WO2001033670A1

WO2001033670A1 - Electrical cable connector and insert therefor

Info

Publication number: WO2001033670A1
Application number: PCT/GB2000/004172
Authority: WO
Inventors: Albert Renaud Perrin; Roland Sion Timsit
Original assignee: Tyco Electronics Canada Limited; Tyco Electronics Uk Limited
Priority date: 1999-11-01
Filing date: 2000-10-30
Publication date: 2001-05-10
Also published as: AU1154201A

Abstract

An electrical connector for electrically connecting a source wire and a tap wire. The invention relates to an electrical connector including an outer member and an inner member made of a non-highly-electrically-conductive material or insulating material, and an electrically conductive insert that provides an electrical connection path between the wires. The outer member has a first inner recess that houses the tap wire and an opposing second inner recess that houses source wire. The electrically conductive member is inserted between the tap wire and the source wire whereby the electrically conductive member provides an electrical connection between the source wire and the tap wire. The inner member is inserted or wedged within the outer member between portions of the electrically conductive insert contacting the tap wire and the source wire. The invention also provides embodiments for electrically connecting the source and tap wires which comprise insulated and uninsulated conductors.

Description

ELECTRICAL CABLE CONNECTOR AND INSERT THEREFOR

The present invention relates to an electrical connector for electrically connecting together a source wire and a tap wire. More specifically, the invention relates to an electrical connector including an outer member, an inner member, and a conductive insert that provides an electrical path between the connected wires . During the installation and maintenance of electrical distribution systems, such as those formed from distribution transformers or substations, it is necessary to connect respective pairs of lead wires. In order to construct a practicable electrical distribution system, it is further necessary to maintain solid mechanical retentions of the wires, as well as a good electrical connection therebetween, despite typical electrical loading cycles that most likely result in a wide variation in operating conditions.

Conventional electrical cable connectors include a generally C-shaped member for electrically connecting lead wires with a wedge member, for example U.S. Patent Number 5,567,186, issued on October 22, 1996, to Diniz et al .

Typically, the C-shaped members are made by extruding a conductive material and blanking thereof followed by press forming and heat treating. As used herein, the terms non- conductive material and non- electrically conductive material are meant to mean non-highly electrically conductive material, e.g., steel, or electrical insulative material, e.g., non-conductive polymer or ceramic material. Manufacturing steps are necessary with a conductive material such as aluminum, a copper alloy, or a composite material in order to obtain the necessary material properties, such as strength, ductility and acceptably high electrical conductivity. Similar manufacturing methods may also be necessary in order to produce the wedge members of these electrical connectors that are often made by casting. These manufacturing processes are expensive, yet they are necessary in order to produce an electrical connector having a C-shape and wedge members. Consequently, there exists a need for an electrical connector that is relatively inexpensive to produce. The present invention solves this problem by inserting a conductive member within an outer, generally C-shaped, member between the source wire and the tap wire and an inner member inserted within the conductive member. In this configuration the conductive member is responsible for electrically connecting the source and tap wires together, therefore, allowing the outer C-shaped member and the inner member to be made from less conductive, cheaper, yet adequately strong materials.

U.S. Patent Number 3,329,928, issued on July 4, 1967, to Broske describes an electrical connector including a C-shaped member, a V-shaped member, and a wedge member. However, in the patent to Broske the problem set forth above is not described nor is the solution of using a conductive insert.

Consequently, the need still exists for an electrical connector that is relatively inexpensive to produce.

In addition to the previously identified needs for electrical connectors, a further need is to provide an electrical connector that establishes solid mechanical retentions of wires, as well as good electrical connections therebetween, even when one wire is insulated and its associated wire is uninsulated. Summary of the Invention The present invention provides a novel electrical connector designed to address one or more of the aforementioned needs. The invention embodies an electrical connector having an electrically conductive insert that provides an electrical connection path between a source wire and a tap wire. The conductive insert eliminates the need for constructing the outer member and the inner member of the electrical connector from expensive electrically conductive materials. More importantly, the outer member and the inner member do not have to be highly electrically conductive but rather are preferred to be non-highly-electrically conductive or insulating material . Consequently, the outer member and the inner members may be made from material such as various forms of relatively inexpensive steel or other materials such as polymers and ceramics. In the case of steel, the steel material provides strength for the outer member and for the inner member, thereby avoiding the problems of constructing the outer member and the inner member from thicker bodies of weaker materials which need to be press-formed and/or heat treated in order to provide structure stability so as to prevent failure.

