AU2008230018B2

AU2008230018B2 - A Mains-Power Electrical Coupler

Info

Publication number: AU2008230018B2
Application number: AU2008230018A
Authority: AU
Inventors: Robert James Battle
Original assignee: Sicame Australia Pty Ltd
Current assignee: Sicame Australia Pty Ltd
Priority date: 2007-11-05
Filing date: 2008-10-20
Publication date: 2011-12-01
Anticipated expiration: 2028-10-20
Also published as: AU2008230018A1

Abstract

The present invention relates to a mains-power electrical coupler for coupling a cable to a busbar. The coupler includes a body defining both a cable passage for receiving the cable, and a terminal passage. A terminal can be located within the terminal passage, and is able to be rotated within the terminal passage to an orientation for fastening the terminal to the busbar. Typically, the terminal includes a lug with a cylindrical stalk for being received in the terminal passage and the terminal can freely swivel 3600 within the terminal passage. (~7\ \\~\ __ KJ~1 \'~\ ------

Description

AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION STANDARD PATENT A MAINS-POWER ELECTRICAL COUPLER The following statement is a full description of this invention including the best method of performing it known to me: I A MAINS-POWER ELECTRICAL COUPLER TECHNICAL FIELD 5 The present invention relates to a mains-power electrical coupler for coupling a cable to a busbar. The present invention has particular, although not exclusive application in electrical distribution systems. BACKGROUND 10 In electrical distribution systems, cables with terminating terminals are fastened to busbars when connecting, for example, mains-power (e.g. 240V, 415V, etc.) to a factory load. Each terminal is crimped to a respective cable and is then bolted to the busbar. The cables tend to be quite rigid in nature, 15 owing to their relatively thick diameter, which makes them difficult to manipulate manually. In practice, terminals are invariably crimped to corresponding cables at undesirable orientations which complicates fastening of the cables to the 20 busbar. It is an object of the present invention to provide an improved arrangement for coupling the cables to the busbar. SUMMARY OF THE INVENTION 25 According to one aspect of the present invention, there is provided a mains power electrical coupler for coupling a cable to a busbar, the coupler including: a body defining both a cable passage in which the cable can be fastened, and a terminal passage; 30 at least one releasable fastener; and a terminal for locating within the terminal passage, and able to be rotated within the terminal passage upon release of the fastener to an orientation for fastening the terminal to the busbar whilst the cable remains fastened within the cable passage.

2 The terminal may include a lug, in turn, defining one or more holes for receiving respective fasteners. The lug may be dog-legged or straight. The lug may include a cylindrical stalk for being received in the terminal passage, and a flat blade extending from the stalk and in which the holes are defined. The 5 stalk may define one or more endless grooves for receiving respective said releasable fasteners. The terminal may define a retainer extending from the tip of the stalk and for retaining a polymeric sealing member. The retainer may be integrally formed with the stalk or removably received within the stalk. The electrical coupler may further include a polymeric cover defining a hole 10 through which the stalk can be received and for receiving an end of the body. The cable and terminal passages may seamlessly interconnect and have a common diameter. Alternatively, the cable and terminal passages may have sectored profiles. The body may define one or more threaded cable fastening holes extending 15 from the cable passage and for receiving respective cable fasteners. The body may define one or more threaded terminal fastening holes extending from the terminal passage and for receiving respective terminal fasteners. The terminal may be able to freely swivel 3600 within the terminal passage. According to another aspect of the present invention, there is provided a 20 mains-power electrical coupler for coupling a cable to a busbar, the coupler including: a body in which the cable can be fastened; at least one releasable fastener; and a terminal which upon release of the fastener can be rotated relative to 25 the body to facilitate fastening of the terminal to the busbar whilst the cable remains fastened to the body. According to another aspect of the present invention, there is provided a method for coupling a cable to a busbar, the method including the steps of: coupling a body of a mains-power electrical coupler as defined above 30 to a cable; and 3 rotating a terminal of the coupler relative to the body to facilitate fastening of the terminal to the busbar. According to another aspect of the present invention, there is provided a 5 busbar assembly including: a busbar; and the electrical coupler for coupling to the busbar. The electrical coupler may include another coupler for coupling to the busbar, 10 the couplers being coupled on either the same or opposite sides of the busbar. The busbar assembly may further include at least one electrical distribution or insulation piercing connector coupled to the busbar. 15 BRIEF DESCRIPTION OF THE DRAWINGS Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient 20 information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: 25 Figure 1 is an upper perspective view of a mains-power electrical coupler in accordance with an embodiment of the present invention; Figure 2 is sectioned side view of the electrical coupler of Figure 1; 30 Figure 3 is an upper side perspective view of the unassembled electrical coupler of Figure 1; Figure 4 is an upper end perspective view of the electrical coupler of Figure 3; 4 Figure 5 is an upper side perspective view of a busbar assembly including a pair of electrical couplers of Figure 1, with one of the electrical couplers disconnected; 5 Figure 6 is an upper end perspective view of a busbar assembly including a pair of electrical couplers of Figure 1; Figure 7 is an upper perspective view of a mains-power electrical coupler in accordance with another embodiment of the present invention; 10 Figure 8 is sectioned side view of the electrical coupler of Figure 7; Figure 9 is an upper side perspective view of the unassembled electrical coupler of Figure 7; 15 Figure 10 is an upper end perspective view of the electrical coupler of Figure 9; Figure 11 is an upper side perspective view of a busbar assembly including a 20 pair of electrical couplers of Figure 7, with one of the electrical couplers disconnected; and Figure 12 is an upper end perspective view of a busbar assembly including a pair of electrical couplers of Figure 7. 25 DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS According to an embodiment of the present invention, there is provided a mains-power electrical coupler 2 as shown in Figure 1. The coupler 2 is 30 suitable for electrically coupling a multi-strand cable 4 to a mains-power busbar 6 as shown in Figure 5. A detailed description of the coupler 2 is provided below.

