Plug-in busbar cable connector

Abstract

An end connector 34 suitable for a cable 10, comprises a first end 40 with a cable receptacle 36 sized to receive an end of a cable 10, and a second end 42 opposite to the first end 40. A plug portion

Description

Technical Field

[0001] The present disclosure relates generally to an end connector for connection with a busbar and a cable. Background

[0002] Electrical connections to busbars require mechanical fasteners, like nuts and bolts that must be individually and separately handled and installed. This increases the cost and complexity of the installation and requires more direct contact with metal surfaces on and in the area of the busbar. Summary

[0003] In at least some implementations, an end connector for a cable includes a first end with a cable receptacle sized to receive an end of a cable, a second end opposite to the first end, a plug portion and a retaining surface. The plug portion is at least partly between the first end and the second end and has an electrical connection surface sized for receipt within an opening, and the plug portion includes a void that defines at least part of a contact portion of the electrical connection surface that is radially flexible so that the plug portion has a first state with a first size and a second state with a second size that is less than the first size. The retaining surface is adjacent to the electrical connection surface and extends radially relative to the electrical connection surface.

[0004] In at least some implementations, a stop surface is located at an end of the electrical connection surface that is closer to the first end than the second end, wherein the stop surface extends outwardly beyond the electrical connection surface.

[0005] In at least some implementations, the retaining surface is partially defined by at least one void that permits inward flexing of the plug portion and retaining surface. In at least some implementations, the void extends into at least part of the electrical connection surface. In at least some implementations, the electrical connection surface is cylindrical and has a central axis, and multiple voids are provided, the voids are circumferentially spaced apart and extend axially from the second end, through the retaining surface and at least partially into the electrical connection surface.

[0006] In at least some implementations, an inner surface is defined by a cavity open to the second end, extending axially toward the first end, and located radially inwardly of the retainer and at least part of the electrical connection surface. In at least some implementations, a biasing member is received at least partly within the cavity and provides onto the inner surface a radially outwardly acting and biasing force. In at least some implementations, the biasing member is a torsion spring having an outer surface that is engaged with at least part of the inner surface. In at least some implementations, the biasing member is received outboard of or defines an outer surface of at least part of the electrical connection surface. In at least some implementations, the biasing member includes at least one portion that is radially compressible.

[0007] In at least some implementations, the retaining surface is formed in the electrical connection surface and is defined by a radially inwardly extending groove.

[0008] In at least some implementations, the retaining surface is defined by an outwardly extending surface at an end of the electrical connection surface. In at least some implementations, the retaining surface is defined by a flexible retainer located within the plug portion. In at least some implementations, the flexible retainer is carried within a groove formed in the electrical connection surface.

[0009] In at least some implementations, a busbar and cable assembly includes a busbar having a body with an opening formed through the body, a cable having a conductor and an end conductor. The end connector has a first end with a cable receptacle in which part of the conductor is received, a second end opposite to the first end, and a plug portion at least partly between the first end and the second end and having an electrical connection surface sized for receipt within the opening. The plug portion includes a retaining surface adjacent to the electrical connection surface and extending radially relative to the electrical connection surface. A retainer is carried by one of the end connector and the busbar, and the retainer is arranged to engage the retaining surface when the plug portion is within the opening to resist removal of the plug portion from the opening.

[0010] In at least some implementations, the retainer is carried by the busbar and is within the opening, and the retaining surface is arranged to engage the retainer when the plug portion is installed in the opening. In at least some implementations, the busbar includes a groove that is open to the opening and the retainer is received within the groove, and the retainer extends radially inwardly into the opening. In at least some implementations, the end connector includes a groove in which the retainer is partly received when the plug portion is installed in the opening.

[0011] In at least some implementations, the retainer is carried by the end connector and is partially received in a groove formed in the electrical connection surface, and wherein the retainer defines the retaining surface and the busbar includes a groove that is open to the opening and in which the retainer is partly received when the plug portion is installed in the opening.

