Electrical connectors with screw-terminated contacts and methods for assembling the same

Abstract

This invention provides an exemplary electrical connector having a contact, an inner housing, a terminal, and a screw. The contact has a plate portion defining a contact hole and a contact portion extending from the plate portion. The inner housing has a groove shaped to receive the plate portion and hold the contact in a substantially fixed position. The terminal is movably disposed within the inner housing and has a contact surface and a threaded hole. The screw is sized to be received through the contact hole and interface with the threaded hole. Rotating the screw causes the terminal to move relative to the plate portion of the contact and compress a wire between the plate portion of the contact and the terminal.

Description

Electrical Connector with Screw Terminal Contacts The present invention generally relates to an electrical connector that includes securing an electrical wire in place with a screw. Specifically, the present application relates to an electrical connector having screw terminal contacts. Current electrical connectors require crimping or overmolding to secure wires and cables in place within the connector, thereby increasing the risk of damage to the inserted wires or cables. One specific example of the present application relates to an electrical connector that includes: a contact that includes: a plate portion that defines a contact hole; and a contact portion that extends from the plate portion; an inner housing that includes a slot shaped to receive the plate portion and hold the contact in a substantially fixed position; a terminal movably disposed within the inner housing, the terminal including: a contact surface; and a threaded hole; and a screw sized to be received by the contact hole and interfaced with the threaded hole, wherein rotating the screw moves the terminal relative to the plate portion of the contact and compresses a wire between the plate portion of the contact and the terminal. Another specific example of the present application relates to an electrical connector that includes: an inner housing that includes: a first end having a first chamber and a second chamber; and a second end configured to receive a mating electrical connector; a first contact having a first plate portion disposed in the first chamber and a first contact extension disposed at the second end of the inner housing; a second contact having a second plate portion disposed in the second chamber and a second contact extension disposed at the second end of the inner housing; a first terminal plate disposed in the first chamber; a second terminal plate disposed in the second chamber; a first screw configured to be received by the first chamber and the first plate portion and interfaced with the first terminal plate; a second screw configured to be received by the second chamber and the second plate portion and interfaced with the second terminal plate; and a cable inserted into the first end of the inner housing, the cable including a hot wire disposed in the first chamber and a ground wire disposed in the second chamber, wherein: rotating the first screw causes the first terminal plate to compress the hot wire into the first plate portion, and rotating the second screw causes the second terminal plate to compress the ground wire into the second plate portion. Another specific example of the present application relates to a method for assembling a connector assembly, the method comprising: providing a connector comprising: a contact member comprising: a plate portion comprising a contact hole; and a contact portion extending from the plate portion; an inner housing defining a slot shaped to receive the plate portion and hold the contact member in a substantially fixed position; and a terminal plate movably disposed within the inner housing, the terminal plate comprising: a terminal surface; and a threaded hole; inserting a threaded member through the contact hole to interface with the threaded hole; inserting an electrical wire into the inner housing between the plate portion and the terminal surface; and rotating the exposed end of the threaded member such that the terminal surface compresses the electrical wire against the plate portion. The novel electrical connector according to the present invention enables an electrical wire or cable to be fastened within the connector via a screw, which eliminates the need for crimping or overmolding. This not only reduces the risk of damage to the inserted electrical wire or cable, but also enables a user to couple a cable to the connector without specific equipment. Thus, when the user is out and at a job site, the connector (or the cable coupled to the connector) can be freely replaced. In addition, these screw-based tightening mechanisms enable a wider range of cables and / or electrical wires to be compatible with the connector. Referring now to the drawings, in which like reference numerals refer to the same or similar features in the various views, FIGS. 1 to 6 illustrate an exemplary electrical connector plug 10. The connector plug 10 may include a housing 100, a clamp 105, and a plug portion 130. The housing 100 may be configured to surround and protect an inner housing 200, which is described in more detail below with reference to FIGS. 7 to 14. The housing 100 may be removably fastened to the inner housing 200 via a first housing screw 108 and a second housing screw 109. The clamp 105 may be disposed around an opening at the rear of the housing 110 (e.g., relative to the direction in which the connector plug 10 may be mated with another connector), and includes an upper clamp portion 110 and a lower clamp portion 120, as well as a first spacer 102 and a second spacer 103 of the housing 100. The first spacer 102 and the second spacer 103 may jointly define an aperture 104. The plug portion 130 may extend in a forward direction away from the housing 100 and be configured to mate with another connector. In operation, one or more wires or cables may extend through the aperture 104 to the inner housing 200, and each may be electrically coupled to a respective electrical contact of the inner housing 200. Once the wire or cable is inserted into the aperture 104, the clamp 105 may be tightened around the wire or