle body end 100 (Fig. 16) and an end part 47 on each undeformed electrical conducting element 42 extends axially outwardly past spindle body end 100. End part 47 is grasped and bent back, through a corresponding respective slot (e.g. 110) in spindle body 41, all the way to the particular peripheral groove 53 at which that particular slot terminates. This bending action forms second portion 56 of electrical conducting element 42. The remainder of the electrical conducting element is then wrapped around the outer surface of spindle body 42 within its peripheral groove 53, thereby forming ring portion 57 of the electrical conducting element.

0041The sequence of fabricating operations described in the preceding paragraph is repeated for each of the electrical conducting elements 42, 42. When the electrical conducting elements have been thus fabricated into their respective component portions, each of slots 110-113 contains the second portion 56 of an electrical conducting element. Slots 110-113 facilitate the wrapping of the electrical conducting element's ring portion 57 around the outer surface 102 of spindle body 41 within a respective spindle body peripheral groove 53.

0042Referring now to Figs. 17-20, in the embodiment illustrated in these figures, spindle body 41 has a single slot 116 extending radially inwardly from the spindle body's outer surface 102. Slot 116 also extends along the axis of the spindle body from one spindle body end 100 to an end wall 122 adjacent the other spindle body end 101, and slot 116 communicates with all of the peripheral grooves 53, 53 on spindle body 41. Slot 116 terminates at a groove 53 which is relatively remote from spindle body end 100 and which is defined by a pair of adjacent dividers integral with the spindle body Slot 116 slidably receives a holding member 117 for holding electrical conducting elements 42, 42 in insulated relation to each other. Slot 116 mounts holding member 117 in a predetermined position within spindle body 41, fixed against movement in a direction transverse to the axis of the spindle body.

0043Holding member 117 comprises a pair of radially spaced, flat side surfaces 118, 119 and a pair of axially spaced opposite ends 120, 121. End 120 is inclined in a direction non-perpendicularly transverse to the axis of the spindle body, and end 120 is located closer to end 100 of the spindle body then is the other end 121 of holding member 117. The holding member's flat side surface 118 has a plurality of grooves 123, 123 extending between the holding member's ends 120, 121. Each groove 123 comprises structure for holding the first portion 55 of a respective electrical conducting element.

0044Before holding member 117 is inserted in slot 116, an electrical conducting element 42 is placed in each of the grooves 123, 123 of the holding member. The holding member is then slidably inserted into slot 116 until end wall 121 of holding member 117 abuts against the inner surface of end wall 122 adjacent spindle body end 101 (Fig. 18). End wall 122 contains a plurality of aligned openings 132, 132 through each of which a respective electrical conducting element 142, 142 extends. Each groove 123, 123 in holding member 117 has a different dimension in an axial direction so that, when holding member 117 is positioned within spindle body 41 as shown in Fig. 18, each end of a groove 123, 123 at inclined end 120 is radially aligned with a different respective peripheral groove 53, 53 on spindle body 41.

0045When holding member 117 is initially inserted into spindle body 41, the end parts 47, 47 of electrical conducting elements 42, 42 extend axially outwardly from spindle body 41 beyond end 100 thereof. In order to fabricate the electrical conducting elements 42, 42 into their respective component portions, the end part 47 of each electrical conducting element is grasped and bent back in an axial direction through slot 116 until it is radially aligned with a respective peripheral groove 53 on the spindle body. In the course of doing so, the electrical conducting element's second portion 56 is formed. The remainder of end part 47 is then wrapped around the outer surface of spindle body 41 within a respective peripheral groove 53. The bending and wrapping procedures described above are performed on end parts 47, 47 sequentially from top to bottom as viewed in Figs. 17-18.

0046As shown in Fig. 20, slot 116 has a relatively wide inner portion 124 for receiving holding member 117 and a relatively narrow outer portion 125 for receiving the second portion 56 of an electrical conducting element. Slot portion 125 is narrower than the width of holding member 117, and as a result, the holding member is restrained against movement in a radial direction parallel to its side surfaces 118, 119.