5 As can best be seen in Figure 2, the coupler 2 includes an elongate barrel-like body 8 defining a cable passage 10 at one end and a terminal passage 12 at the other end. The body 8 is integrally formed from electrically conductive material and a stripped end of the electrical cable 4 is fastened within the 5 cable passage 10. The coupler 2 further includes a terminal 14 that can be located within the terminal passage 12. The terminal 14 is able to be rotated within the terminal passage 12, about a longitudinal axis of the body 8, to a desired orientation for fastening the terminal 14 to the busbar 6. When the terminal 14 is manually rotated to the desired orientation relative to the body 10 8, the terminal 14 can then be fixedly fastened within the body 8 using fasteners 32. Turing to Figure 3, the terminal 14 includes a dog-legged lug 16 which is also integrally formed from electrically conductive material. The lug 16 defines a 15 pair of mounting holes 18 for receiving respective busbar fasteners 20 (see Figure 5). The lug 16 includes a generally cylindrical stalk 22 for being received in the terminal passage 12, and a flat blade 24 extending from the stalk 22 and in which the busbar mounting holes 18 are defined. 20 As can best be seen in Figure 2, the stalk 22 defines two adjacent endless grooves 26, 28 for receiving respective fasteners 30, 32. The lug 16 defines a retaining knob 36 extending from the tip of the stalk 22. A polymeric sealing member 34 can be snap fitted over the retaining knob 36 and is retained in place by the retaining knob 36. The sealing member 34 is sized to form a 25 sealing engagement with the inside of the terminal passage 12 and, in use, impedes moisture from moving from the terminal passage 12 to the cable passage 10. Returning to Figure 3, the coupler 2 further includes a polymeric cover (or 30 cap) 38 defining a central hole through which the stalk 22 can be fitted. The cover 38 receives the terminal end of the body 8 in sealing engagement to impede the ingress of moisture into the terminal passage 12.