[0012] In at least some implementations, a method of manufacturing a busbar and cable assembly includes providing the bus bar having at least one through opening and said cable assembly having a cable assembled with said end connector, and inserting the end connector with its second end into the at least one through opening and moving the end connector until the retainer is arranged to engage the retaining surface when the plug portion is within the opening to resist removal of the plug portion from the opening. Brief Description of the Drawings

[0013] The following detailed description of preferred implementations and best mode will be set forth with regard to the accompanying drawings, in which:

[0014] FIG. 1 is a perspective view showing multiple cables connected to a busbar;

[0015] FIG. 2 is a side view showing a cable with an end connector coupled to the busbar;

[0016] FIG. 3 is an enlarged fragmentary view showing a retaining surface of the end connector on a back side of the busbar;

[0017] FIG. 4 is an end view of the cable connector showing a biasing member within the end connector;

[0018] FIG. 5 is a sectional view of the end connector and part of the busbar;

[0019] FIG. 6 is an end view of a spring element that may be part of the end connector or busbar;

[0020] FIG. 7 is a partial sectional view showing a retainer carried by the busbar and releasably engageable with the end connector;

[0021] FIG. 8 is a side sectional view showing an end connector and part of the busbar prior to assembly of the end connector to the busbar; and

[0022] FIG. 9 is a side sectional view like FIG. 8 and showing the end connector assembled to the busbar. Detailed Description

[0023] Referring in more detail to the drawings, FIG. 1 illustrates a plurality of cables 10 coupled to one or more busbars 12. The busbars 12 are typically uninsulated, air-cooled conductive members having multiple connection points to which cables 10 may be connected to distribute electrical power. The busbars 12 may be mounted in any suitable way to a support structure, which may be insulated.

[0024] In at least some implementations, such as shown in FIGS. 2-5, the busbar 12 is generally rectangular in cross-section and has opposite first and second ends 14, 16 (FIG. 1), a front side 18, an opposite back side 20, and left and right sides 22, 24 extending between the ends 14, 16 and sides 18, 20, and multiple openings 26 formed through the busbar 12. In at least some implementations each busbar opening 26 is located between the busbar sides 22, 24 and extends through the front side 18 and the back side 20, has a circular periphery and a central axis 28, and the central axis 28 may be perpendicular to the front side 18 and the back side 20.

[0025] Each cable 10 may include an insulative outer layer 30 surrounding an inner conductor 32, and an end connector 34 that is fixed to the conductor 32 at a first location and releasably coupled to the busbar 12 at a second location. The end connector 34 is formed from an electrically highly conductive material, such as metals like copper or aluminum, by way of two, non-limiting examples. For connection to the conductor 32 of the cable 10, the end connector 34 may include a cable receptacle 36 that includes an inlet 38 at a first end 40 of the end connector 34, and is defined by a cavity located inboard of the first end 40 (e.g. between the first end 40 and a second end 42 of the end connector 34). The cable receptacle 36 may be defined by an inner surface 44 (FIG. 5) of a tubular portion 46 of the end connector 34, and an outer surface 48 of the tubular portion 46 defines part of an exterior surface of the end connector 34. An end 50 of the conductor 32 may be fixed in the cable receptacle 36, in at least some implementations, such as by crimping or otherwise plastically deforming the tubular portion 46 around or into firm engagement with the conductor 32. If desired, the cable 10 could be fixed in other ways, such as with a fastener, weld or the like.

[0026] To facilitate connecting the end connector 34 to the busbar 12, the end connector 34 includes an electrical connection surface 52, shown in FIG. 5. The electrical connection surface 52 is arranged to be received in the busbar opening 26 when the end connector 34 is coupled to the busbar 12. At least a portion of the electrical connection surface 52 maybe complementary in shape to the opening 26, and sized for direct contact between the surface of the busbar 12 that defines the opening 26 and the electrical connection surface 52. In the illustrated examples, the busbar openings 26 are cylindrical and the electrical connection surface 52 is cylindrical, and defined by part of the exterior surface of the end connector 34. The electrical connection surface 52 may be axially arranged between the cable receptacle 36 and the second end 42 of the end connector 34, and may extend to the second end 42 of the end connector 34 in some implementations.