cable by tightening a first clamp screw 113 and a second clamp screw 114 that may be disposed on either side of the aperture 104. The wire or cable connected to the respective electrical contacts in the inner housing 200 may further extend beyond the connector plug 10 for connection to a signal source or destination (e.g., via the plug portion 130 that mates with a respective socket). Although the first clamp screw 113 and the second clamp screw 114 (and other screws in the present invention) are referred to as screws, each may be any suitable threaded member (e.g., a bolt), such that the present invention should not be construed as limited to screws. As shown in FIG. 4, which is a perspective view of the housing 100, the housing 100 may include a body 101, and the first spacer 102 and the second spacer 103 may extend from the body 101 in opposite rearward directions. The first spacer 102 and the second spacer 103 may be disposed on either side surface of the aperture 104 such that the inner sides of the first spacer 102 and the second spacer 103 each define a part of the aperture 104. In other embodiments, the first spacer 102 and the second spacer may be disposed on either vertical side of the aperture 104. The first spacer 102 may include a first spacer passage 106 that may be sized to receive the first clamp screw 113. Similarly, the second spacer 103 may include a second spacer passage 106 that may be sized to receive the second clamp screw. Each of the first spacer 102 and the second spacer 103 may be integrally formed with the body 101 such that the housing 100 comprises a monolithic and continuous structure that may be molded (e.g., injection molded) as a single component. Referring now to FIGS. 7A through 7C, the upper jaw portion 110 and the lower jaw portion 120 are shown separately. The upper jaw portion 110 may include a first upper jaw passage 111 and a second upper jaw passage 112, each of the upper jaw passages being sized to receive a first jaw screw 113 and a second jaw screw 114. In some embodiments, the first upper jaw passage 111 and the second upper jaw passage 112 may be threaded to directly interface with the first jaw screw 113 and the second jaw screw 114, while in other embodiments, the first upper jaw passage 111 and the second upper jaw passage 112 may be relatively smooth to allow the first jaw screw 113 and the second jaw screw 114 to pass therethrough without direct interfacing. In some embodiments, the first upper jaw passage 111 and the second upper jaw passage 112 may each include a first lip 115 and a second lip 116, the lips being capable of interfacing with the head of the first jaw screw 113 or the second jaw screw 114, such that the threaded portions of the first jaw screw 113 and the second jaw screw 114 may pass completely through the first upper jaw passage 111 and the second upper jaw passage 112, but the relatively large heads will abut the first lip 115 or the second lip 116. The first lip 115 and the second lip 116 may be separate portions of material that cause the first upper jaw passage 111 and the second upper jaw passage 112 to have a relatively small diameter for the length of the separate portions, or the first lip 115 and the second lip 116 may be formed as a transition region within the first upper jaw passage 111 and the second upper jaw passage 112 from a first larger diameter to a second smaller diameter. The first lip 115, the second lip 116 may be or may include an annular surface that projects inwardly from the sidewalls of the first upper jaw passage 111, the second upper jaw passage 112 and is generally perpendicular to the direction in which the first jaw screw 113, the second jaw screw 114 move into and out of the first upper jaw passage 111, the second upper jaw passage 112. Similarly, the lower jaw portion 120 may include a first lower jaw passage 121 and a second lower jaw passage 122, each of the jaw passages being sized to receive the first jaw screw 113 and the second jaw screw 114. In some embodiments, the first lower jaw passage 121 and the second lower jaw passage 122 may be threaded to directly engage and interface with the threads of the first jaw screw 113 and the second jaw screw 114. In use, the upper clamp portion 110 can be disposed on the opposing tops of the first spacer 102 and the second spacer 103 such that the first upper clamp passage 111 is aligned with the first spacer passage 106 and the second upper clamp passage 112 is aligned with the second spacer passage 107. The lower clamp portion 120 can be disposed on the opposing bottoms of the first spacer 102 and the second spacer 103 such that the first lower clamp passage 121 is aligned with the first spacer passage 106 and the second lower clamp passage 122 is aligned with the second spacer passage 107. When both the upper clamp portion 110 and the lower clamp portion 120 are in place on either side of the first spacer 102 and the second spacer 103, the first upper clamp passage 111, the first spacer passage 106, and the first lower clamp passage 121 can together form a first passage, and the second upper clamp passage 112, the second spacer passage 107, and the second lower passage 123 together form a second passage. The first clamp screw 113 can be inserted into the first passage formed thereby in common, and the second clamp screw 114 can be inserted into the second passage formed thereby in common. In the specific example shown in FIG. 1, the first clamp screw 113 and the second clamp screw 114 are first inserted through the upper clamp portion 110 such that the heads of the first clamp screw 113 and the second clamp screw 114 are exposed from the upper clamp portion 110. By rotating at least one of the first clamp screw 113 or the second clamp screw 114 in the tightening direction, the upper clamp portion 110 and the lower clamp portion 120 can be pulled towards each other to reduce the effective size (e.g., diameter and / or perimeter) of the aperture 104. For example, rotating the first clamp screw 113 causes the first clamp screw 113 to longitudinally move along the axis defined by the length of the first clamp screw 113 due to at least meshing with the threads of the first lower clamp passage 121. By rotating the first clamp screw 113 in the tightening direction (e.g., clockwise rotation), the first clamp screw 113 can be