6 Turning to Figure 4, the cable and terminal passages 10,12 have sectored profiles that seamlessly interconnect. The passages 10,12 are oppositely disposed to receive a respective sector cable 4 and terminal 14 from opposite ends. The tubular body 8 defines a threaded orientation hole 42 extending 5 from the terminal passage 12. In use, a grub screw 30 is engaged within the orientation hole 42 and the groove 26 of terminal 14 (see Figure 2). The terminal 14 can then be freely swiveled 3600 within the terminal passage 12 about a longitudinal axis of the body 8, but cannot be axially removed from the terminal passage 12. 10 The body 8 further defines a pair of threaded terminal fastening holes 40 extending from the terminal passage 12. In use, the threaded terminal fasteners 32 are engaged within respective terminal fastening holes 40 and clamp down within the groove 28 of terminal 14 (see Figure 2) when the 15 terminal 14 is at a desired orientation. Upon clamping, the terminal 14 maintains its orientation relative to the body 8. In addition, the body 8 defines a pair of threaded cable fastening holes 44 extending from the cable passage 10. In use, a pair of threaded cable 20 fasteners 46 are engaged within respective cable fastening holes 44 and clamp the stripped end of the cable 4 within the cable passage 10 (see Figure 2). The fasteners 32, 46 are integrally formed from electrically conductive 25 material. These fasteners 32, 46 are typically shear fasteners (e.g. bolts) for mitigating over-tightening, and have a head from which a threaded shaft extends. The head rests upon a narrow neck and can be separated from the rest of the fastener by shearing with a spanner during tightening, thereby giving the tightened fasteners a lower profile. The heads of the tightened 30 fasteners 32, 46 do not extend beyond the flat blade 24 of the terminal 14 prior to shearing. Upon shearing, no part of the fasteners 32, 46 may protrude from the body 8.

7 A method for coupling the cable 4 to the busbar 6 with the coupler 2 is now described. Initially, the attachment end of the sector cable 4 is stripped of insulation 5 material so that the inner strands of wire are exposed. The cable 4 is then fed into the cable passage 10 where it is clamped firmly inside with threaded cable fasteners 46. The terminal 14 can then be inserted into the terminal passage 12. The grub 10 screw 30 is then tightened within orientation hole 42 until it engages within groove 26. The user can then move the coupler 2 (and attached cable 4) to the busbar 6. Next, the terminal 14 is rotated relative to the body 8 to an orientation for facilitating fastening of the terminal 14 to the busbar 6. The sealing member 34 and cover 38 generally remain stationary with respect to 15 the body 8 during rotation of the terminal 14. The terminal 14 is fixedly fastened relative to the body 8 with the terminal fasteners 32 which are clamped into the groove 28. As shown in Figure 5, busbar fasteners 20 are also used to attach the blade 24 of the terminal 14 to 20 the busbar 6. With particular reference to Figure 2, an electrical path is formed: from the cable 4, through the fasteners 46, through the body 8, through the fasteners 32, through the lug 16, through the busbar fasteners 20 and to the busbar 6. 25 Figure 6 shows a busbar assembly 50 which includes the busbar 6 and a pair of electrical couplers 2 coupled to the busbar 6. The busbar assembly 50 further includes a pair of electrical distribution connectors 52 electrically coupled to either side of the busbar 6. Each connector 52 includes an 30 electrically conductive housing 54 in which a pair of chambers 56 is defined. Each housing 54 is in electrical communication with the centrally located busbar 6. A pair of apertures extends from each chamber 56 and, in use, receives the threaded shaft of respective shear bolts 58. In use, wires 60 are 8 located within respective rubber end seals 61 which, in turn, are located within respective chambers 56. The rubber end seals 61 impede water from entering the wires 60. 5 The bolts 58 are engaged within the chambers 56 so as to clamp the wires 60 therein and form an electrical connection between the wires 60 via the housing 54 (and bolts 58). The wires 60 can be stripped of their insulation before connection or, in some applications, the chambers 56 may include piercing teeth for piercing the insulation skin of the wire 60 when the wire is 10 clamped within the chambers 56 by bolts 58. A person skilled in the art will appreciate that many embodiments and variations can be made without departing from the ambit of the present invention. 15 In the preferred embodiment, the passages 10,12 defined in the tubular body 8 had a sectored profile. In an alternative embodiment, the passages 10,12 may be cylindrical and have a common diameter. 20 In one embodiment, the body 8 of the coupler 2 may include an outer insulator skin. In the preferred embodiment, the cable 4 was multi-stranded sector cable. In another embodiment, the cable 4 may consist of a single strand only. 25 As can best be seen in Figure 5, the busbar assembly 50 may include a pair of polymeric covers 62 which surround respective housings 54 to impede moisture from entering the chambers 56. 30 According to another embodiment of the present invention, there is provided a mains-power electrical coupler 2 as shown in Figures 7 to 10. As before, the coupler 2 is suitable for electrically coupling a multi-strand cable 4 to a mains power busbar 6 as shown in Figures 11 and 12. Like reference numerals shown in these drawings refer to like features previously described.

