Encapsulated connection system forming an encapsulated connection between conductors and method comprising the same

Abstract

This invention relates to an encapsulated connection system for forming an encapsulated connection between conductors and a method thereof. Specifically, an encapsulated connection system for mechanically and electrically connecting a first cable and a second cable includes an electrical connector, a housing, and a protective end cap, wherein each of the first and second cables includes an elongated electrical conductor covered by an insulating layer. The electrical connector is configured to form a connection with the first and second cables, wherein the conductors of the first and second cables are electrically connected via the electrical connector. The housing is configured to receive and cover the connection and to protect the electrical connector. The housing includes a plurality of housing ports, each configured to receive a cable. The protective end cap is configured to selectively cover at least a selected housing port of the housing ports.

Description

[0001] Related applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application No. 62 / 976,390, filed on February 14, 2020, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates to connectors and methods for forming connections, and more particularly to connection housings and methods for connecting elongated electrical conductors. Background Technology

[0004] Electrical conductors often need to be terminated or connected in various environments, such as underground or overhead. Such conductors can be, for example, high-voltage distribution or transmission lines. Connectors are used to form such connections. For example, in power systems, it is sometimes necessary to connect power lines. One known system for connecting power lines is the use of tap connectors to electrically connect the main cable to one end of the tap conductor.

[0005] Insulation piercing (IP) connectors are commonly used to establish mechanical and electrical connections between insulated cables. Typically, an IP connector includes a metal piercing blade with a set of teeth at either end. The piercing blade is housed within a housing component (e.g., along with an environmental seal). The housing component clamps the insulated main cable and tap cable so that one set of teeth on the piercing blade engages the main cable while the other set engages the tap cable. The teeth penetrate the cable insulation and contact the underlying conductor, thereby providing electrical continuity between the conductors through the piercing blade. Summary of the Invention

[0006] According to some embodiments, an encapsulated connection system for mechanically and electrically connecting a first cable and a second cable includes an electrical connector, a housing, and a protective end cap, wherein each of the first and second cables includes an elongated electrical conductor covered by an insulating layer. The electrical connector is configured to form a connection (or joint) with the first and second cables, wherein the conductors of the first and second cables are electrically connected via the electrical connector. The housing is configured to receive and cover the connection and to protect the electrical connector. The housing includes a plurality of housing ports, each configured to receive a cable. The protective end cap is configured to selectively cover at least a selected housing port of the housing ports.

[0007] According to some embodiments, a method for forming an encapsulated connection assembly around a first cable and a second cable, each of the first cable and the second cable comprising an elongated electrical conductor covered by an insulating layer, the method comprising: connecting the first cable and the second cable to an electrical connector to form a connection (or joint), wherein the conductors of the first and second cables are electrically connected via the electrical connector; encapsulating the connection in a housing to protect the electrical connector, wherein the housing includes a plurality of housing ports, each configured to receive a cable; and covering at least a selected housing port among the housing ports with a protective end cap.

[0008] According to some embodiments, an encapsulated connection assembly includes first and second cables, an electrical connector, a housing, and a protective end cap. The first and second cables each include an elongated electrical conductor covered by an insulating layer. The electrical connector forms a connection (or joint) with the first and second cables, wherein the conductors of the first and second cables are electrically connected through the electrical connector. The housing receives and covers the connection to protect the electrical connector. The housing includes a plurality of housing ports, each configured to receive a cable. The protective end cap covers at least a selected housing port of the housing. Attached Figure Description

[0009] Figure 1 This is a perspective view of an encapsulation connection system according to some embodiments, wherein a protective end cap forming part of the encapsulation connection system is not yet mounted on the housing assembly of the encapsulation connection system.

[0010] Figure 2 Is using Figure 1 A perspective view of the encapsulated connection components formed by the encapsulated connection system.

[0011] Figure 3 yes Figure 2 A top view of the encapsulated connection component.

[0012] Figure 4 yes Figure 2 The top perspective view of the encapsulated connection component.

[0013] Figure 5 yes Figure 2 The bottom perspective view of the encapsulated connection component.