[0027] In at least some implementations, the electrical connection surface 52 is coaxial with the busbar opening 26, and the end connector 34 is constructed so that it may be “plugged into” the busbar opening 26. This may be done by aligning the second end 42 of the connector 34 with the opening 26 at the front side 18 of the busbar 12 and pushing / slidably advancing the second end 42 of the end connector 34 into the busbar opening 26 until at least part of the electrical connection surface 52 is received within the opening 26, and in direct contact with the busbar 12 within the opening 26.

[0028] To facilitate insertion of the end connector 34 into the busbar opening 26, the electrical connection surface 52 may be defined in a plug portion 54 of the end connector 34 that is tubular or hollow, and the end connector 34 includes one or more voids 56 (FIGS. 3-5) extending through the electrical connection surface 52. The voids 56 define edges of flexible contact portions 58 (FIG. 5) of the end connector 34 that are cantilevered at one end and may flex inwardly when pushed into the busbar opening 26, and the contact portions 58 may be resilient and seek to return to their unflexed state where the return / resilient force provides a contact force on the busbar 12 within the opening 26 and improves electrical conduction between the busbar 12 and the electrical connection surface 52 of the end connector 34.

[0029] In at least some implementations, the plug portion 54 of the end connector 34 is the portion that is received in the opening 26 of the busbar 12 during assembly and / or when fully assembled to the busbar 12. The plug portion 54 has a first state with a first size (which may be a peripheral length or diameter) when not received in the busbar opening 26, and a second state having a second size (e.g. peripheral length) when received in the busbar opening 26, where the second size is less than the first size. Here, the size includes the circumferential dimension of the material of the end connector 34 and the voids 56 formed therein. So arranged, the plug portion 54 of the end connector 34 is adapted to be compressed, wherein contact portions 58 of the plug portion 54 are flexed inwardly, as the plug portion 54 is inserted into the busbar opening 26. The resilient nature of the material of the plug portion 54 / end connector 34 causes the contact portions 58 to tend to return toward their unflexed state and provides direct metal-to-metal contact between at least some the contact portions 58 and the busbar 12, within the opening 26.

[0030] While the resilient nature of the plug portion 54 material may, in at least some implementations, provide an outward force on the busbar 12 within the opening 26, as noted above, the end connector 34 may also or instead include a biasing member 60 to permit some flexing upon insertion of the plug portion 54 into a busbar opening 26 and some contact force between the busbar 12 and the end connector 34.

[0031] As shown in FIGS. 4 and 5, part of all of the plug portion 54 may be hollow and a biasing member 60 may be received within a cavity 62 of the plug portion 54. The biasing member 60 may engage an inner surface 64 of the contact portion(s) 58 and yieldably outwardly bias the engaged contact portion(s) 58. In the example shown, the biasing member 60 is a torsion spring that is in compression when installed in the cavity 62 and has an outer surface in contact with and providing an outwardly directed force on part of the inner surface 64 of the plug portion 54. Other springs or biasing members may be used, as desired. By way of a non-limiting example, a split or c-shaped spring may be received under compression within the cavity.

[0032] Further, as shown in FIG. 6, a flexible sleeve or ring, or a split or c-shaped ring 66 may be provided on (e.g against) the outside of the plug portion 54 and have a first state or at rest diameter / size / periphery larger than the busbar opening 26 and a second state that is radially compressed or smaller relative to the opening 26 and which fits within the busbar opening 26 with metal-to-metal contact between the busbar 12 and the ring 66, and between the ring 66 and the electrical connection surface 52 / the plug portion 54 of the end connector 34. The ring 66 may be considered an intermediate part between the busbar 12 and the electrical connection surface 52 or the ring 66 may define all or part of the electrical connection surface 52. Instead of a split or c-shaped ring 66, or on such a ring, the biasing member on the outside of the plug portion 54 may include ridges or outward extending regions 67 (shown in dashed lines in FIG. 6) that are flexible and which can be radially compressed upon insertion of the plug portion 54 into the busbar opening 26, and which may resiliently expand upon removal of the plug portion 54 form the busbar opening 26 to permit multiple insertions and removal of the end connector 34 with sufficient electrical connection between the end connector 34 and the busbar 12.