moved relatively downward, which in turn can cause the head of the first clamp screw 113 to abut the first lip 115 of the first upper clamp passage 111. Further downward movement of the first clamp screw 113 can be transferred to the upper clamp portion 110 via the abutment of the head, which can cause the upper clamp portion 110 to move downward in a similar manner (e.g., towards the first spacer 102 and the second spacer 103). If the upper clamp portion 110 cannot move further downward (e.g., because the upper clamp portion 110 abuts the first spacer 102 and the second spacer 103, because the upper clamp portion 110 abuts the inserted wire, etc.), then the meshing of the first clamp screw 113 can alternatively cause the lower clamp portion 120 to move relatively upward (e.g., towards the first spacer 102 and the second spacer 103, towards the inserted wire, etc.). Since the size of the aperture 104 can be adjusted by the upper clamp portion 110 and the lower clamp portion 120, the exemplary electrical connector plug 10 can be configured to accommodate cables (or wires) having varying sizes. In the exemplary specific example shown, the aperture 104 can be sized to accommodate wires in the range from gauge 18 (e.g., approximately 1.024 mm diameter) to gauge 10 (e.g., approximately 2.588 mm diameter). Referring now to FIGS. 8 through 13, the internal housing 200 may include a first chamber 210, a second chamber 220, and a third chamber 230. Each chamber may be configured to receive an electric wire (e.g., from an inserted cable or as an independently inserted wire). For example, a live wire (e.g., a wire carrying a signal from an original source) may be inserted into the first chamber 210, and a ground wire may be inserted into the second chamber 220. The internal housing 200 may also be configured to establish and maintain a minimum distance between the wire contacts (e.g., to avoid arcing between the contacts). In the exemplary embodiment shown, the minimum distance between each wire contact (e.g., the wire contact in the first chamber 210 and the wire contact in the second chamber 220, etc.) may be 7 mm. In other embodiments, the minimum distance between each wire contact may be 6 mm. Although the internal housing 200 shown includes only three chambers, internal housings 200 having fewer or more chambers are within the scope of the present invention such that the present invention should not be construed as limited to an internal housing 200 having three chambers. Instead, the internal housing according to the present invention may alternatively have two chambers, four chambers, or any other number of chambers suitable for a given application. The internal housing 200 may also include a first housing hole 201 and a second housing hole 202 sized to receive a first housing screw 108 and a second housing screw 109 to couple the shell 100 to the internal housing 200. The first chamber 210 may include a first slot 211, a first contact 212, a first chamber screw 214, and a first terminal 216. The first slot 211 may be shaped to receive the first contact 212 and hold the first contact 212 in a substantially fixed position relative to an axis defined by the length of the first chamber screw 214. The first contact 212 may include a hole (e.g., a hole similar to the contact hole 229 described below) shaped to receive the first chamber screw 214. After passing through the first contact 212, the first chamber screw 214 may interface with a hole in the first terminal plate 216. This hole may be threaded such that the first chamber screw 214 can directly interface with the first terminal plate 216. In operation, a wire may be inserted into the space between the first terminal 216 and the first contact 212. Once the wire is in place, the first chamber screw 212 may be rotated in a tightening direction (e.g., clockwise), which may cause the first chamber screw 212 to move in an upward direction (relative to the orientation shown in FIG. 8). Because the first contact 212 is in a substantially fixed position (relative to the movement of the first chamber screw 214), further longitudinal movement of the first chamber screw 214 may be prevented by the first contact 212, which may cause the rotational force to be transferred to the first terminal 216 via the interface between the hole in the first terminal 216 and the threads of the first chamber screw 214. As shown in FIG. 10, the shape and size of the first chamber 210 may be such that the first terminal plate 216 abuts or nearly abuts the wall of the first chamber 210, which prevents the first terminal plate 216 from rotating within the first chamber 210. Thus, when the rotational force of the first chamber screw 214 is transferred to the first terminal plate 216, the first terminal plate 216 moves longitudinally within the first chamber 210 because the first terminal plate 216 cannot rotate. Due to the threads, when the first chamber screw 214 is rotated in the tightening direction, the first terminal plate 216 may move longitudinally downward (relative to the view shown in FIG. 10), such that the first terminal plate 216 may be pulled toward the first contact 212, thereby compressing the inserted wire. The size (e.g., diameter, length, threads, etc.) of the first chamber screw 214 may be based on the specifications of the inserted wire, where larger wires require larger screw sizes. Since the aperture 104 can accommodate cables up to gauge 10, the first chamber screw 214 may be large enough to hold the wires contained within a gauge 10 cable. Thus, the inner housing 200 may be constructed to accommodate screws of sufficient size (e.g., the first chamber screw 214). The second chamber 220 and the third chamber 230 can be substantially the same as the first chamber 210, such that each includes similar components and functions in substantially the same manner. As shown, the second chamber 220 can include a second slot 221 similar to the first slot 211, a second contact 222 similar to the first contact, a second chamber screw 224 similar to the first chamber screw 214, and a second terminal 226 similar to the first terminal 216. Similarly, the third chamber 230 can include a third slot 231 similar to the first slot 211, a third contact 232 similar to the first contact, a third chamber screw 234 similar to the first chamber screw 