[0014] Figure 6 yes Figure 2 The encapsulation connection component along Figure 5 The perspective section view intercepted by line 6-6.

[0015] Figure 7 yes Figure 2 The encapsulation connection component along Figure 5 The top section view taken by line 6-6.

[0016] Figure 8 yes Figure 2 The encapsulation connection component along Figure 5 The enlarged top section view taken by line 6-6.

[0017] Figure 9 yes Figure 2 The encapsulation connection component along Figure 5 Another enlarged top section view taken by line 6-6.

[0018] Figure 10 yes Figure 2 The encapsulation connection component along Figure 5 The cross-sectional view taken by line 10-10.

[0019] Figure 11 yes Figure 2 The encapsulation connection component along Figure 5 A magnified cross-sectional view of a portion of the section intercepted by line 10-10.

[0020] Figure 12 yes Figure 2 A perspective view of the connection of the encapsulation connection component and the housing component.

[0021] Figure 13 yes Figure 12 Exploded perspective view of the connection and housing components.

[0022] Figure 14 It is formed Figure 1 Top perspective view of an insulating puncture connector, which is part of an encapsulated connection system.

[0023] Figure 15 yes Figure 14 Exploded top perspective view of the insulating puncture connector.

[0024] Figure 16 yes Figure 14 Insulation puncture connector along Figure 14 The cross-sectional view taken by line 16-16.

[0025] Figure 17 It is formed Figure 2 A perspective view of a portion of the housing assembly.

[0026] Figure 18 yes Figure 17 A top view of the casing.

[0027] Figure 19 yes Figure 17 Bottom view of the shell.

[0028] Figure 20 yes Figure 1 Rear perspective view of the protective end cap.

[0029] Figure 21 yes Figure 1 Front perspective view of the protective end cap.

[0030] Figure 22 yes Figure 1 Side view of the protective end cap.

[0031] Figure 23 yes Figure 1 Top view of the protective end cap.

[0032] Figure 24 yes Figure 1 Rear view of the protective end cap.

[0033] Figure 25 yes Figure 1 The protective end cap along Figure 24 The cross-sectional view taken by line 25-25.

[0034] Figure 26 yes Figure 1 The protective end cap along Figure 24 The cross-sectional view taken by line 26-26.

[0035] Figure 27 yes Figure 1 The protective end cap along Figure 24 The enlarged section view taken by line 26-26. Detailed Implementation

[0036] The invention will now be described more fully below with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. In the drawings, the relative dimensions of areas or features may be enlarged for clarity. However, the invention may be embodied in many different forms and should not be construed as limited to the embodiments described herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0037] It should be understood that when an element is referred to as "connected" or "attached" to another element, it can be directly connected or linked to the other element, or there may be an intermediary element. Conversely, when an element is referred to as "directly connected" or "directly linked" to another element, there is no intermediary element. The same label always refers to the same element.

[0038] Furthermore, for ease of description, spatially related terms such as “below,” “under,” “down,” “above,” and “above” may be used in the text to describe the relationship of an element or feature relative to another element(s) or feature(s) as illustrated in the figures. It should be understood that, in addition to the orientation depicted in the figures, spatially related terms are intended to cover different orientations of the device in use or operation. For example, if the device in the figure is flipped, the element described as “below” or “under” other elements or features will then be oriented “above” that other element or feature. Therefore, the exemplary term “below” can cover both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or otherwise) and the spatially related descriptive terms used in the text shall be interpreted accordingly.

[0039] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to also include the plural forms unless the context clearly indicates otherwise. It will be further understood that the terms “comprising” and / or “including” as used in this specification mean the presence of the claimed features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof. As used herein, the expression “and / or” includes any and all combinations of one or more of the associated listed items.

[0040] Unless otherwise specified, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It will also be understood that terms defined, for example, in commonly used dictionaries, shall be interpreted as having a meaning consistent with their meaning in the context of this disclosure and the relevant field, and shall not be interpreted in an idealized or excessive sense unless expressly so defined herein.

[0041] As used in the text, "whole" means an object formed or composed of materials without joints or seams, as a single, monolithic piece.

