Stud-type junction block

• US 8,047,868 B1
• Filed: 03/30/2009
• Issued: 11/01/2011
• Est. Priority Date: 03/28/2008
• Status: Active Grant

• Current Assignee: GEP Power Products, Inc.
• Original Assignee: GEP Power Products, Inc.
• Inventors: Korczynski, Jacek M.
• Primary Examiner(s): Le; Thanh Tam
• Application Number:
  US12/414,169
• Time in Patent Office: 946 Days
• Field of Search: 439/522, 439755-758, 439/801, 439/805, 439/810
• US Class Current: 439/522
• CPC Class Codes: H01R 11/281 for connections to batteries
• CPC Class Codes: H01R 13/5213 Covers
• CPC Class Codes: H01R 4/302 having means for preventing loosening of screw or nut, e.g. vibration-proof connection
• CPC Class Codes: H01R 4/34 Conductive members located under head of screw
• CPC Class Codes: H01R 4/64 Connections between or with conductive parts having primarily a non-electric function, e.g. frame, casing, rail

Abstract

A stud-type junction block assembly having a mounting member and a body constructed from a highly conductive material. A non-conductive or insulating sheath may be provided over a portion of the body. The body defines a bore configured to receive and retain at least one post constructed from a high-strength material. The bore may include threads for receiving an external threaded surface of the post for securing the post with the bore. In addition, a locking agent or adhesive may be provided to secure the post within the bore. An electrical connector having a ring is coupled to the body over the post to provide an electric path of conduction. A nut or other connector is provided on the post for securing the ring of the electrical connector to the body. A non-conductive cap may be provided over the nut.

Claims

1. A stud-type junction assembly comprising:

a mounting member configured for engagement with a support structure;

an electrically conductive body carried by the mounting member, wherein the electrically conductive body defines first and second exposed oppositely facing conductor engagement surfaces and a threaded passage that extends through the electrically conductive body and opens onto the first and second conductor engagement surfaces;

a threaded post that is separate from the body and that is coupled to the electrically conductive body via engagement of the threaded post within the threaded passage of the electrically conductive body, wherein the threaded post defines a first threaded end portion that extends outwardly from the first exposed conductor engagement surface and a second threaded end portion that extends outwardly from the second exposed conductor engagement surface; and

first and second threaded connectors configured for movable threaded engagement with the first and second threaded end portions of the post, respectively, wherein the first and second threaded connectors are movable on the respective first and second threaded end portions toward and away from the first and second conductor engagement surface of the body, respectively, wherein movement of the first and second connectors toward the first and second conductor engagement surfaces, respectively, is operable to sandwich first and second electrical conductors between the first and second connectors and the first and second conductor engagement surfaces, respectively.

2. The junction assembly of claim 1 wherein the threaded post comprises a pair of post sections engaged within the threaded passage, wherein a first one of the post sections extends outwardly from the first conductor engagement surface and defines the first threaded end portion, a second one of the post sections extends outwardly from the second conductor engagement surface and defines the second threaded end portion.

3. The junction assembly of claim 1 wherein the electrically conductive body is formed of a first conductive material and the post is formed of a second material different from the first conductive material.

4. The junction assembly of claim 3 wherein the first conductive material is copper or brass and the second material is steel.

5. The junction assembly of claim 1 further comprising a bonding agent interconnected between the post and the body.

6. The junction assembly of claim 1, wherein the post defines an outer end that includes a recess, and wherein the recess is configured as a driving socket for receiving a driver to enable rotation of the post relative to the electrically conductive body.

7. The junction assembly of claim 1, wherein each electrical conductor includes a ring adapted to be sandwiched between one of the conductor engagement surfaces of the electrically conductive body and one of the connectors to provide a path of electrical conduction between the electrically conductive body and the electrical conductor.

8. The junction assembly of claim 1, wherein each connector comprises an internally threaded nut configured for engagement with the threads on one of the end portions of the post for sandwiching the electrical conductor between the connector and the conductor engagement surface.

9. The junction assembly of claim 8 further comprising a cap assembly having a loop portion that is inserted onto the first end portion of the post before the nut is engaged with the first end portion of the post to retain the cap assembly, and further having a cap portion connected to the loop portion that fits over the nut.

10. The junction assembly of claim 1, wherein the mounting member comprises a non-conductive sheath within which the electrically conductive body is positioned.

11. The junction assembly of claim 10, wherein the sheath includes a base having one or more mounting holes for receiving fasteners to secure the junction assembly to the support structure.