214, and a third terminal 236 similar to the first terminal 216. As described above, the internal housing 200 can include any number of chambers and any configuration of the chambers. In the exemplary embodiment shown, the internal housing 200 has three chambers (e.g., 210, 220, and 230) and can accommodate three wires - two hot wires and one ground wire. For example, a first hot wire can be inserted into the first chamber 210, a second hot wire can be inserted into the third chamber 230, and the ground wire can be inserted into the second chamber 220. Referring now to FIG. 13, the second contact 222 is shown separately. The second contact 222 can include a contact plate 227, a contact extension 228, and a contact hole 229. The contact plate 227 can be configured to receive current or a signal from the exposed wire (e.g., a hot wire or a ground wire inserted into the second chamber 220). In some embodiments, the contact plate 227 can be textured (e.g., ribbed) to increase the amount of surface area of the contact plate 227, which can increase the contact quality with the exposed wire (e.g., connection consistency, no signal loss, etc.). The contact extension 228 can be formed monolithically with the contact plate 227 and extend away from the contact plate 227 such that the contact extension 228 can be configured to further carry the current transmitted from the exposed wire to the contact plate 227 to a point away from the exposed wire. As shown in FIG. 11, which is a cross-sectional view taken along line 11-11 of FIG. 10, the contact extension 228 can extend from the second chamber 220 of the internal housing 200 into the plug portion 130, where the contact extension 228 can be exposed to and electrically coupled to respective contacts of a socket that mates with the connector plug 10. As described above with reference to the first contact 212, the contact hole 229 can be sized to receive the second chamber screw 224. In some embodiments, the contact hole 229 can be non-threaded to allow the second chamber screw 224 to rotate freely within the contact hole, while in other embodiments, the contact hole 229 can be threaded to facilitate rotation of the second chamber screw 224. As shown, the second contact 222 may be characterized by a bent portion such that the contact member extension 228 may be on a different horizontal plane than the contact plate 227. Because the inner housing 200 may be configured to maintain a minimum distance between the contact members (e.g., contact members 212, 222, 232), but the mating surface of the connector plug 10 may require relatively close contact points (e.g., based on the configuration of the mating surface), the bent portion of the second contact member 222 may enable the minimum distance to be maintained at one end of the connector plug 10 without obstructing or limiting the available mating surface configurations. Accordingly, the rear portion of the connector plug 10 (e.g., relative to the direction in which the connector plug 10 may mate with another connector) may be larger than the front portion of the connector plug 10. For example, the rear portion of the connector plug 10 may have a larger surface area than the mating front portion of the connector plug, and the rear portion may have a larger diameter than the diameter of the mating front portion (e.g., perpendicular to the central axis defined by the mating direction). The transition region from the larger rear portion to the smaller front portion may be a vertical plane, or may be a curved or similar intermediate transition region. The bent portion of the second contact member 222 may be included within the transition region such that the bent portion of the second contact member 222 may define a part of the transition region. Referring now to FIG. 14 showing an exploded view of the connector plug 10, the first contact member 212 and the third contact member 232 may be shaped differently than the second contact member 222. Regardless of the specific configuration of the components, each of the first contact member 212 and the third contact member 232 may include components similar to the contact surface 227, the contact member extension 228, and the contact hole 229 of the second contact member. FIG. 15 is a flowchart depicting an exemplary method 1500 for assembling a connector assembly. In some embodiments, the method 1500 or one or more portions of the method 1500 may include the plug assembly 10 (e.g., creating an assembly including the plug assembly 10). The method 1500 may include providing a connector at block 1510. This connector may be the plug assembly 10 and may include any one or all of the components of the plug assembly 10 described above. For example, providing the connector may involve providing a connector (e.g., the second connector 222), an inner housing (e.g., the inner housing 200), and a terminal plate (e.g., the second terminal 226). The contact member may include a plate portion (e.g., the contact plate 227) having a contact hole (e.g., the contact hole 229) and a contact portion (e.g., the contact member extension 228) extending from the plate portion. The inner housing may define a slot (e.g., the second slot 221) shaped to receive the plate portion and hold the contact member in a substantially fixed position. The terminal plate may be movably disposed within the inner housing and may include a terminal surface and a threaded hole. Method 1500 may also include inserting a threaded member through the contact hole at block 1520 to interface with the threaded hole of the terminal plate, and at block 1530, inserting an electric wire into the inner housing and positioning it between the plate portion and the terminal surface. Method 1500 may further include rotating the exposed end of the threaded member at block 1540, which may cause the terminal surface to compress the inserted electric wire onto the plate portion. The connector plug 10 of the present invention offers many advantages over current electrical connectors. First, since the electric wires and cables inserted into the connector plug 10 can be fastened in place via screws, there is no need for coiling or overmolding. This not only reduces the risk of damage to the inserted electric wires or cables, but it also enables the user to couple a cable to the connector plug 10 without specific