[0042] Referring to the accompanying drawings, an encapsulated connection system 20 according to an embodiment of the present invention can be used to form an encapsulated and protected connection assembly 24. The encapsulated connection system 20 includes an insulating piercing connector 200 (which may be referred to herein as an IPC, IP connector, or IPC connector) and a housing system 101. The housing system 101 includes a housing or housing assembly 100 and a protective end cap 300. The connector 200 can be used to form a connection (or joint) 22 (…). Figure 12The connection comprises a pair of elongated conductor cables 12, 14 (e.g., power lines) mechanically and electrically connected (or coupled) via connector 200. Typically, and as described in more detail below, driver 26 ( Figure 14 This can be used to secure connector 200 to cables 12, 14. According to an embodiment of the invention, housing assembly 100 can be mounted on and surrounds connection 22 to form encapsulated connection assembly 24. Then, protective end cap 300 is mounted on housing assembly 100 to protect housing assembly 100 from accidental intrusion.

[0043] Connector 200 is a multi-cable insulation piercing connector. Connector 200 can be adapted to be used, for example, as a splicing or tapping connector for connecting slender electrical tap or feed cables 14 to slender main cables 12 in a public power distribution system. The connected cables 12, 14 can be other combinations of cables, such as spliced ​​cables.

[0044] See Figure 4 In an exemplary embodiment, the second cable 14 may be a conductive metallic high-voltage, medium-voltage, or low-voltage cable or wire having a generally cylindrical form. The first cable 12 may also be a generally cylindrical high-voltage, medium-voltage, or low-voltage cable or wire. Cable 14 includes a metallic electrical conductor 14A surrounded by an insulating layer 14B. Cable 12 includes a metallic electrical conductor 12A surrounded by an insulating layer 12B. One or more of conductors 12A and 14A may be formed from a multi-strand bundle (e.g., parallel or stranded bundles) as illustrated in the figures, or may be a solid cylindrical conductor (solid wire). Multi-strand conductors may be easier to handle and have better bending properties. Suitable materials for conductors 12A and 14A may include aluminum or copper. Insulating layers 12B and 14B may be formed from polymeric materials such as PVC, polypropylene, polyethylene, or cross-linked polyethylene. Conductors 14A and 12A may have the same or different wire gauges in different applications, and connector 200 is adapted to accommodate (or receive) a range of wire gauges for conductors 14A and 12A. In some embodiments, conductor 12A has a larger cross-sectional diameter than conductor 14A. Cable 12 has a longitudinal axis EE, and cable 14 has a longitudinal axis FF.

[0045] When installed on the first cable 12 and the second cable 14, the connector 200 provides electrical continuity between conductors 12A and 14A. This connection can be used, for example, in a utility power distribution system to feed power from the main conductor 12A to the tap conductor 14A. Alternatively, the connection can be used, for example, in a power generation system to feed power from the feed conductor 14A to the main conductor 12A. The power distribution or generation system may include a plurality of main cables having the same or different wire gauges, and a plurality of tap or feeder cables having the same or different wire gauges.

[0046] See Figures 14 to 16 The connector 200 includes a connector body assembly 210, a first pair of blade components 252 (hereinafter referred to as the "lower blade components"), a second pair of blade components 254 (hereinafter referred to as the "upper blade components"), a sealing component 260, a cable end cap 262, an end cap retainer 264, and a clamping or compression mechanism 270. The connector 200 has a longitudinal axis GG.

[0047] The connector body assembly 210 includes a first or upper body component 220 and a second or lower body component 230.

[0048] The upper body component 220 includes a support portion 222 and a pair of laterally opposed leg or gripper portions 224, 225 extending laterally from the support portion 222 relative to the connector axis GG. The support portion 222 includes a through hole 222A. The gripper portion 224 includes a cable slot or seat 224A. The gripper portion 225 includes a cable slot or seat 225A. The gripper portion 224 further includes a pair of blade slots or seats 224B within the cable seat 224A. The gripper portion 225 further includes a pair of blade slots or seats 226B within the cable seat 225A.

