Electrical connector

Nov. 11, 1958 η. w. kost 2,860,19.7

ELECTRICAL CONNECTOR

Filed March 13, 1953 3 Sheets-Sheet 1

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Hazdlu W.KD3T.

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Nov. 11, 1958

2,860,197

H. W. KOST

ELECTRICAL CONNECTOR

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Nov. 11, 1958 η. w. kost 2,860,197

ELECTRICAL CONNECTOR

Filed March 13, 1953 3 Sheets-Sheet 3

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2,860,197

Patented Nov. 11, 1958

United States Patent Office

2,860,197 ELECTRICAL CONNECTOR Harold W. Kost, Ottawa Hills, Ohio Application March 13,1953, Serial No. 342,171 3 Claims. (Cl. 191—12) a side elevational view showing a form of a plan view of the construction shown in a view similar to Figure 1 of the opposite

This invention relates to electrical connectors and, more especially, to connectors of the flexible conductor or cord type for use in conducting electric current to currentconsuming appliances and apparatus.

It has been conventional practice to utilize lengths of flexible insulated conductors or cords for providing electrical energy conveying means between a current supply outlet and an appliance, especially those appliances which are of a portable or movable character, such as toasters, coffee makers, motor-driven food mixers, flat irons, radios and the like. In many instances several appliance connectors or cords are joined with a single power outlet through suitable multiple-outlet fittings, such an arrangement presenting an unsightly assemblage of connector cords, even though one or more of the connected appliances are in use for only short periods of time.

The present invention embraces an electrical connector of a character which may be readily disconnected from either the power source or the appliance and stored in compact condition when not in use.

An object of the invention is the provision of an elec- ³⁵trical connector of the flexible cord type associated with a rotatable supporting element or reel· adapted to store the connector when the latter is out of: use.

An object of the invention resides in the provision of a rotatable cord-storing reel embodying means for estab- 40 lishing a positive electrical connection or contact with a power source irrespective of the extent that the cord or electrical connector is unwound or withdrawn from the reel.

Another object of the invention resides in a reel con- 45 struction supporting an extensible current conductor or cord adapted for connection with a power source embodying resiliently biased means effective to establish a circuit at all times between the current conductor or cord and the power source and resiliently urging the reel in one 50 direction of rotation to automatically wind the cord upon the reel.

Another object of the invention resides in the provision of a current conductor storage means which may be incorporated in a current-consuming appliance or may be permanently installed in a building or supporting structure and utilized as a current supply outlet.

Still another object of the invention is the provision of an electrical conductor and storage reel assembly which may be utilized as a portable means for conducting electrical energy from a stationary current outlet or power supply to a current-consuming appliance, the assembly being arranged whereby the current conductor may be maintained in stored position when not in use.

A further object of the invention is the provision of inexpensive yet effective means associated with the rotatable current conductor receiving reel and: the reelsupporting means engageable with the current conductors for relieving the electrical connections from tension or mechanical shock that may be imparted to the conductors during use of the reel construction.

Further objects and advantages are within the scope of this invention such as relate to the arrangement, operation and function of the related elements of the structure, to various details of construction and to combinations of parts, elements per se, and to economies of manu5 facture and numerous other features as will be apparent from a consideration of the specification and drawing of a form of the invention, which may be preferred, in which:

Figure 1 is the invention;

Figure 2 is

Figure 1;

Figure 3 is side of the construction;

Figure 4 is a sectional view taken substantially on the line 4—4 of Figure 3;

Figure 5 is an enlarged sectional view of a portion of the structure illustrated in Figure 4;

Figure 6 is an isometric view of a current-consuming appliance illustrating a form of the invention incorporated therein;

Figure 7 illustrates a form of the invention utilized for direct connection with a conventional current supply outlet;

Figure 8 is a view illustrating an installation of the invention as a permanent current supply connector;

Figure 9 is a view similar to Figure 5 showing a modified form of mounting for the cord-supporting means;

Figure 10 is an elevational view illustrating a modified form of the invention;

Figure 11 is a plan view of the construction shown in : Figure 10;

Figure 12 is a detail sectional view taken substantially on the line 12—12 of Figure 10;

Figure 13 is a sectional view taken substantially on the line 13—13 of Figure 12;

Figure 14 is a detail sectional view through the hub of a reel showing another form of means of securing a cord to the hub;

Figure 15 is an elevational view showing a modified form of reel-supporting means and enclosure therefor, and

Figure 16 is a detail view showing current-conducting means embedded in a reel-supporting means.