equipment. Thus, when the user is out and at the work site, the connector plug 10 (or the cable coupled to the connector plug 10) can be freely replaced. Second, the screw-based tightening mechanisms (such as those of the clamp 105 and those within the inner housing 200) enable a wider range of cables and / or electric wires to be compatible with the connector plug 10. In some embodiments of the present invention, an electrical connector may include a contact, an inner housing, a terminal, and a screw. The contact may include: a plate portion defining a contact hole; and a contact portion extending from the plate portion. The inner housing may include a groove shaped to receive the plate portion and hold the contact in a substantially fixed position. The terminal may be movably disposed within the inner housing and may include a contact surface; and a threaded hole. The screw may be sized to be received by the contact hole and interface with the threaded hole. Rotating the screw causes the terminal to move relative to the plate portion of the contact and compress an electric wire between the plate portion of the contact and the terminal. In some of these embodiments, the inner housing may be shaped to prevent lateral and rotational movement of the terminal relative to the axis defined by the screw. In some of these embodiments, the inner housing may further include a first end and a second end opposite the first end. The first end may be configured to receive an electric wire, and the second end may be configured to receive a second electrical connector. In some of these embodiments, the electrical connector may include a connector shell shaped to fit around the first end and prevent access to the exposed end of the screw. In some of these embodiments, the connector shell may be coupled to the inner housing via a second screw. Among other of these specific examples, the connector housing may further include an opening defined by the housing and configured to receive an electric wire; and a clamp disposed around the opening. In some of these specific examples, the clamp may include: an upper clamp portion that defines a first upper passage and a second upper passage; a lower clamp portion that defines a first lower passage and a second lower passage; a first spacer body disposed between the upper clamp portion and the lower clamp portion, the first spacer body defining a first spacer passage aligned with the first upper passage and the first lower passage; a second spacer body disposed between the upper clamp portion and the lower clamp portion, the second spacer body defining a second spacer passage aligned with the second upper passage and the second lower passage; a first clamp screw received by the first spacer passage, the first upper passage, and the first lower passage; and a second clamp screw received by the second spacer passage, the second upper passage, and the second lower passage. Rotating each of the first clamp screw and the second clamp screw may cause the upper clamp portion and the lower clamp portion to move toward the first spacer body and toward the second spacer body and compress the electric wire. In some of these specific examples, the first spacer body and the second spacer body are formed monolithically with the connector housing. In some specific examples, the electrical connector may include an inner housing that may include a first end having a first chamber and a second chamber; and a second end configured to receive a mating electrical connector. The electrical connector may also include: a first contact having a first plate portion disposed in the first chamber and a first contact extension disposed in the second end of the inner housing; a second contact having a second plate portion disposed in the second chamber and a second contact extension disposed in the second end of the inner housing; a first terminal plate disposed in the first chamber; a second terminal plate disposed in the second chamber; a first screw configured to be received by the first chamber and the first plate portion and interface with the first terminal plate; a second screw configured to be received by the second chamber and the second plate portion and interface with the second terminal plate; and a cable inserted into the first end of the inner housing, the cable including a live wire disposed in the first chamber and a ground wire disposed in the second chamber. Rotating the first screw causes the first terminal plate to compress the live wire into the first plate portion, and rotating the second screw causes the second terminal plate to compress the ground wire into the second plate portion. In some of these specific examples, the first chamber may be shaped to prevent lateral and rotational movement of the first terminal plate relative to a first axis defined by the first screw, and the second chamber may be shaped to prevent lateral and rotational movement of the second terminal plate relative to a second axis defined by the second screw. In some of these specific examples, the electrical connector may further include a connector housing, which is shaped to fit around the first end and prevent access to the first screw and the second screw. In some of these specific examples, the connector housing may further include an opening configured to receive a cable; and a clamp disposed around the opening. In some of these specific examples, the clamp may include: an upper clamp portion having a first upper passage and a second upper passage; a lower clamp portion having a first lower passage and a second lower passage; a first spacer disposed between the upper clamp portion and the lower clamp portion, the first spacer having a first spacer passage aligned with the first upper passage and the first lower passage; a second spacer disposed between the upper clamp portion and the lower clamp portion, the second spacer including a second spacer passage aligned with the second upper passage and the second lower passage; a first clamp screw received by the first spacer passage, the first upper passage, and the first lower passage; and a second clamp screw received by the second spacer passage, the second upper passage, and the second lower passage. Rotating each of the first clamp screw and the second clamp screw can cause the upper clamp portion and the lower clamp