12. A junction block kit comprising:

a mounting member configured for engagement with a support structure, wherein the mounting member defines an internal cavity;

an electrically conductive member at least partly contained within the internal cavity of the mounting member and having a threaded bore extending therethrough, wherein the threaded bore opens onto each of a pair of conductor engagement surfaces defined by the electrically conductive member;

a threaded post separate from the electrically conductive member and threadedly engaged within the bore, wherein the post defines a first threaded end portion that extends outwardly from a first one of the conductor engagement surfaces and a second threaded end portion that extends outwardly from a second one of the conductor engagement surface; and

first and second threaded connectors configured for movable threaded engagement with the first and second threaded end portions of the post, respectively, wherein each connector is movable on the respective end portion toward and away from the respective conductor engagement surface, wherein movement of the each connector toward the respective conductor engagement surface is operable to sandwich an electrical conductor between the respective connector and the respective conductor engagement surface.

13. The kit of claim 12 wherein the post comprises first and second post sections, wherein the first post section is adapted to be inserted into the bore at the first conductor engagement surface and the second post section is adapted to be inserted into the bore at the second conductor engagement surface, and wherein the post sections define inner ends that engage each other within the passage.

14. A junction block kit comprising:

a sleeve configured to engage a support structure, wherein the sleeve has a first bore extending therethrough;

an electrically conductive member at least partly contained within the first bore, the electrically conductive member having a first end, a second end, and a second bore extending therethrough from the first end to the second end;

a first post configured to be received within the second bore at the first end and coupled to the electrically conductive member;

a second post configured to be received within the second bore at the second end and coupled to the electrically conductive member;

a first connector engageable with the first post and adapted to secure a first electrical member on the first post and against the electrically conductive member; and

a second connector engageable with the second post and adapted to secure a second electrical member on the second post and against the electrically conductive member.

15. The kit of claim 14 wherein the electrically conductive member is composed of a highly conductive material and the first post and the second post are each composed of a high-strength metallic material.

16. A method of making a junction block assembly comprising the steps of:

providing an electrically conductive body having first and second oppositely facing conductor engagement surfaces and a threaded passage that extends inwardly from the conductor engagement surfaces;

positioning the electrically conductive body within an internal cavity defined by a mounting member such that the electrically conductive body is carried by the mounting member and the first and second conductor engagement surfaces are exposed, wherein the mounting member is configured for engagement with a support structure;

threadedly engaging a threaded post with the threaded passage of the electrically conductive body such that a first threaded outer portion of the post extends outwardly from the first exposed conductor engagement surface of the body and a second threaded outer portion of the post extends outwardly from the second exposed conductor engagement surface of the body; and

providing first and second threaded connectors that are movably engageable with the first and second threaded outer portions of the posts, respectively, wherein the first threaded connector is movable on the first threaded outer portion of the post toward and away from the first conductor engagement surface and the second threaded connector is movable on the second threaded outer portion of the post toward and away from the second conductor engagement surface, wherein movement of the first and second connectors on the respective first and second outer portions of the posts is operable to sandwich respective first and second electrical conductors between the connector and the respective conductor engagement surface of the body.

17. The method of claim 16, further comprising the step of applying a locking agent to the post to secure the post to the body.

18. The method of claim 16, wherein the step of threadedly engaging a threaded post with the threaded passage is carried out by engaging a first threaded post section within the passage from the first conductor engagement surface and engaging a second threaded post section within the passage from the second conductor engagement surface, and engaging the first and second post sections with each other within the threaded passage.

19. The method of claim 16, wherein the body is constructed of a highly conductive material.

20. The method of claim 19, wherein the post is constructed of a material different than the highly conductive material.

21. The method of claim 16, further comprising the step of capping one of the connectors with a non-conductive member.

22. A junction block kit comprising:

a mounting member configured to engage a support structure, wherein the mounting member has a passage extending therethrough;

an electrically conductive member at least partly contained within the passage, the electrically conductive member having a first end, a second end, and a threaded bore extending therethrough from the first end to the second end;

a first threaded post received within the threaded bore at the first end;

a second threaded post received within the threaded bore at the second end;

a first threaded connector engageable with the first post and adapted to secure a first electrical member on the first post and against the electrically conductive member; and

a second connector engageable with the second post and adapted to secure a second electrical member on the second post and against the electrically conductive member.

23. The junction block kit of claim 22, wherein the first and second posts define inner ends that engage each other within the threaded bore of the electrically conductive member.