Accordingly, the present invention relates to an electrical connector for electrically connecting together a first wire or cable (e.g. a source wire) and a second wire or cable (e.g. a tap wire) . The invention relates to an electrical connector including an outer member preferably having a generally C-shaped configuration, an inner member, and an electrically conductive insert that provide an electrical connection path between the wires. The outer member has a first inner recess that houses the first (tap) wire or cable and an opposing second inner recess that houses the second (source) wire or cable. The invention hereinafter will be described for convenience in terms of the aforementioned tap wire and source wire, but without limitation to those specific forms or uses of wires or cables. The electrically conductive member is inserted between the tap wire and the source wire, whereby the conductive member provides an electrical connection between the source wire and the tap wire. The inner member is inserted or wedged within the outer member, whereby a first portion of the electrically conductive member is positioned between the inner member and the tap wire, and a second portion of the electrically conductive member is positioned between the inner member and the source wire .

Preferably, the electrically conductive member includes a U-shaped, or C-shaped, portion connecting between the first portion and the second portion thereof. In this embodiment, the U-shaped, or C-shaped, connecting portion of the conductive member may be flexed or compressed as the electrically conductive member is being inserted whereby the first portion and the second portion thereof are moved toward each other, thereby facilitating the insertion of the electrically conductive member between the source wire and the tap wire.

In other embodiments, the electrically conductive member has a flat connecting portion extending between the first portion and the second portion thereof. In this embodiment, the conductive member is snapped or locked into position on the inner member, and the resulting assembly may be inserted within the outer member. The electrically conductive member can be configured in a variety of different sizes and shapes using a variety of different manufacturing processes.

In other embodiments, the electrical connector assemblies may be provided for electrical connection between insulated and uninsulated conductors, preferably with an implementation of at least one insulation-piercing serration. In one such embodiment, at least one piercing serration is provided on both the electrically conductive member and on the outer member, and in another embodiment at least one piercing serration is provided on each of opposing surfaces on one side of the electrically conductive member. The invention itself, together with further objects and advantages, may be best understood by reference to the following detailed description by way of example taken in conjunction with the accompanying drawings. Brief Description of the Drawings Figure 1 is a perspective view of an electrical connector according to the present invention depicting a source wire, a tap wire, an outer member, a conductive insert, and an inner member .

Figure 2A is a cross-sectional end view of an outer member with a source wire and a tap wire inserted therein according to the present invention.

Figure 2B is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein according to the present invention and depicting a conductive insert being inserted between the wires.

Figure 2C is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein and a conductive member inserted between the wires according to the present invention. Figure 2D is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein, a conductive member inserted between the wires, and an inner member inserted therein according to the present invention. 4-1

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thereof, and therefore the cost of materials used, and yet large enough to prevent cracking of the outer member 20 when it is fabricated, and later on when it is operationally forced into high pressure contact with the tap and source wires 12 and 14 respectively. The material used to form outer member 20 should also be strong and ductile enough to withstand the application of large bending and tensile forces without cracking or failing, and to ensure acceptable spring-back when used in an electrical connector contemplated by the practice of this invention.

As depicted in Figures 1, 2B, and 2C, the conductive member 30 includes a first portion 32, a second portion 34, and a portion 36 between the first portion 32 and the second portion 34. The conductive member 30 also has bent portions 38 and 40 shown in Figure 2B . When the conductive member 30 is inserted within a cavity 26 of the outer member 20, as depicted in Figure 2C, the conductive member 30 has a cavity 42 (also shown in Figure 1) between the first portion 32 and the second portion 34. The first portion 32 includes a contact surface 33 that is generally arcuate in shape and is configured to abut and rest generally adjacent to the tap wire 12. The second portion 34 includes a contact surface 35 that is generally arcuate in shape and is configured to abut and rest generally adjacent to the source wire 14. Alternatively, the contact surfaces 33 and 35 may be configured using a variety of different shapes.