portion to move toward the first spacer and toward the second spacer and compress the cable. In some of these specific examples, the first spacer and the second spacer are formed monolithically with the connector housing. In some specific examples, a method for assembling a connector assembly includes providing a connector that may include a contact, an inner housing, and a terminal plate. The contact may include: a plate portion including a contact hole; and a contact portion extending from the plate portion. The inner housing may define a slot shaped to receive the plate portion and hold the contact in a substantially fixed position. The terminal plate may be movably disposed within the inner housing and may include a terminal surface; and a threaded hole. The method may also include inserting a threaded member through the contact hole to interface with the threaded hole; inserting an electrical wire into the inner housing between the plate portion and the terminal surface; and rotating the exposed end of the threaded member such that the terminal surface compresses the electrical wire against the plate portion. In some of these specific examples, the connector may further include a connector housing, which is shaped to fit around the inner housing and prevent access to the threaded member. In some of these specific examples, the method further includes coupling the connector housing to the inner housing using a second threaded member. In some of these specific examples, the connector may further include: a clamp, which may include an opening shaped to provide access to the internal housing for the wire; an upper clamp portion defining an upper side of the opening; a lower clamp portion defining a lower side of the opening; a first spacer disposed between the upper clamp portion and the lower clamp portion, the first spacer defining a left side of the opening; and a second spacer disposed between the upper clamp portion and the lower clamp portion, the second spacer defining a right side of the opening. In these specific examples, the method may further include: inserting a first clamp threaded member into the upper clamp portion, the first spacer, and the lower clamp portion; inserting a second clamp threaded member into the upper clamp portion, the second spacer, and the lower clamp portion; and compressing the wire by rotating each of the first clamp threaded member and the second clamp threaded portion such that the upper clamp portion and the lower clamp portion compress the wire. In some of these specific examples, the first spacer and the second spacer are formed monolithically with the connector housing. In some of these specific examples, the internal housing may be further shaped to prevent lateral and rotational movement of the end plate relative to the axis defined by the screw member. Although the present invention has described certain specific examples, it should be understood that unless expressly recited in the claims, the claims are not intended to be limited to these specific examples. On the contrary, the present invention is intended to cover alternatives, modifications, and equivalents that may be included within the spirit and scope of the present invention. Additionally, in the detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the disclosed specific examples. However, it will be apparent to those of ordinary skill in the art that systems and methods consistent with the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure various aspects of the present invention. 10: Connector Plug 100: Housing 101: Body 102: First Spacer 103: Second Spacer 104: Aperture 105: Clamp 106: First Spacer Passage 107: Second Spacer Passage 108: First Housing Screw 109: Second Housing Screw 110: Upper Clamp Portion 111: First Upper Clamp Passage 112: Second Upper Clamp Passage 113: First Clamp Screw 114: Second Clamp Screw 115: First Lip 116: Second Lip 120: Lower Clamp Portion 121: First Lower Clamp Passage 122: Second Lower Clamp Passage 123: Second Lower Passage 130: Plug Portion 200: Inner Housing 201: First Housing Hole 202: Second Housing Hole 210: First Chamber 211: First Groove 212: First Contact 214: First Chamber Screw 216: First Terminal 220: Second Chamber 221: Second Groove 222: Second Contact 224: Second Chamber Screw 226: Second Terminal 227: Contact Plate 228: Contact Extension 229: Contact Hole 230: Third Chamber 231: Third Groove 232: Third Contact 234: Third Chamber Screw 236: Third Terminal 1500: Method 1510: Block 1520: Block 1530: Block 1540: Block [FIG. 1] is a front perspective view of an exemplary electrical connector plug. [FIG. 2] is a front view of the exemplary electrical connector plug of FIG. 1. [FIG. 3] is a front view of the exemplary electrical connector plug of FIG. 1 without the inner housing. [FIG. 4] is a perspective view of the connector housing of the exemplary electrical connector plug of FIG. 1. [FIG. 5] is a top view of the exemplary electrical connector plug of FIG. 1. [FIG. 6] is a left view of the exemplary electrical connector plug of FIG. 1. [FIG. 7A] is a perspective view of the upper clamp of the exemplary electrical connector plug of FIG. 1. [FIG. 7B] is a top view of the upper clamp of FIG. 7A. [FIG. 7C] is a perspective view of the lower clamp of the exemplary electrical connector plug of FIG. 1. [FIG. 8] is a front perspective view of the inner housing of the exemplary electrical connector plug. [FIG. 9] is a perspective view of the inner housing of FIG. 8 without the terminals, contacts and screws. [FIG. 10] is a front view of the inner housing of FIG. 8. [FIG. 11] is a cross-sectional view of the inner housing of FIG. 8 taken along line 11-11 in FIG. 10. [FIG. 12] is a front view of the inner housing of FIG. 8 without the terminals, contacts and screws. [FIG. 13] is a perspective view of the contact of the exemplary electrical connector plug of FIG. 1. [FIG. 14] is an exploded view of the exemplary electrical connector plug of FIG. 1. [FIG. 15] is a flowchart of an exemplary method for assembling a connector assembly. 10: Connector Plug 100: Housing 101: Body 102: First spacer 103: Second spacer 104: Aperture diameter 105: Clamp 110: Upper clamp portion 111: First upper clamp passage 112: Second upper clamp passage 113: First clamp screw 114: Second clamp screw 120: Lower clamp portion 130: Plug portion