While the arrangement of the invention is particularly adapted as an extension cord connector for electrical household appliances, it is to be understood that the principles of the invention may be adapted for use with othei types of current-consuming equipment,

Referring to the drawings and initially to Figures 1 through 5, there is illustrated a form of the invention wherein the cord-supporting reel construction is journally mounted upon a. support 10_: formed: with substantially parallel, spaced wall or leg portions 11 and 12 connected 55 by a base portion 14 as shown in Figure 2, The portion 14 may be provided with openings to accommodate securing screws 15 for mounting the construction, upon a suitable surface or appliance.

The cord-supporting arrangement includes a reel or spool construction 18 which is formed with spaced disklike flanges or walls 20 and 21 and a central drum or hub portion 22. The flanges 20 and 21 and the hub or drum 22 are preferably molded of nonmetallic material in an integral unit although the_; flanges may be assembled 65 to. the hub portion as. independent members if desired. In the form shown, the hub portion must be formed of insulating material. Disposed axially, of the reel, at the sides thereof are hub members 24 and: 25 having tenon portions 26 which are received into openings formed in the portions 11 and 12 of the support 10, In the embodiment illustrated, the members 24 and 25 are relatively stationary with respect to the support 10 and the reel 18

2,860,197 revolves relative to members 24 and 25. Each of the hub members 24 and 25 is formed with a keyway or recess to receive a projection 16 formed on the wall portions 11 and 12 to avoid relative rotation of the hub members.

As particularly shown in Figure 5, the hub or drum portion 22 of the reel is provided with axial bores adapted to snugly receive pins or stub shafts 28 and 29, the juxtaposed ends of the pins being separated by insulating material of the hub as indicated at 30. The member 24 is bored to snugly receive a sleeve or bearing bushing 32 which forms a support for the pin or trunnion 28, and member 25 is bored to accommodate a similar sleeve 33 of shorter length and journally supports the pin or trunnion 29. Through this arrangement the reel 18 is journally supported for rotation about the axis of the pins or trunnions 28 and 29 which are in aligned relation and are journaled in the relatively stationary bearing sleeves 32 and 33. The ends of the bores in members 24 and 25 are closed by suitable plugs 36 and 37 of nonmetallic material such as resin or plastic.

Means is provided to bias the reel in one direction of rotation to automatically wind the cord 55 upon the drum 22 of the reel. As illustrated in Figures 3 and 4, the biasing means includes a coil spring 40, preferably formed of a flat strip of spring steel or the like, disposed in a chamber or recess 48 formed in the flange 21 of the reel 18. The inner end, viz., the end adjacent the hub member 24, is provided with a hook portion 42 which engages in a recess 43 formed in member 24. The outer end of the spring 40 is provided with a hook-like portion 45 which engages in a recess 46 formed in the circular wall 47 defining the perimeter of the chamber 48. The member 24 may be formed with a radially extending, disk-like flange or wall 50 which serves to enclose the chamber 48 containing the spring 40 preventing damage to the spring and the ingress of dirt and foreign matter into the chamber. As viewed in Figure 3, the spring 40 normally biases the reel 18 for rotation in a clockwise direction indicated by the arrow “A” tending to wind the cord 55 upon the drum 22 of the reel 18.

