Abstract: A tapped hole produced in a metallic material by threading a preselected standard threaded fastener into an untapped hole formed in the material. The diameter of the hole to be formed is determined by using a formula that takes into account the hardness and thickness of the material to be tapped and the basic major diameter and pitch of the preselected threaded fastener to be used to tap the hole. This formula can only be used with threaded fasteners having threads of the Unified Thread Standard type. This formula is particularly useful in tapping a hole formed in a mounting strap of an electrical wiring device.

Abstract: A light fixture has a light-transparent cover at substantially grade level and a photocontrol device with a self-flushing outer surface for preventing accumulation of opaque material thereon. The light fixture is adapted to be positioned within a recess in the graded environment and includes a housing which encloses a lamp electrically connected to the photocontrol device. The self-flushing outer surface of the photocontrol device discourages the build-up of opaque material so that the photocontrol device can reliably detect changes in the ambient light conditions outside the light fixture and operate the lamp in response to the detected changes.

Abstract: A modular electrical assembly is enclosed in an elastomeric weathershed housing, and has a plurality of electrical components aligned in a row with terminals at the row ends. The electrical components and the terminals are in electrical connection with one another via their axially-directed ends and are axially compressed by a non-conductive filament winding. The filament winding has axial end portions wrapped about the terminals and extending axially beyond the terminals in a direction opposite to the electrical components. The winding end portions are prestressed in axial compression to increase cantilever strength and to decrease cantilever deflection.

Abstract: An electrical device includes a plurality of electrical assemblies formed as interchangeable modules, aligned in an end-to-end serial array and enclosed in a polymeric weathershed housing, the electrical assemblies being electrically and mechanically coupled together. Each electrical assembly in turn has a plurality of electrical components aligned in a row and in electrical connection with one another via their axially-directed ends and under an axially-directed compressive force via a non-conductive filament winding. A plastic film barrier laterally surrounding the electrical components is interposed between the electrical components and the filament winding. A surge arrester with voltage ratings can be enlarged merely by serially coupling a plurality of separately wrapped electrical components in the form of MOV blocks. Enclosing the electrical assemblies is a weathershed housing.

Abstract: A ceiling box for mounting and supporting a ceiling fan thereto. The ceiling box includes a top wall portion with a side wall portion surrounding the periphery of the top wall portion. The box is open at the end opposite the top wall portion and the side wall portion has a pair of flanges extending normal thereto into the open end of the box. These flanges have holes therein for receiving fan supporting screws. In a first embodiment, a pair of threaded mounting screw holes are formed in the top wall portion and are each axially aligned with an unthreaded hole that extends through the respective flange. In a second embodiment, the holes in the flanges are also threaded for added support.

Abstract: A tapped hole produced in a metallic material by threading a preselected standard threaded fastener into an untapped hole formed in the material. The diameter of the hole to be formed is determined by using a formula that takes into account the hardness and thickness of the material to be tapped and the basic major diameter and pitch of the preselected threaded fastener to be used to tap the hole. This formula can only be used with threaded fasteners having threads of the Unified Thread Standard type. This formula is particularly useful in tapping a hole formed in a mounting strap of an electrical wiring device.

Abstract: A connector for metal clad cable that is easily made up and disassembled and is readily reusable. The connector includes a tubular body, a split grounding ring with straight and angled leading tines and angled trailing tabs slidably received in the body, an annular rubber grommet engaging the tabs on the grounding ring and received in the body, and a tubular closure threaded to the body for maintaining the grounding ring and grommet therein. The metal clad cable can be easily coupled to the connector by merely inserting an end of the cable through the closure, grommet and grounding ring, the angled leading tines and grommet engaging the outer surface of the cable. The cable can be easily uncoupled from the connector by unthreading the closure, pulling the cable out of the tubular body with the grounding ring and grommet attached thereto, and removing the ring and grommet from the cable. Since the grounding ring is split, it is readily removed from the cable and can be reused.

Abstract: A fixture box for supporting a ceiling fan or other fixture. The fixture box comprises a top portion, a side portion coupled to the top portion, a continuous flange coupled to the side portion along the entire periphery of the side portion, and a pair of mounting holes formed in the flange. The mounting holes in the continuous flange receive mounting screws from the ceiling fan or fixture. The fixture box itself is secured to a joist or other structural support. In a modified embodiment, the fixture box includes a mounting bracket especially adapted to mount the fixture box to a joist or other structural support. The continuous flange of the fixture box advantageously resists fatigue due to dynamic loading of the ceiling fan or fixture.

Abstract: An electrical coupling for conducting electricity between areas of different pressures including a hollow housing extending between the areas of different pressures, an electrical cable extending through the housing, a seal located in the housing, a compression assembly for compressing the seal, a first pressure-equalizing assembly at one end of the housing for maintaining the pressure inside the housing at least equal to the pressure outside the housing at that end, and a second pressure-equalizing assembly at the other end of the housing for maintaining the pressure inside the housing at least equal to the pressure outside the housing at that other end. Each of the pressure-equalizing assemblies comprises a dielectric flowable grease filling the otherwise empty spaces inside the housing and a movable wall, that is exposed to the exterior pressure, pressurizing the grease.

Abstract: A lead sheathed power cable especially useful for powering electric submersible pumps in brine wells. The cable is easy to grip and support and resists damage during flexing and chemical attack. The cable comprises at least one power conduit, vulcanized filler material enclosing the power conduit, a lead tube enclosing the filler material, a spacer assembly enclosing the tube, and an outer armor sheath. The armor sheath has a helically grooved inner surface which is interfitted with a conforming helically grooved outer surface on the malleable tube. The outer surface on the tube is helically grooved during initial heating of the cable, which vulcanizes and thermally outwardly expands the filler material and outwardly expands the tube so that the groove on the armor sheath is impressed into the tube.