0047Referring now to Figs. 21-24, the embodiment illustrated therein is similar to that illustrated in Figs. 17-20, except that instead of employing a single holding member composed of electrical insulating material, such as 117, the embodiment of Figs. 21-24 employs a plurality of electrical insulating layers 130, 130 each enclosing part of a separate, respective electrical conducting element 42.

0048More particularly, each electrical conducting element 42, 42 has its first portion 55 surrounded by circular insulating layer 130 having a pair of opposite ends 131, 133. Each insulating layer 130 has a different respective dimension in an axial direction.

0049Extending radially inwardly from the outer surface 102 of spindle body 41 is a slot 126 extending from one spindle body end 100 toward the other end 101 in a direction parallel to the axis of the spindle body. Slot 126 comprises a plurality of radially spaced, connected grooves 127, 127 each defining a circular cross-section, and the outermost groove 127 communicates with a narrow, outermost slot portion 128 in turn communicating with each of the peripheral grooves 53, 53 on the outer surface of the spindle body. Each circular groove 127 receives and holds in a fixed position in the spindle body, a respective tubular, cylindrical insulating layer 130 having an annular cross-section.

0050Each of the insulated electrical conducting elements 42, 42 is inserted into the spindle body until the insulating layers 130, 130 are in the position shown in Fig. 23 wherein an end 133 of the insulating layer abuts against the inner surface of a spindle body end wall 134 adjacent spindle body end 101. End wall 134 has a plurality of openings 135, 135 through each of which extends an uninsulated part of a respective electrical conducting element 42. End 131 of the insulating layer is located closer to end 100 of the spindle body. When the electrical conducting elements 42, 42 are in the position shown in Fig. 23, each insulating layer end 131 is radially aligned with a respective spindle body peripheral groove 53.

0051After electrical conducting elements 42, 42 have been inserted in slot 126, the terminal end 47 of each element 42 is grasped and bent back axially through slot 126 until it is aligned with a respective peripheral groove 53 in the spindle body, thus forming second portion 56 of the electrical conducting element. The remainder of the electrical conducting element is then wrapped around the outer surface of the spindle body in its respective peripheral groove 53 to form ring portion 57 of the electrical conducting element. The bending and wrapping procedures described above are performed on end parts 47, 47 sequentially from top to bottom as viewed in Figs. 21 and 23.

0052Figs. 10-12 depict a method for fabricating a spindle assembly wherein the electrical conducting elements are in planar form rather than wire as in the other embodiments described above.

0053Referring initially to Fig. 10, the method comprises initially providing a sheet of electrical conducting material (e.g. copper or the like). This sheet is stamped into an intermediate planar form 140 having a multiplicity of conducting groups 141, 141 each comprising a plurality of parallel, spaced apart, planar, electrical conducting elements 142, 142 each connected to a pair of marginal portions 143, 144 on intermediate planar form 140.

0054Intermediate form 140 is then positioned at a molding station accommodating a plurality of molds for forming spindle bodies. There is one mold for each conducting group 141, 141.

0055Each marginal portion 143, 144 has holes 145, 146 respectively for receiving pins 149, 150 attached to a conveying system (not shown). The pins received in holes 145, 146 hold intermediate form 140 in a fixed disposition at the molding station illustrated in Fig. 10 and convey the molded spindle bodies with electrical conducting elements embedded therein away from the molding station after the completion of the molding operation, which will be subsequently described.

0056Each electrical conducting group 141 on intermediate form 140 has portions 157, 157 each corresponding to the ring portion of an electrical conducting element, portions 158, 158 each corresponding to the portion of an electrical conducting element which is connected to male electrical connector element 33, and transversely extending barb portions 159, 160. Portions 157-160 are unenclosed by the mold at the molding station, but all the other portions of a conducting group 141 are enclosed, as shown with respect to the three conducting groups 141, 141 to the left in Fig. 10.

0057There are four molds at the molding station, and each mold is a cavity mold of conventional construction composed of two halves held in place by pins located at 147 (Fig. 10). After the molds have been positioned for all four conducting groups 141, 141 of an intermediate planar form 140, a non-conducting, plastic material in molten form is introduced into each mold. The molten plastic material is then solidified around the enclosed part of each group 141 to embed the enclosed portions within a molded plastic spindle body 151. Each conducting element 142 in each conducting group 141 has a pair of free unembedded parts, one such part corresponding to ring portions 157, 157 and the other such part corresponding to portions 158, 158. Portions 157, 158 are respectively connected to marginal portions 143, 144 of planar intermediate form 140.