In one embodiment, portion 36 protrudes beyond the outer member 20 and is generally U-shaped, or C-shaped, as depicted in Figures 1-4. However, the present invention contemplates other protruding shapes, such as other arcuate shapes, and V- shapes that are able to perform a similar function as described below. The portion 36 is preferably configured such that when a force F is applied thereto, the first portion 32 moves toward the second portion 34 to facilitate the insertion of the conductive member 30 between the tap wire 12 and the source wire 14, one embodiment of which is depicted in Figure 2B . In the embodiment depicted in Figure 2B, the force F is applied in opposite directions to opposing bends, 38 and 40, of the portion 36. The electrically conductive member 30 of the present invention is made of a conductive material, such as copper, a copper alloy, aluminum, an aluminum alloy, a bimetallic aluminum-copper material, or other conductive material, for example, currently experimental conductive polymers. One method of manufacturing the electrically conductive member 30 is by stamping the conductive member 30 from a sheet of electrically conductive material and bending the resulting stamped piece of material to form the electrically conductive member 30. The conductive member 30 should have a thickness great enough to accommodate the full power range experienced by electrical connectors contemplated by the present invention. The conductive member 30 should also be configured and made of a material capable of withstanding bending of the portion 36 during insertion of the electrically conductive member 30 between the tap wire 12 and the source wire 14. The contact surfaces, 33 and 35, of the conductive member 30 provide an electrical connection between the tap wire 12 and the source wire 14. The conductive member 30 still provides a proper conductive path even when inserted in an inverted position. As depicted in Figures 1 and 2D, an inner member 50 is preferably slightly tapered for ease of insertion within the cavity 42 of the electrically conductive member 30, although a taper is not essential to proper operation of the present invention. A leading end 52 (best seen in Figure 1) of the inner member 50 that enters the cavity 42 first is narrower than trailing end 54 of the inner member 50. Opposing sides, 56 and 58, of the inner member 50 are shaped to abut the first portion 32 and the second portion 34, respectively, of the conductive member 30. The inner member 50 is dimensioned so as to fit snugly within the cavity 42 (best seen in Figure 2D) of the conductive member 30 such that the first portion 32 and the second portion 34, more particularly surfaces 33 and 35 respectively, of the conductive member 30 are pressed against the tap wire 12 and the source wire 14, respectively, thereby causing a good electrical interconnection to be made therebetween .

As discussed above, for the outer member 20, a benefit of the present invention is that it allows the inner member 50 to be constructed using a variety of different methods and a variety of different materials, such as aluminum, aluminum alloys, copper, copper alloys, brass, plated/coated mild or stainless steel, other types of steel, a bimetallic material, plastics, ceramics, polymers, or other similar materials. This allows the inner member 50 to be constructed using inexpensive construction methods and inexpensive materials. The inner member 50 can be constructed of non-electrically conductive materials having poor electrical conductivity or no conductivity at all since the conductive member 30 is being used to electrically connect the tap wire 12 to the source wire 14. The inner member 50 is preferably made from a spring, a spring device or a resilient material. The springy inner member 50 is preferably made from sheet, plate, or other metal or material structure.

The inner member 50 may be configured to be inserted within the cavity 42 by an explosively-driven or power actuated portable tool, such as an AMPACT^® tool supplied by AMP Incorporated of Harrisburg, Pennsylvania. Alternatively, the inner member 50 may be configured to be inserted within the cavity 42 by bolting or other mechanical driving tool.

Figures 2A-2D depict a method of electrically connecting a tap wire 12 to a source wire 14. Figures 2A depicts the first step that includes positioning the tap wire 12 and the source wire 14 within opposing recesses, 22 and 24, respectively, of the outer member 20. Figure 2B depicts the step of inserting the conductive member 30 between the tap wire 12 and the source wire 14. As depicted in Figure 2B, one method of inserting the conductive member 30 includes using a force, indicated as F, to compress the U-shaped portion 36 so as to move the first portion 32 toward the second portion 34, thereby, facilitating the insertion of the conductive member 30 between the tap wire 12 and the source wire 14. Alternatively, the conductive member 30 may be slid into position between the tap wire 12 and the source wire 14.

Figure 2C depicts the conductive member 30 as being inserted between the tap wire 12 and the source wire 14. And finally, as depicted in Figure 2D, the inner member 50 is inserted within the outer member 20 whereby the first portion 32 of the conductive member 30 is positioned between the inner member 50 and the tap wire 12 and a second portion 34 of the conductive member 30 is positioned between the inner member 50 and the source wire 14. Figure 3 is a schematic view of an assembled electrical connector 10 according to the present invention depicting an electrical current flow path, indicated by the letter C, flowing between the source wire 14, the conductive member 30, and the tap wire 12. In various embodiments of the present invention where conductive material is used to make the outer member 20 and/or the inner member 50, some or all of the electrical current may flow through one or both of those conductive members.