The method and arrangement of supporting the reel or spool 18 facilitate and make possible the establishment of electrical connections between current supply conductors and the flexible current-conducting member or cord 55, the latter being normally wound upon the drum 22. The cord 55 is of the dual-conductor type having electrical conductors 57 and 58, each being individually insulated by a covering 59 of rubber, plastic or any suitable insulating material. Each of the conductors 57 50 and 58 is formed of a linear bundle or strand of fine metal wires. The drum portion 22 of the reel is formed with radial passages 60 and 61 respectively intersecting the bores containing the pins or shafts 28 and 29.

In order to establish electrical connection between the 55 conductors of the cord 55 and the reel-supporting pins 28 and 29, the uninsulated extremities of the conductors are projected into the passages 60 and 61 formed in the drum 22 before the pins 28 and 29 are driven or pressed into the bores in the drum. As particularly shown in 60 Figure 5, the insertion of the pins 28 and 29 causes the ' fine wires of the conductors 57 and 58 to be drawn along the cylindrical periphery of the pins, the extremities of the fine wires of the conductors also occupying the bottoms of the bores which are contacted by the pins 28 and 65 29. In this manner the fine wires of the conductors are frictionally locked in contact with the surfaces of the reel-supporting pins to form circuit connections and to secure the inner end of the cord 55 to the drum. The insulation covering 59 on each of the conductors is nor- 70 mally molded into a single cable or cord 55 as shown n Figure 2. In order to effect the connections of the conductors to the pins 28 and 29, the insulated conductors are split from the integrated cord 55 as shown in Figure2. _7S

The cord and drum assembly is particularly illustrated in Figure 4 wherein electrical connections are established between each of the conductors 57 and 58 of the cord 55 through the pins 28 and 29 to the bushings 32 and 33 in 5 the manner above described. Current-conducting means is connected to each of the bushings for establishing a circuit with a current supply. As shown in both Figures 4 and 5 the hub portions 24 and 25 are provided with radial bores to receive the fine wires of metallic con10 ductors 67 and 68 forming current conductors for connection with a current supply or in the alternative are connected to an appliance in a manner hereinafter explained. A circuit connection is established between the bushings or bearing sleeves 32 and 33 and the fine wires 15 of the conductors 67 and 68 in substantially the same manner that current connections are made between conductors 57 and 58 and the pins 29 and 28, that is, the bearing sleeves or bushings 32 and 33 are pressed or driven into the axial bores formed in the hubs 24 and 25 20 causing the fine wires of the conductors to be frictionally locked in contact with the cylindrical peripheries of the bushings 32 and 33. The current conductors 67 and 68 are insulated by sheathing 70 and 71 except at the zone of engagement of the conductors with the metal bushings. 25 An effective electrical connection is maintained between conductors 58 and 67 and conductors 57 and 68 through the trunnion pins and bushings under the influence. of the spring 40 which exerts a biasing pressure holding the pins or shafts 28 and 29 in constant contact with the bushings. 32 and 33, respectively, whether the cord 55 is in static position or is being wound or unwound relative to the drum portion or spool 22. Thus, irrespective of the extensible position of the cord 55 with respect to the reel, an operative circuit is established ⁰⁰ through the reel-supporting means.

The arrangement of the invention is adaptable in various ways for establishing circuit connections between a current supply and a current-consuming appliance or unit. For example, the conductors 67 and 68 may be connected to conductors of a current supply and the frame 10 of the reel construction secured to a suitable support 16 by means of. screws 15 in the manner shown in Figures 1 and 2 With, this type of mounting, the frame 10 supports the reel m a relatively stationary location and the appliance45 connecting cord 55 may be unwound from the reel so as to engage the male-type connector or plug 56 at the extremity of the cord with a suitable female connector or receptacle carried by a current-consuming appliance to which current is to be supplied. During winding or unwinding of the cord 55 on the drum 22 of the reel, the reel 18 is rotated while the hub portions 24 and 25 remain in stationary position with respect to the supporting frame 10. When the cord is being extended, that is unwound, from the drum 22, the reel is rotated in a counterclockwise direction as viewed in Figure 3 causing the spring 40 to be wound up. The tension of the spring 40 impresses a continuously acting biasing pressurethrough the reel hub 22 and through the pins 28 and 29 to assure a constant engagement and electrical connection between ihe pins or trunnions and the reel-supporting bushings. The biasing pressure of the spring 40 exists in any position of the cord 55. Thus current may be conveyed to an appliance by simple joining the connector 56 of the cord 55 with the current-consuming appliance.