0058Each electrical conducting group 141 comprises openings 148, 148 which fill with plastic during the molding operation to help lock the group in place within the molded plastic spindle body 151 and help hold barbed portions 159, 160 in place when the spindle assembly is in final form.

0059After the molten plastic material has solidified, the molds are opened to effect the separation therefrom of a one-piece, molded, plastic spindle body 151 with electrical conducting elements embedded therein. All of the spindle bodies at this stage are connected together by the marginal portions 143, 144 of planar form 140.

0060The assemblage of molded spindle bodies 151, 151 with embedded electrical conducting elements 142, 142 and connected marginal portions 143, 144 are then conveyed by pins 149, 150 extending through marginal holes 145, 146 to another station where the marginal portions 143, 144 are severed from the unembedded portions 157, 158 of each conducting element to form individual, separated spindle bodies with conducting elements 142, 142 embedded therein. Thereafter, each unembedded part corresponding to a ring portion 157 is wrapped around the outer surface of the corresponding spindle body 151 in a groove 153 formed therein during the molding step.

0061In its final form, the spindle assembly comprises, in addition to the spindle body, a plurality of electrical conducting elements 142, 142 each having a planar first portion 155 extending through the spindle body in a direction substantially parallel to the axis of the spindle body, a second planar portion 156 extending transversely from the first portion through the outer surface of the spindle body and a ribbon-like ring portion 157 integral with the second portion and received in a respective peripheral groove 153 on the spindle body.

0062As shown in Fig. 10, in each group of conducting elements 142, 142, the two outermost conducting elements have portions 159, 160 extending radially outwardly, on opposite sides of the conducting element, adjacent an end 164 of the spindle body, at a location axially spaced from the peripheral grooves 153, 153. Portions 159, 160 terminate at barbs. The location and shape of portions 159, 160 correspond to the location and shape of portions 169, 170 on the spindle shank 162 on which a male connector element 33 is mounted. Portions 169, 170 comprise structure for embeddingly engaging with the male electrical connector element to help hold it in place on shank 162.

0063As noted above, each ribbon-like portion 157, 157 is wrapped around the outer surface of the spindle body at a respective groove 153, 153. Each ring portion has a terminal end part 165, comprising barbs 166, 166 for embedding engagement with the side walls of a peripheral groove 153 to help hold the ring portion 157 in place in the groove.

0064Referring to Fig. 12, there is an opening 147 in spindle body 151 which corresponds to the location of the pins which held the two halves of a cavity mold in place during the molding step.

0065Referring again to Fig. 10, in lieu of a manufacturing method in which one-piece spindle bodies are molded about the electrical conducting elements, one may employ a method utilizing pre-molded spindle body sections or halves similar to those illustrated in Fig. 7 at 60, 60. In such a method, intermediate form 140 would be positioned at a station accommodating a plurality of spaced spindle body sections or halves 60, 60, as in Fig. 10. There, each group 142 of electrical conducting elements 141, 141 would be placed atop a respective spindle body section or half 60 each having longitudinal and lateral slot portions such as 67, 68 (Fig. 2) appropriately sized and shaped to accommodate flat first and second portions 155, 156 of an electrical conducting element 142 as well as flat edge portions 159, 160 on the two outermost elements. Then another, similarly contoured spindle body half 60 would be placed atop each conducting group 42 and engaged to the lower spindle half through the medium of pins and holes 62, 63 and pegs and slots 64, 65 (Fig. 7). Next, the opposite ends of conducting elements 42, 42 would be severed from marginal portions 143, 144. The ribbon-like portions 157, 157 are then wrapped within their respective grooves and the rest of the manufacturing operation is as described above.

0066The features disclosed in the foregoing description, in the claims and/or in the accompanying drawings may, both separately and in any combination thereof, be material for realising the invention in diverse forms thereof.