Figure 4 is a cross-sectional end view of an outer member 20 with a source wire 14 and tap wire 12 inserted therein, an alternative embodiment of a conductive member 130 inserted between the wires, and an inner member 50 inserted therein according to the present invention. As depicted in Figure 4, the first portion 132 and a second portion 134 of the conductive member 130 can be constructed using a variety of dimensions. The first and second portions, 132 and 134, depicted in Figure 4 are elongated relative to those depicted in Figure 3, for example. The first and second portions 132 and 134 could also be constructed so as to be shorter than those depicted in Figure 3. The present invention contemplates a limitless variety of sizes, shapes, and configurations for all of its members.

Figures 5A-5C depict an alternate method of electrically connecting a tap wire 212 to a source wire 214, as contemplated by the present invention. Figure 5A depicts a step that includes positioning a conductive member 230 on an inner member 250 to form an assemblage. Opposing sides, 256 and 258, of the inner member 250 abut the first portion 232 and the second portion 234, respectively, of the conductive member 230. Figure 5B includes positioning the tap wire 212 and the source wire 214 within opposing recesses, 222 and 224, respectively, of an outer member 220. The steps depicted in Figures 5A and 5B can be performed in the opposite order if so desired. Figure 5C depicts the step of inserting the assemblage <s r-~ o QJ J

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piercing serration 504 located along its inner wall and facing the insulated conductor 12' having an insulative covering 12A.

The electrical connector 500 further comprises the inner member 20 of Figure 1 and an electrically conductive member 506 which is similar to the electrically conductive member 42 of

Figure 1 except that it has at least one piercing serration 506 located on its outer wall 32 and facing the insulated conductor 12' . The piercing serration 504 of the outer member 502 and the piercing serration 508 of the conductive member 506 are both suitable for piercing the electrical insulation 12A of the electrical cable 12'. The outer member 502 operatively cooperates with the conductive member 56 as well as with the inner member 50 which may be further described with reference to Figure 9 which illustrates an embodiment which provides for satisfactory electrical connections between cables 12' and 14. Figure 9 is quite similar to Figure 3 , but illustrates the embodiment of Figure 8 rather than Figure 3 illustration of the embodiment of Figure 1. The piercing serrations 504 and 508 are preferably arranged to be in alignment with each other and with both 504 and 508 piercing the insulation 12A of the electrical cable 12'. Further, the inner member 50 is wedged into the conductive member 506. The embodiment of Figure 9 captures the electrical cable 12 ' between the piercing serrations 504 and 506, so as to fix the cable 12' in a stationary position. In the embodiment of Figure 9, electrical current need not pass through the outer member 506 and the inner member 50, but rather current only needs to pass from one cable 12 ' to the other cable 14 by conduction only through the conductive member 506 and is shown therein by both path C . In the embodiment of Figure 9, the piercing serration 504 need not conduct electricity. Instead, the piercing serration 508 penetrates through the conductor insulation 12A to make mechanical contact with the conductor 12 ' . This provides mechanical support directly to the metal conductor 12 ' . Such mechanical support, coupled with the mechanical support provided by piercing member 504 of the outer member 502, minimizes mechanical support by the insulation 12A of the cable 12'. This, in turn, eliminates mechanical flow of the insulation material during service, particularly if the conductor temperature becomes elevated. More particularly, direct mechanical support by the insulation material 12A of the cable 12 ' is to be avoided since the insulation material 12A flows particularly if the cable 12 ' temperature becomes elevated, or if the interface with the cable 12' allows mechanical support by the insulation sleeve making up the insulation 12A. Flow of insulation material 12A would lead to loss of mechanical load at the electrical interfaces in the cables 12' and 14, thus leading to a potential degradation of the connector performance. More particularly, the piercing serration-to-metal conductor 12 ' contact provided by the piercing serrations 504 and 508 biting into the electrical conductor 12 ' should be used to provide the desired mechanical load bearing function so as to avoid degradation of the connector performance. A further embodiment having the benefits of the embodiment of Figures 8 and 9 may be described with reference to Figures 10 and 11 for an embodiment 510.