[0049] The lower body component 230 includes a support portion 232 and a pair of laterally opposed leg or jaw portions 234, 235 extending laterally from the support portion 232 relative to the connector axis GG. The support portion 232 includes a through hole 232A. The jaw portion 234 includes a cable slot or seat 234A. The jaw portion 235 includes a cable slot or seat 235A. The jaw portion 234 further includes a pair of blade slots or seats 234B within the cable seat 234A. The jaw portion 235 further includes a pair of blade slots or seats 236B within the cable seat 235A.

[0050] The gripper portion 224 and the gripper portion 234 define a first or main side cable receiving slot 211A between them. The gripper portion 225 and the gripper portion 235 define a second or tap side cable receiving slot 211B between them.

[0051] Body components 220 and 230 may be formed of any suitable material. According to some embodiments, body components 220 and 230 are formed of a polymeric material. In some embodiments, the polymeric material is selected from the group consisting of polyamide (PA) 6.6, PA 6.6 reinforced with glass fiber or talc, polycarbonate, or polycarbonate blends. Body components 220 and 230 may be formed using any suitable technique. According to some embodiments, body components 220 and 230 are molded. According to some embodiments, each of body components 220 and 230 is integral and formed monolithically.

[0052] Compression mechanism 270 includes a bolt 272 and a torque control component in the form of a nut 276. A washer 277 may be provided between the nut 276 and the upper body component 220. However, other types of compression mechanisms may also be used in compression mechanism 270. For example, the compression mechanism may include, for instance, an inclined surface device operable to provide mechanical advantages.

[0053] Bolt 272 may be a carriage bolt and includes a threaded shank 272A and a head 272B.

[0054] In some embodiments and as shown, the nut 276 is a shear nut that includes a shear head 276A, a base portion 276B, a shear or break section 276C of the connecting portions 276A and 276B, and a tubular, internally threaded connecting section 276D extending from the base portion 276B to the break section 276C.

[0055] Bolt 272 extends through holes 222A and 232A and is axially constrained by bolt head 272B and body component 230. Nut 276 is rotatably mounted on bolt 272 and is axially constrained by body component 220. Holes 222A and 232A may be circular or elongated so that the upper connector body can swing when it is screwed downward against two conductors with different outer diameters.

[0056] The axial spacing distance D4 between cable connectors 224A, 234A and 225A, 235A Figure 16 The height of the slots 211A and 211B can be changed. The body component 220 allows the bolt 272 to slide up and down again relative to the lower body component 230 along the sliding axis BB. Therefore, the height of the slots 211A and 211B can be changed independently.

[0057] In use, the shearing head 276A of the nut 276 is engaged by an actuator and thereby forced to rotate. The shearing head 276A may be planarized or otherwise configured to engage with a tool. The nut 276 thus rotates axially relative to the bolt 272, which may be rotationally constrained by anti-rotation features or mechanisms of the tool or connector 200. This causes the bolt 272 to translate upwards via the nut 276, which causes the body portions 220 and 230 together (in the respective convergence direction) to slide or translate along the sliding axis BB. When subjected to a specified torque, the shearing head 276A will shear (or break off) from the base portion 276B at the break-off section 276C. The base portion 276B may be planarized or otherwise configured to engage with a tool to allow the nut 276 to loosen, allowing the connector 200 to be removed from the cable.

[0058] According to some embodiments, bolt 272 and nut 276 may be formed of any suitable material, such as steel (e.g., galvanized steel or stainless steel), aluminum alloy, plastic or zinc alloy.

[0059] Each lower blade component 252 is mounted in one of the blade slots 236B for movement with the lower body component 230. Each lower blade component 252 includes a body or base 252A having laterally opposed ends. Each end is provided with an integrally formed cable engagement or insulation piercing feature 252B. Each insulation piercing feature 252B includes a plurality of serrations or teeth 252C spaced apart by the slot and having terminal points. The points of the teeth 252C may collectively lie on an arc that generally corresponds to the profile of the arcuate outer surface of the corresponding cable conductors 12A, 14A.