Figure 6 is. illustrative of another use of the connector of the invention wherein the reel and cord assembly is carried by the appliance and the cord is adapted to be extended to establish a current connection between the connector 56 and a current outlet connection which is permanently attached to a current supply. A typical installation in an appliance such as a toaster 8© is illustrated in Figure 6. As shown, the toaster includes a frame member 83 to which the reel frame 10 may be secured by means of suitable screws 84. The conductors contained within the insulating sheaths 70 and 71 are re2,860,107 s

spectiv.ely connected to terminals 85 and 86 supported upon insulating means carried by the frame 83 and connected to the heating units 88 of the toaster. The extensible cord 55 is guided to the reel by a suitable grommet 89 carried by the housing of the toaster 80. When the toaster or other appliance is not in use, the connector 56 may be released from its connection with a current outlet or supply fixture, and under the influence of the coil spring 40, the cord is automatically rewound upon the reel 18 until the insulation block 56' of the connector 56 engages the grommet 89. With the installation of the reel construction of the invention in any current-consuming appliance in the manner shown in Figure 6, the appliance may be utilized in any position within the extensible range 6r length of the cord 55. When the appliance is not in use, the cord remains wound upon the reel and is thus stored within the appliance.

The arrangement of the present invention may be utilized as an auxiliary extension where an appliance is used in a position where the conventional appliance cord is. of insufficient length to connect the appliance with a current supply outlet. Such an arrangement is shown in Figure 7 wherein the frame 10 supporting the reel 18 is secured to a member or plate 95 of insulating material by means of rivets 96; the plate-95 of insulating material may be provided with projections 98 and-99 of spring brass or other metal for insertion into a conventional current supply outlet or receptacle mounted in a wall 101. The projections 98 and 99 are secured to the plate 95 by means of rivets 102 or other suitable securing means. The extremities of the conductors enclosed in the insulating sheaths 70 and 71 may be secured to the rivets 102 by soldering or other means so as to establish circuit connections between the projections 98 and 99 and the conductors in the connector cord 55. Thus in the arrangement shown in Figure 7 the reel construction being secured to the insulating plate 95 may foe mounted or supported by an outlet box 100 of conventional character through the insertion of the projections 98 and 99 in openings in the outlet box. When the reel and cord 4θ arrangement is used in this manner, the free end of cord 55 is provided with a female fitting 104 and is adapted to receive prongs or connectors 106 of a conventional cord 107 connected to a current-consuming appliance (not shown).

Figure 8 is illustrative of the reel and cord construction of the invention mounted in a metal fixture or box for permanent installation in the wall of a building or upon any other support. The fixture or box 110 may be of conventional character formed of sheet metal having 50 ear. portions 112 secured to the building,wall 114 by means of screws 115. The front of the box is of open construction and is adapted to be closed by an escutcheon orcover plate 118 held to the box 110 by means of screws 119.

The reel construction 18 is . contained within the box 55 110, the frame or support 10 of the reel construction being secured to the rear wall 120 of the fixture or box by means of rivets 121. or other securing means. The conductors 70 and 71 may be permanently joined as by . soldering to conductors 125 and 126 contained within a 60 metak sheath or cable 127, the wires or conductors 125 and 126-being connected to a source of current supply. The extensible cord 55 passes through a suitable opening 130 formed in the escutcheon 118 and the cord is pro6 ment in a wall and hence the inconvenience of the presence of an exposed extension cord when the appliance is not in use is eliminated. Furthermore, the extensible cord 55 is at all times adapted for connection to the appliance and only the amount of cord necessary to reach the appliance is unwound from the reel 18.