Claims

1. An electrical connector comprising: a contact including: a plate portion defining a contact hole; and a contact portion extending from the plate portion; an inner housing including a groove shaped to receive the plate portion and hold the contact in a substantially fixed position; and a terminal movably disposed within the inner housing, the terminal including: a contact surface; and a threaded hole; and a screw sized to be received by the contact hole and interfacing with the threaded hole, wherein rotating the screw causes the terminal to move relative to the plate portion of the contact and compress a wire between the plate portion of the contact and the terminal, and wherein the inner housing is shaped to prevent lateral and rotational movement of the terminal relative to an axis defined by the screw.

2. The electrical connector of claim 1, wherein the inner housing further includes a first end and a second end opposite to the first end, the first end being configured to receive the wire, and the second end being configured to receive a second electrical connector.

3. The electrical connector of claim 2, further comprising a connector housing shaped to fit around the first end and prevent access to the exposed end of the screw.

4. The electrical connector of claim 3, wherein the connector housing is coupled to the inner housing via a second screw.

5. The electrical connector of claim 3, wherein the connector housing further comprises: an opening defined by the housing, the opening being configured to receive the wire; and a clamp disposed around the opening.

6. The electrical connector of claim 5, wherein the clamp comprises: an upper clamp portion defining a first upper passage and a second upper passage; a lower clamp portion defining a first lower passage and a second lower passage; a first spacer body disposed between the upper clamp portion and the lower clamp portion, the first spacer body defining a first spacer passage aligned with the first upper passage and the first lower passage; a second spacer body disposed between the upper clamp portion and the lower clamp portion, the second spacer body defining a second spacer passage aligned with the second upper passage and the second lower passage; a first clamp screw received by the first spacer passage, the first upper passage, and the first lower passage; and a second clamp screw received by the second spacer passage, the second upper passage, and the second lower passage. Rotating either the first clamp screw or the second clamp screw causes the upper clamp portion and the lower clamp portion to move toward the first spacer body and toward the second spacer body, respectively, and compresses the wire.