[0060] Each upper blade component 254 is mounted in one of the blade slots 226B for movement with the upper body component 220. Each main blade component 254 includes a body or base 254A having axially opposed ends. Each end is provided with an integrally formed cable engagement or insulation piercing feature 254B. Each insulation piercing feature 254B includes a plurality of serrations or teeth 254C spaced apart by the slots and having terminal tips. The tips of the teeth 254C may collectively lie on an arc that generally corresponds to the profile of the arcuate outer surface of the corresponding cable conductors 12A, 14A.

[0061] The blade components 252 and 254 are attached to their respective blade holders such that the tooth 254C of the blade component 254 faces the tooth 252C of the blade component 252.

[0062] According to some embodiments, the width of each blade component 252, 254 is at least ten times its thickness. According to some embodiments, the thickness of each blade component 252, 254 is in the range of about 0.05 inches to 0.125 inches.

[0063] The blade components 252 and 254 can be formed from any suitable conductive material. According to some embodiments, the blade components 252 and 254 are formed of metal. According to some embodiments, the blade components 252 and 254 are formed of aluminum, aluminum alloys, or copper and may be zinc-plated. The blade components 252 and 254 can be formed using any suitable technique. According to some embodiments, each blade component 252 and 254 is integral and formed monolithically. According to some embodiments, each of the blade components 252 and 254 is extruded and cut, stamped (e.g., punched), cast, and / or machined.

[0064] The sealant-filled casing 100 includes a housing 120 and a mass of sealant 160, 170 disposed therein. According to some embodiments, and as discussed in more detail below, the sealant 160, 170 may be a gel. The housing 120 includes a first shell or cap component 122 and a second shell or cap component 124, which are connected to each other by a hinge 126 and adapted to, for example... Figure 12 The opening position shown and as Figure 1 Movement between the closed positions shown. In other embodiments, cover components 122, 124 are not hinged. In the open position, housing assembly 100 may receive adjacent portions of connection 22 and cables 12, 14. In the closed position, housing assembly 100, including mass blocks of sealant 160, 170, is operable to seal and protect connection 22. The shape or geometry of housing cavity 106 may resemble or substantially conform to the shape or geometry of connector 200.

[0065] For more details, turn to housing 120 and refer to Figures 17 to 19 The cover components 122 and 124 are constructed in a substantially similar manner, except for the shape of their cavities, the shape of their outer contours, and the construction of their latching structures.

[0066] Each cover component 122, 124 includes a bottom wall 130. Opposite side walls 132 and opposite end walls 134 extend upward from the bottom wall 130. Opposite paired port extensions 140 extend longitudinally from either end of each cover component 122, 124. Each port extension 140 is terminated by a port wall 142.

[0067] In the closed position, the housing assembly 100 defines the housing cavity 106. Figure 7 ) and the opposing paired port channels 109 communicating with the housing cavity 106. Figure 7 More specifically, when the cover components 122 and 124 are closed, each pair of opposing port extensions 140 combine to collectively form corresponding chamber ports CP1, CP2, CP3, and CP4. Figure 1 and Figure 7 ), and corresponding tubular chamber port channels 109 extending from chamber ports CP1-CP4 to the housing cavity 106. Each pair of opposing port walls 142 covers the corresponding chamber ports in chamber ports CP1-CP4.

[0068] Each port wall 142 is constructed and configured to open or be displaced to receive cables in the corresponding chamber ports CP1, CP2, CP3, CP4 and the corresponding chamber port channel 109. In some embodiments, each port wall 142 is a break-down wall. In some embodiments, each port wall 142 is fragile (i.e., the port wall 142 is configured to be broken and detached by disruption (e.g., tearing) of the port wall 142). For example, each port wall 142 may include corrugation comprising a series of fingers connected by a relatively thin membrane as shown, and the port wall 142 can be opened by tearing two or more of the fingers at one or more locations on the membrane.

[0069] The upper edges of walls 132 and 134 form a peripheral edge 138 defining the opening. The walls 130, 132, and 134 of each cover component 122 and 124, and the port extension 140, define an overall cover component chamber or cavity 136 and a front opening 130A communicating with the cavity 136. Cavity 136 ( Figure 18 It includes a main cavity portion 136A and a conductor port sub-channel 136B defined within each port extension 140.