[0033] In at least some implementations, a retainer or retaining surface 70 is provided in one or both of the end connector 34 and the busbar 12 to yieldably, releasably retain the plug portion 54 in the busbar opening 26 until removal efforts are intentionally undertaken, and to thus inhibit or resist unintended disconnection of the end connector 34 from the busbar 12. As shown in FIGS. 2-5, the retaining surface 70 may be defined by an enlarged end portion of the end connector 34. In at least some implementations, the retaining surface is defined by a flange 70 that extends radially outwardly relative to the electrical connection surface 52, axially from the second end 42 of the end connector 34 to or toward the electrical connection surface 52, and circumferentially about a periphery of the end connector 34. The void or voids 56 extend through the retaining surface 70 such that the retaining surface is not circumferentially continuous. At the second end 42, the flange 70 may be tapered so that it is smaller at the second end 42 that at a location axially spaced from the second end 42. This may facilitate aligning and initial insertion of the second end 42 and retaining surface 70 into the busbar opening 26. Spaced from the tapered portion of the flange 70, the flange may include a retaining surface 72 that overlaps and may engage the backside 20 of the busbar 12. That is, when the end connector 34 is fully installed in the busbar 12, the retaining surface 70 may be received fully through the opening 26 and may rest against or be located adjacent to the backside 20 of the busbar 12, and may be directly adjacent to the busbar 12, including arrangements wherein the retaining surface 70 is in contact with the busbar 12. So arranged, the retaining surface 70 engages the busbar 12 and resists a certain magnitude of force tending to withdraw the plug portion 54 form the busbar opening 26, although the resistance can be overcome by a sufficient force to permit intentional removal of the end connector 34 from the busbar 12.

[0034] FIG. 7 illustrates a retainer 74 that is carried by the busbar 12, and which extends radially into the busbar opening 26 to engage a retaining feature or retaining surface 76 of the end connector 34 when the plug portion 54 is installed in the busbar opening 26. The retainer 74 is flexible and resilient and is outwardly flexed or compressed when part of the plug portion 54 passes the retainer 74, and which resiliently returns toward its unflexed position to radially overlap a retaining surface 76 that defines the retaining surface of the plug portion 54 when aligned therewith. In the example shown, the retainer 74 includes an annular spring received within a groove 78 that is open to the busbar opening 26. The spring 74 may be a coil spring, or other type of spring as desired. The retaining surface 76 is defined by a groove 78 formed in the plug portion 54 of the end connector 34 that, when aligned with the spring 74, allows the spring 74 to expand / unflex into the groove 78 so that the spring radially overlaps the retaining surface 76 of the plug portion 54. Until a sufficient magnitude of force is applied to the end connector 34, the spring 74 resists movement of the end connector 34 and when sufficient force is applied, the spring 74 yields / flexes and permits the end connector 34 to be withdrawn from the busbar opening 26.

[0035] Other constructions and arrangements may be used. For example, a retainer 84 (e.g. spring or other flexible member) could instead be carried by and movable with the end connector 34, such as by being retained within a slot 86 formed in the periphery of the plug portion 54, as generally shown in FIGS. 8 and 9. The retainer 84 in an at rest state, as shown in FIG. 8 prior to assembly of the end connector 34 to the busbar 12, extends radially outwardly farther than the electrical connection surface 52. As the end connector 34 is slid into the opening 26 of the busbar 12, the retainer 84 is compressed to permit passage of the plug portion 54 into the opening 26. In the assembled state or position, shown in FIG. 9, the end connector is received in the opening 26 until the retainer 84 is moved fully through the opening 26 and is received adjacent to the backside 20 of the busbar 12. In this position, the retainer 84 defines a retaining surface 70 that engages the busbar 12 when a force in the direction tending to cause removal of the end connector 34 from the opening 26 is applied to the end connector 34.