7. The electrical connector of claim 6, wherein the first spacer body and the second spacer body are monolithically formed with the connector shell.

8. An electrical connector comprising: an inner housing including: a first end having a first chamber and a second chamber; and a second end configured to receive a mating electrical connector; a first contact having a first plate portion disposed in the first chamber and a first contact extension disposed in the second end of the inner housing; a second contact having a second plate portion disposed in the second chamber and a second contact extension disposed in the second end of the inner housing; a first terminal plate disposed in the first chamber; a second terminal plate disposed in the second chamber; a first screw configured to be received by the first chamber and the first plate portion and to interface with the first terminal plate; a second screw configured to be received by the second chamber and the second plate portion and to interface with the second terminal plate; and a cable inserted into the first end of the inner housing, the cable including a live wire disposed in the first chamber and a ground wire disposed in the second chamber, wherein: Rotating the first screw causes the first terminal board to compress the live wire into the first board portion, and rotating the second screw causes the second terminal board to compress the ground wire into the second board portion; And wherein: the first chamber is shaped to prevent lateral and rotational movement of the first terminal plate relative to the first axis defined by the first screw, and the second chamber is shaped to prevent lateral and rotational movement of the second terminal plate relative to the second axis defined by the second screw.

9. The electrical connector of claim 8, further comprising a connector housing shaped to fit around the first end and prevent access to the first screw and the second screw.

10. The electrical connector of claim 9, wherein the connector housing further comprises: an opening configured to receive the cable; and clamps disposed around the opening.

11. The electrical connector of claim 10, wherein the clamp comprises: an upper clamp portion having a first upper passage and a second upper passage; a lower clamp portion having a first lower passage and a second lower passage; a first spacer disposed between the upper clamp portion and the lower clamp portion, the first spacer having a first spacer passage aligned with the first upper passage and the first lower passage; a second spacer disposed between the upper clamp portion and the lower clamp portion, the second spacer including a second spacer passage aligned with the second upper passage and the second lower passage; a first clamp screw received by the first spacer passage, the first upper passage and the first lower passage; and a second clamp screw received by the second spacer passage, the second upper passage and the second lower passage. Rotating either the first clamp screw or the second clamp screw causes the upper clamp portion and the lower clamp portion to move toward the first spacer and toward the second spacer, respectively, and compresses the cable.

12. The electrical connector of claim 11, wherein the first spacer and the second spacer are monolithically formed with the connector shell.

13. A method for assembling a connector assembly, the method comprising: providing a connector comprising: a contact including: a plate portion including a contact hole; and a contact portion extending from the plate portion; an inner housing defining a groove shaped to receive the plate portion and hold the contact in a substantially fixed position; and a terminal plate movably disposed within the inner housing, the terminal plate including: a terminal surface; and a threaded hole; and a threaded member inserted through the contact hole to interface with the threaded hole; inserting a wire into the inner housing between the plate portion and the terminal surface; and rotating an exposed end of the threaded member such that the terminal surface compresses the wire onto the plate portion, wherein the inner housing is further shaped to prevent lateral and rotational movement of the terminal plate relative to an axis defined by the threaded member.

14. The method of claim 13, wherein the connector further comprises a connector shell shaped to fit around the inner housing and prevent access to the threaded member.

15. The method of claim 14, further comprising coupling the connector shell to the inner housing using a second threaded member.

16. The method of claim 14, wherein the connector further comprises clamps, the clamps comprising: an opening shaped to provide access to the inner housing for the wire; an upper clamp portion defining an upper side of the opening; a lower clamp portion defining a lower side of the opening; a first spacer disposed between the upper clamp portion and the lower clamp portion, the first spacer defining a left side of the opening; and a second spacer disposed between the upper clamp portion and the lower clamp portion, the second spacer defining a right side of the opening, wherein the method further comprises: inserting a first clamp threaded member into the upper clamp portion, the first spacer and the lower clamp portion; inserting a second clamp threaded member into the upper clamp portion, the second spacer and the lower clamp portion; and compressing the wire by rotating each of the first clamp threaded member and the second clamp threaded portion.

17. The method of claim 16, wherein the first spacer and the second spacer are monolithically formed with the connector shell.

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