The reel construction 18 and the hub members 24 and 24 are formed of material having noncurrent-conducting characteristics and are preferably molded or formed from thermoplastic or thermosettable resins. Such materials as acrylate and methacrylate resins; alkyd resins; vinyl resins such as polymers and copolymers of vinyl chloride, vinyl acetate and the like; phenol-formaldehyde resins; polyamid resins; polystyrene; polyethylene; synthetic rubber such as butadiene acrylonitrile, and urea resins are examples of resins suitable for the purpose.

Figure 9 is a view similar to Figure 5 showing a modification of the reel construction supporting means. In this form of construction, the reel hub 22' is formed with 20 bores adapted to receive bearing sleeves 32' and 33' which are pressed or driven into the bores. The current conductors 60' and 61' are engaged by the bushings so that an electrical connection is established between each conductor and the adjacent bushing. In this form the trun²⁵ nion pins 28' and 29' are pressed into or driven into suitable bores in the hub members 24' and 25' whereby the pins are nonrotatably supported in the hub members. The extremities of current conductors 67' and 68' extend into the bores in the hub members and are engaged by ³⁰ the pins when the latter are forced or driven into the bores in the hubs to establish an electrical connection between each pin and the adjacent conductor. The pins 28' and 29' are relatively stationary in this form of construction and the bushings 32' and 33' carried by the reel are rotatable upon the pins. The spring 40' of the same construction as spring 40 is connected to the reel and to the hub member 24' and exerts a biasing pressure to wind the reel in one direction, the biasing pressure also serving to cause continuous engagement between the trunnion pins and the bushings so that circuits are at all times established to the conductors contained in the cord 55.

Figures 10 through 13 illustrate a modified form of reel-supporting means, the reel assembly being substantially of the same construction as that shown in Figures 1 through 3. The reel assembly 21 is rotatably mounted upon a supporting frame or bracket 150 formed of sheet metal. The reel assembly 21 is provided with the journal pins 28 and 29 which are fixedly carried in the reel hub 22, the pins extending into openings formed in bearing members 153 and 154. The wires or current conductors contained in the cord 55 are engaged with the pins 28 and 29 in the same manner as shown in Figure 4. The member 153 is formed of suitable nonmetallic molded material such as phenolformaldehyde resin and is formed with a bearing portion 155 which forms a journal for pin 28. The member 154, also of molded nonmetallic or resinous material, is formed with a bearing portion 156 which journally supports the pin 29.

In this form of the invention the current conductors or wires contained within the insulating members or -..- ________ ...- -.- sheaths 70 and 71 are secured respectively to resilient vided with a. female connector 104 to receive the male 65 ^or A^ble plate-like^ contact members 158 shown in Figconnector with which an appliance may be equipped or the male connector of a conventional extension cord 107.

The . arrangement shown in Figure .8 facilitates withdrawal of the cord 55 from its stored position on the ures 12 and 13, each of said contact members having a semicylindrical central portion 159 which has a substantial area of engagement with the journal pins to establish _______ _________ _ ______ ____________________ ____ effective electrical contact therewith. The members 153 reel in the wall'for connection with a current-consuming 70 ^and 154 are each formed with slots 160 in communicaappliance. When the appliance is not in use, the fitting 104 may be disconnected from the appliance or an extension cord and the cord 55 automatically rewound upon the reel 18 contained within the fixture or box 110.

In this mariner the .cord 55 may be stored in .a comparttion with a recess 161 which accommodates the plate-like contact members or elements 158 in the manner shown in Figure 13. The plate members 158 may be of flexible metal, for example, spring brass or the like, having good current-conducting characteristics.

The elements

2,860,197

158 may be soldered or otherwise joined to the conductors contained in sheaths 78 and 71 in the manner illustrated at 163 in Figure 13.