[0036] Next, in this embodiment, the electrical connection surface 52 is defined at least in part by a flexible or deformable member 88 or spring which could be formed integrally, in the same piece of material, as the plug portion 54 or as a separate component assembled to the plug portion 54, and which may be defined by one or more than one distinct component, as desired. The deformable member 88 has an outer surface 90 that, in the at rest or pre-assembly state shown in in FIG. 8, has a greater size or diameter than the busbar opening 26. In the assembled state, shown in FIG. 9, the deformable member 88 is radially inwardly deformed or compressed and the outer surface 90 thereof directly contacts the busbar 12 within the opening 26, and defines at least part of the electrical connection surface 52, enabling electrical conduction between the busbar 12 and end connector 34.

[0037] Further, the retaining surface could be formed in or associated with the busbar 12. For example, the retaining surface could be a groove in the busbar opening 26 into which a radially outer portion of the spring is received when aligned with the groove. In this example, the spring would be radially inwardly compressed upon insertion of the plug portion 54 mto the busbar opening 26 and would slide within the busbar opening 26 as the plug portion 54 is advanced in the opening. When the spring becomes axially aligned with the groove, the spring outwardly expands and is partially received in the groove to resist unintended withdrawal of the end connector 34 from the busbar opening 26.

[0038] In at least some implementations, to limit the depth of insertion of the end connector 34 into the busbar opening 26, the end connector 34 includes a radially outward extending stop surface 80, which may be defined by an axial end of an annular flange 82, if desired. The stop surface 80 is arranged between the electrical connection surface 52 and the first end 40 of the end connector 34. The stop surface 80 flange 82 is not received in the busbar opening 26 and instead radially overlaps part of the front side 18 of the busbar 12 when the end connector 34 is coupled to the busbar 12. When the stop surface 80 contacts the front side 18 of the busbar 12, the end connector 34 is fully installed and the electrical connection surface 52 fully within the busbar opening 26. In this position, a retainer, if provided, may also overlap a stop surface to releasably retain and inhibit withdrawal of the end connector 34 from the busbar opening 26, as noted above.

[0039] Accordingly, a cable 10 can be simply and efficiently coupled to a busbar 12 via an end connector 34 that is pushed or plugged into an opening 26 of the busbar 12. The coupling simultaneously provides electrical connection and mechanical connection and retention of the end connector 34 to the busbar 12 with simple linear / axial motion of the end connector 34 relative to the busbar 12. Mechanical fasteners, like nuts and bolts or otherwise, that must be individually and separately actuated are not needed to secure the end connector 34 to the busbar 12 or establish electrical connection. Thus, connection and disconnection of a cable 10 to the busbar 12 can be achieved simply and in less time and at least cost. Further, while the plug portion 54 and busbar opening 26 are shown as being cylindrical and complementary in size and shape, these components need not be complementarity shaped. For example, the plug portion 54 could have a different polygonal shape (e.g. peripheral shape), providing discrete areas, lines or regions of contact with the busbar 12 within the busbar opening 26, if desired.

[0040] All terms used in the claims are intended to be given their broadest reasonable construction and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.

Claims

1. An end connector for a cable, comprising:a first end with a cable receptacle sized to receive an end of a cable;a second end opposite to the first end;a plug portion at least partly between the first end and the second end and having an electrical connection surface sized for receipt within an opening, the plug portion including a void that defines at least part of a contact portion of the electrical connection surface that is radially flexible so that the plug portion has a first state with a first size and a second state with a second size that is less than the first size; anda retaining surface adjacent to the electrical connection surface and extending radially relative to the electrical connection surface.

2. The end connector of claim 1, which includes a stop surface located at an end of the electrical connection surface that is closer to the first end than the second end, wherein the stop surface extends outwardly beyond the electrical connection surface.

3. The end connector of claim 1 wherein the retaining surface is partially defined by at least one void that permits inward flexing of the plug portion and retaining surface.

4. The end connector of claim 3 wherein the void extends into at least part of the electrical connection surface.5.The end connector of claim 3 wherein the electrical connection surface iscylindrical and has a central axis, and multiple voids are provided, the voids are circumferentially spaced apart and extend axially from the second end, through the retaining surface and at least partially into the electrical connection surface.

6. The end connector of claim 5 which includes an inner surface defined by a cavity open to the second end, extending axially toward the first end, and located radially inwardly of the retainer and at least part of the electrical connection surface.