9 Turning to Figure 8, the terminal 14 includes a straight lug 80 which is also integrally formed from electrically conductive material. A recess 82 is formed in an end of the stalk 22 and a retaining rivet 84 (or pin) extends from within 5 the recess 82 and through the polymeric sealing member 34. Turning to Figure 11, the flat blade 24 of the terminals 14 can be fastened to opposite sides of the busbar 6. In compliance with the statute, the invention has been described in language 10 more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims 15 appropriately interpreted by those skilled in the art.

Claims

1. A mains-power electrical coupler for coupling a cable to a busbar, the coupler including: a body defining both a cable passage in which the cable can be fastened, and a terminal passage; at least one releasable fastener; and a terminal for locating within the terminal passage, and able to be rotated within the terminal passage upon release of the fastener to an orientation for fastening the terminal to the busbar whilst the cable remains fastened within the cable passage.

2. An electrical coupler as claimed in claim 1, wherein the terminal includes a lug defining one or more holes for receiving respective fasteners.

3. An electrical coupler as claimed in claim 2, wherein the lug includes a cylindrical stalk for being received in the terminal passage, and a flat blade extending from the stalk and in which the holes are defined.

4. An electrical coupler as claimed in claim 3, wherein the stalk defines one or more endless grooves for receiving respective said releasable fasteners.

5. An electrical coupler as claimed in claim 3 or claim 4, wherein the terminal defines a retainer extending from the tip of the stalk and for retaining a polymeric sealing member.

6. An electrical coupler as claimed in any one of claims 3 to 5, wherein the electrical coupler further includes a polymeric cover defining a hole through which the stalk can be received and for receiving an end of the body.

7. An electrical coupler as claimed in any one of the preceding claims, wherein the cable and terminal passages seamlessly interconnect and have a common diameter.

8. An electrical coupler as claimed in any one of the preceding claims, wherein the cable and terminal passages have sectored profiles. 11

9. An electrical coupler as claimed in any one of the preceding claims, wherein the body defines one or more threaded cable fastening holes extending from the cable passage and for receiving respective cable fasteners.

10. An electrical coupler as claimed in any one of the preceding claims, wherein the body defines one or more threaded terminal fastening holes extending from the terminal passage and for receiving respective said releasable fasteners.

11. An electrical coupler as claimed in any one of the preceding claims, wherein the terminal can freely swivel 3600 within the terminal passage.

12. A mains-power electrical coupler for coupling a cable to a busbar, the coupler including: a body in which the cable can be fastened; at least one releasable fastener; and a terminal which upon release of the fastener can be rotated relative to the body to facilitate fastening of the terminal to the busbar whilst the cable remains fastened to the body.

13. An electrical coupler as claimed in claim 12, wherein the terminal includes a lug with a cylindrical stalk for being received in the terminal passage.

14. An electrical coupler as claimed in claim 13, wherein the stalk defines one or more endless grooves for receiving respective said releasable fasteners and the terminal can freely swivel 3600 within the terminal passage.

15. An electrical coupler as claimed in claim 13 or claim 14, wherein the terminal defines a retainer extending from the tip of the stalk and for retaining a polymeric sealing member.

16. A busbar assembly including: a busbar; and 12 an electrical coupler for coupling to the busbar and as claimed in any one of the preceding claims.

17. A busbar assembly as claimed in claim 16, further including at least one electrical distribution or insulation piercing connector coupled to the busbar.

18. A method for coupling a cable to a busbar, the method including the steps of: coupling a body of a mains-power electrical coupler as defined in any one of claims 1 to 15 to a cable; and rotating a terminal of the coupler relative to the body to facilitate fastening of the terminal to the busbar.

19. An electrical coupler substantially as herein described with reference to the accompanying drawings.

20. A busbar assembly substantially as herein described with reference to the accompanying drawings. SICAME AUSTRALIA PTY LTD by my attorneys Cullens Date: 19 September 2011