Means are provided for embracing and enclosing the exterior portions of members 153 and 154. As shown in Figure 12 the means are in the form of cup-like cap members 165 embracing the bearing members 153 and 154 and functioning as closures for the slots 160 and recesses 161 containing the contact members 158. The cap members are provided with openings to accommodate the conductors contained in the sheaths 70 and 71. Each of the cup-like members 165 is formed with projections 168, as shown in Figures 10, 12 and 13, which extend into openings formed in the leg portions of the support 150, the metal 169 struck up from the openings formed in the support being bent or flexed into engagement with the projections 168. Through this arrangement, the contact members 158 and the ends of the journal pins are completely enclosed to· eliminate electrical shock hazard.

The leg portions of the sheet metal support 150 may be formed with struck-up projections 172 which may be bent or distorted, the projections 172 providing means for relieving stresses upon the connections of the current conductors with the plates 158 in the event that tension is applied or transmitted to the current conductors.

Means may be provided to relieve any stresses at the connections of the pins 28 and 29 with the conductors contained in the cord 55. As shown in Figure 12 the hub portion 22 may be formed with a threaded opening to receive a screw 174 which passes through an opening in a fitting or bracket 175 which is shaped to engage or embrace the cord 55 and secure the cord in frictional engagement with the hub of the reel. Through this means, a tension applied to the cord 55 will be resisted by the fitting or clip 175 so as to prevent the transmission of tension to the connections between the conductors.in the cord 55 and the journal pins 28 and 29.

Figure 14 illustrates a modified form of means associated with the hub of the reel for preventing tension or stress on the cord being transmitted to the connections between the conductors in the cord and the journal pins supporting the reel. In this form of construction, the reel hub 22a is molded or fashioned with an outwardly extending hook-like projection 180 whereby the cord 55 may be passed through the opening or recess 181 between the exterior periphery of the hub 22a and the innermost surface of the hook-like projection 180. The dimension of the recess 1S1 is sufficient to snugly receive a loop in the cord 55 so that the cord is frictionally secured between the projection and the exterior surface of the hub 22α. The hook-like projection 180 may be integrally molded with the hub construction.

Figures 15 and 16 illustrate a modified form of the construction shown in Figure 7. In this form of the invention, the reel construction 21α is journally supported upon fittings (not shown) secured in openings 199 formed in supporting portions 191 of molded material such as phenolformaldehyde resin. A casing or housing 192 completely encloses the reel construction. In this form of the invention, the connectors or current conductors 194 are soldered or otherwise secured to clips or contacts 158' or the clips and connectors may be formed integrally, the clips bearing upon and making the electrical connection with the journal pins supporting the reel. The connectors 194 may be embedded in the supports or members 191, the latter being preferably integrally formed or joined together by suitable means. The connectors 194 may be molded in the supports 191 at the time the supports are formed. The connectors 194 have projecting portions 196 which are spaced to be received in the conventional female electrical outlet fitting. The housing 192 may be formed of sheet metal or of molded material such as phenolformaldehyde or other resin or plastic. The housing may be removably secured to the supports 191 by means of screws 198 or the housing may be of a two-piece construction and the portions or members 190 integrally molded with each section of the housing. The housing is provided with an opening 5 199 accommodating the extension cord 55a to permit the winding and unwinding of the cord upon the reel construction. It will be apparent that the construction shown in Figure 15 completely encloses the movable parts of the reel so as to prevent damage thereto and to ¹⁰ eliminate electrical shock hazard.

It is to be understood that the arrangements of the present invention may be adapted for use with various current-consuming appliances and may be incorporated 15 ’^{n an}· ^aPPl*^ance *ⁿ manner illustrated in Figure 6. The invention is adaptable for incorporation in or for use with appliances such as radio receiving equipment, television receiving equipment, food mixers, grills, coffee makers and other current-consuming devices and is adaptable for use wherever a variable-length or extensible conductor is desired.

It is apparent that, within the scope of the invention, modifications and different arrangements may be made other than is herein disclosed, and the present disclosure is illustrative merely, the invention comprehending all variations thereof.