Abstract: A splice joins two pushing and pulling cables. Each cable has a plurality of gripping members defining a longitudinal cavity, a bendable power line housed in the cavity and elongated tensile elements enclosed and compressed by the gripping members. The adjacent ends of the tensile elements are connected by tensile element splices. Adjacent ends of the power lines are connected by a power line splice. A plurality of splice blocks are located end to end along the longitudinal axis, and enclose and compress the tensile element splices and the tensile element. The splice blocks define a longitudinally extending chamber housing the power line and the power line splice in a relatively stress free state.

Abstract: An armored cable structure which converts a plurality of stranded flexible wire ropes for suspending and retrieving the cable structure in a bore hole into members which are also rigid in longitudinal compression and constrained against birdcaging. The converted ropes serve as positively drivable members for forcing the cable structure and any equipment attached to the down-hole end thereof down-hole.

Abstract: An elongated, reinforced power cable for use in adverse environments. The cable is provided with internal structural members to resist crushing and other mechanical forces. The cable includes at least two power conductor assemblies which extend along the longitudinal axis of the cable. A protective metallic layer is provided for each conductor assembly and completely encases each conductor assembly. The conductor assemblies and protective metallic layers are aligned in a row within the cable, the row having a left end, a right end, a top plane and a bottom plane. A rigid support member is positioned at each end of the row of conductor assemblies. The support members have a height at least equal to the height of the protective layers to prevent compression of the protective layers and conductor assemblies. An armored covering is provided which fully encloses the support members, the protective layers and the conductor assemblies.

Abstract: An electrical outlet box formed of metallic material has an integral boss that angularly aligns, engages and retains wiring device mounting screws. The boss has a bore for receiving the screw comprising in sequence a cylindrical surface having a diameter slightly larger than the crest diameter of the mounting screw threads, and a self-tapping surface defining generally a regular hexagon in transverse cross section. The hexagon has a diameter across its corners slightly larger than the crest diameter of the screw threads, and a diameter across its flat sides slightly larger than the root diameter of the screw threads and slightly smaller than the crest diameter of the screw threads. A slot extends laterally from the bore and into the boss.

Abstract: A reinforced electrical cable having a plurality of conductor assemblies in an armor covering, and filler material filling the interstices between the conductor assemblies and the armor covering, and the method of forming the cable. Each conductor assembly includes a core of conducting material, a layer of insulation which surrounds the core, a second layer of chemical barrier material which surrounds the first layer and a layer of reinforcing material surrounding the insulation layer. The plurality of conductor assemblies are then arranged as desired and the filler material (in the unvulcanized state) is placed around and between the conductor assemblies. The quantity of filler material placed between and around the conductor assemblies is sufficient to fill the interior of the armor covering in its unvulcanized state. The armor covering is next placed around the conductor assemblies and the filler material. The unvulcanized filler material conforms to the interior of the armor covering.

Abstract: An electrical outlet box formed of nonmetallic material which has a pair of integral bosses that angularly align, engage and retain wiring device mounting screws therein. The bosses each have a through bore for receiving the screws comprising in sequence a frustoconical surface, a cylindrical surface having a diameter slightly larger than the crest diameter of the mounting screw threads, and a self-tapping surface defining a regular hexagon in transverse cross section. The hexagon has a diameter across its corners slightly larger than the crest diameter of the screw threads, and a diameter across its flat sides slightly larger than the root diameter of the screw threads and slightly smaller than the crest diameter of the screw threads.

Abstract: A self-threading polymeric fastener and blank therefor which can be used, for example, to support a wall plate over an electrical outlet or switch. The fastener blank comprises three portions, all integrally molded together, including a slotted head, a substantially cylindrical shank and a tapered tip. A helical thread is formed on the shank and tip by deforming the outer surfaces thereof without removing any significant amount of polymeric material therefrom. This is accomplished by rotating the tip and shank in a helically threaded bore, such as that provided in an outlet or switch. The polymeric fastener blank can be integrally molded with a polymeric wall plate to make their colors identical.

Abstract: An electrical assembly comprising a plurality of electrical components aligned in a row under an axial load and wrapped with filament windings. The wrapped components are then preferably enclosed in a housing. MOV blocks can be used as the electrical components, resulting in a surge arrester having excellent heat transfer properties as well as improved tensile and cantilever strengths. The electrical components can be varistors, resistors, capacitors and insulators or any combination thereof.

Abstract: A reinforced cable having hauling, electrical and hydraulic lines. The cable has a substantially rectangular cross section and includes at least one internal support to protect these lines by resisting external compressive forces, and yet is bendable about one of its transverse axes for easy storage on and deployment from a drum. The internal support also protects the hauling lines from compressive forces applied longitudinally thereof by resisting radial displacement of the hauling lines. In one embodiment, the cable comprises an armor layer, a pair of engaged channels inside the armor layer, and a pair of corrugated supports inside the channels and fixedly spaced apart. The hauling lines, in the form of wire ropes, are located inside the corrugated supports, while the electrical lines are located inside the channels between the corrugated supports. The hydraulic lines can alternatively be located inside the channels between the corrugated supports, or inside the wire ropes.

Abstract: A wire retaining assembly for use with an electrical device such as a switch or receptacle. The assembly comprises an anchoring bore and a guide slot formed in a wall adjacent each terminal screw to retain the exposed wire on an electrical conductor. By initially locating the end of the exposed wire in the anchoring bore, then bending the wire around the screw shank and locating the other end of the wire in the guide slot, electrical connection to the device is more quickly and securely accomplished. The bore and slot are substantially parallel and have portions with substantially coplanar bottom surfaces so that the bent wire lies in substantially a single plane.