7. The end connector of claim 6 which includes a biasing member received at least partly within the cavity and providing onto the inner surface a radially outwardly acting and biasing force.

8. The end connector of claim 7 wherein the biasing member is a torsion spring having an outer surface that is engaged with at least part of the inner surface.

9. The end connector of claim 6 wherein the biasing member is received outboard of or defines an outer surface of at least part of the electrical connection surface.

10. The end connector of claim 9 wherein the biasing member includes at least one portion that is radially compressible.

11. The end connector of claim 1 wherein the retaining surface is formed in the electrical connection surface and is defined by a radially inwardly extending groove.

12. The end connector of claim 1 wherein the retaining surface is defined by an outwardly extending surface at an end of the electrical connection surface.

13. The end connector of claim 12 wherein the retaining surface is defined by a flexible retainer located within the plug portion.

14. The end connector of claim 13 wherein the flexible retainer is carried within a groove formed m the electrical connection surface.

15. A busbar and cable assembly, comprising:a busbar having a body with an opening formed through the body;a cable having a conductor;an end connector with a first end with a cable receptacle in which part of the conductor is received, the end connector having a second end opposite to the first end, and the end connector including a plug portion at least partly between the first end and the second end and having an electrical connection surface sized for receipt within the opening, the plug portion including a retaining surface adjacent to the electrical connection surface and extending radially relative to the electrical connection surface; anda retainer carried by one of the end connector and the busbar, wherein the retainer is arranged to engage the retaining surface when the plug portion is within the opening to resist removal of the plug portion from the opening.

16. The busbar and cable assembly of claim 15 wherein the retainer is carried by the busbar and is within the opening, and the retaining surface is arranged to engage the retainer when the plug portion is installed in the opening.

17. The busbar and cable assembly of claim 16 wherein the busbar includes a groove that is open to the opening and the retainer is received within the groove, and the retainer extends radially inwardly into the opening.

18. The busbar and cable assembly of claim 17 wherein the end connector includes a groove in which the retainer is partly received when the plug portion is installed in the opening.

19. The busbar and cable assembly of claim 15 wherein the retainer is carried by the end connector and is partially received in a groove formed in the electrical connection surface, and wherein the retainer defines the retaining surface and the busbar includes a groove that is open to the opening and in which the retainer is partly received when the plug portion is installed in the opening.

20. A method of manufacturing a busbar and cable assembly according to claim 15, comprising the steps of:providing said bus bar having at least one through opening and said cable assembly having a cable assembled with said end connector;inserting the end connector with its second end into the at least one through opening and moving the end connector until the retainer is arranged to engage the retaining surface when the plug portion is within the opening to resist removal of the plug portion from the opening.Application No: GB2407886.7Examiner:Contract Unit ExaminerClaims searched: 1-20Date of search: 27 January 2025Patents Act 1977: Search Report under Section 17Documents considered to be relevant:Category Relevant to claims Identity of document and passage or figure of particular relevance X 1-8,12 US6398592B1 (MORI SHIGEO ET AL) figure 2 X,Y X: 1-4, 7-10, 12-14 Y: 15-20 US4374607 A (BRIGHT EDWARD J ET AL) column 2; figures 1, 2, 3, 4 Y 15-20 EP3886206 Al (SAMSUNG SDI CO LTD) paragraph [0039]; figures 2, 3, 1,4 Y 16-18 LSI 1848516 B2 (TE CONNECTIVITY GERMANY GMBH) figure 3 A - US5486123 A (MIYAZAKI SHO) figures 1-3Categories:X Document indicating lack of novelty or inventive step A Document indicating technological background and / or state of the art. Y Document indicating lack of inventive step if P Document published on or after the declared priority date but combined with one or more other documents of before the filing date of this invention. same category. & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.Field of Search:International Classification:Subclass Subgroup Valid From H01R 0004 / 52 01 / 01 / 2006 H01R 0011 / 11 01 / 01 / 2006 H01R 0013 / 05 01 / 01 / 2006 H01R 0013 / 20 01 / 01 / 2006

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