The embodiment 510 of Figure 10 includes the outer member 20 and the inner member 50 (previously described) and a conductive member 512 having at least one piercing serration, but preferably at least two serrations 514 and 516 oppositely disposed from each other on the same side of the conductive member 512, that is, on the side of conductive member 512 that is arranged to come into contact with the insulative covering 12A of the conductor 12'. The conductive member 512 has the same electrical characteristics as those of conductive member 506 of Figure 8 and, also as those of the conductive member 30 of Figure 1. The conductive member 512 may be further described with reference to Figure 11. Figure 11 is quite similar to that of Figure 4 except that Figure 11 illustrates the conductive member 512 as having piercing serrations 514 and 516 that capture the conductor 12 ' .

As seen in Figure 11, the piercing serrations 514 and 516 along with the conductive member 512 establish the electrical path C" between conductors 12' and 14. Each of the piercing serrations 514 and 516 penetrates through the conductor insulation 12A to make mechanical contact with the conductor metal 12'. Such mechanical support, coupled with the mechanical support provided the outer member 50, minimizes

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so as to make electrical contact with the underlying wire when gripped between said inner member and said outer member.

6. The electrical connector according to claim 5, wherein said electrically conductive insert and said outer member each carry at least one said piercing serration and their respective serrations are arranged substantially in alignment with each other.

7. The electrical connector, according to claim 5, wherein said electrically conductive insert has first and second sides and has at least one said piercing serration on opposite faces of one of said sides with each piercing serration arranged to come into contact and pierce said insulative covering.

8. The electrical connector according to any preceding claim, wherein the wires and said conductive insert and said inner member have been inserted into said outer member so that the wires and said insert are gripped between said inner member and said outer member and said conductive insert provides an electrical connection between the first wire and the second wire.

9. The connector according to any preceding claim, wherein the connecting portion of the conductive insert located between the first portion and the second portion thereof protrudes beyond the outer member when the insert is inserted therein. 10. A method of electrically connecting a first wire or cable ("tap wire") to a second wire or cable ("source wire") by means of a connector according to any preceding claim, said method comprising the steps of: positioning the tap wire and the source wire within opposing recesses of said outer member of the connector; inserting said electrically conductive insert of the connector between the tap wire and the source wire whereby said conductive insert provides an electrical connection between the source wire and the tap wire; and inserting said inner member of the connector within said outer member whereby said tap wire and a first portion of said electrically conductive insert are gripped between the inner member and the outer member and whereby said source wire and a second portion of the electrically conductive member are gripped between the inner member and the outer member.

11. The method of electrically connecting a tap wire to a source wire according to claim 10, wherein the step of inserting said electrically conductive insert includes flexing or compressing a portion of the electrically conductive insert located between the first portion and the second portion thereof, whereby the first portion and the second portion are moved toward each other thereby facilitating the insertion of the electrically conductive member between the source wire and the tap wire .

12. A method of electrically connecting a tap wire to a source wire according to claim 10, said method comprising the steps of : positioning said electrically conductive insert of the connector on said inner member of the connector to form an assemblage; positioning the tap wire and the source wire within opposing recesses of said outer member of the connector; inserting the assemblage between the tap wire and the source wire such that a first portion of the electrically conductive insert is positioned between the inner member and the tap wire and a second portion of the electrically conductive insert is positioned between the inner member and the source wire whereby the electrically conductive insert provides an electrical connection between the source wire and the tap wire .

13. The method of electrically connecting a tap wire to a source wire according to claim 10, wherein one of said tap wire and source wire has an insulative covering thereon, and said electrically conductive insert has at least one piercing serration and is inserted so that the piercing serration pierces the insulative covering at least after insertion of said inner member whereby the conductive member provides an electrical connection between the source wire and the tap wire. 14. The method of electrically connecting a tap wire to a source wire according to claim 13, said method comprising the steps of : positioning the tap wire and the source wire within opposing recesses of said outer member having a piercing serration which is positioned to come into contact with and pierce said insulative covering; and inserting said electrically conductive insert between the tap wire and the source wire with said piercing serration of the insert piercing the insulative covering, whereby the conductive insert provides an electrical connection between the source wire and the tap wire .