[0070] Cover components 122 and 124 are pivotally connected by hinge 126. According to some embodiments, hinge 126 is a flexible, movable hinge. The movable hinge allows for integral formation of the housing 120, and potential cost savings in materials and assembly. Alternatively, other hinge constructions may be used. For example, hinge 126 may be replaced or supplemented by an interlocking, pivotally connected hinge structure and / or a pivot pin. Alternatively, cover components 122 and 124 may be non-hinged.

[0071] See Figure 18 The housing 120 includes a latching system comprising four integrally formed latching mechanisms. Each latching mechanism includes a latching finger 182 on and projecting inwardly from the cover member 124. Each latching mechanism also includes a latching slot or opening 183 in the cover member 122. The latching finger 182 may be integrally formed with the cover member 124. The latching finger 182 and the opening 183 may selectively engage, thereby cooperating to releasably secure the cover members 122, 124 to a position such that... Figure 1 In the closed configuration shown, each latch finger 182 has a resiliently deflectable leg and an integrally formed interlocking section or barb 182B. The barb 182B is configured to enter through the associated opening 183 and interlock with the cover member 124.

[0072] The housing 120 also includes a safety latch mechanism. See below. Figures 17 to 19The safety latching mechanism includes two side-by-side safety latching parts 185 located at the end of the cover part 124 opposite the hinge 126. Each latching part 185 is pivotally connected to the cover part 124 via a hinge 185A (e.g., a movable hinge). The safety latching mechanism also includes an interlocking feature in the form of a laterally extending latch flange 189. Each latching part 185 includes a pair of barbed latch fingers 186.

[0073] See Figures 17 to 19 Each cover component 122, 124 includes a pair of opposing strain relief features, anchoring portions or frame portions 150 extending longitudinally and laterally outward from the port wall 142 on either side. The frame portions 150 together form the cable strain relief system 151.

[0074] Each frame section 150 includes a longitudinally extending strain-relieving wall 152 and a leg 154 connecting the wall 152 to an adjacent sidewall 132. The wall 152 is rigidly attached to the sidewall 132 by the leg 154.

[0075] Each strain relief wall 152 includes a pair of strain relief channels or slots 152A defined therein. In some embodiments, each slot 152A is semi-circular. When the cover members 122, 124 are closed (e.g. Figure 1 and Figure 10 As shown), each pair of opposing slots 152A combine to form corresponding strain relief openings or inlet ports A1, A2, A3, A4 (as shown). Figure 1 , Figure 4 and Figure 8 Each entry port A1-A4 is aligned with the corresponding chamber port among chamber ports CP1-CP4. Each entry port A1, A2, A3, A4 and its aligned chamber ports CP1, CP2, CP3, CP4 together form the corresponding enclosure ports EP1, EP2, EP3, EP4. Figure 1 and Figure 4 ).

[0076] In some embodiments, the distance D15 from each vulnerable port wall 142 to the outer end of the adjacent entry ports A1, A2, A3, A4 is ( Figure 18 (Approximately 0.5 inches to 0.875 inches)

[0077] Each strain relief wall 152 is spaced apart from the adjacent sidewall 132 to define a gap, slot, cavity, opening, or void 155 between each port wall 142 and its adjacent slot 152A.

[0078] Similarly, gap 155 separates port walls 142 (and thus chamber ports CP1-CP4) from their associated entry ports A1, A2, A3, A4. In some embodiments, each wall 152 and each entry port A1, A2, A3, A4 is separated from the adjacent port wall 142 by a standoff distance D14 ranging from approximately 0.2 inches to 0.4 inches. Figure 18 ).

[0079] The housing 120 may be formed of any suitable material. According to some embodiments, the housing 120 is formed of an electrically insulating material. In some embodiments, the housing 120 is formed of a vacuum-formed or molded polymeric material. The housing 120 may be formed of polypropylene, nylon, polyethylene, ABS, and / or PMMA. The housing 120 may be formed of a flame-retardant material. The housing material may be of any color or be transparent.

[0080] Before use, sealant 160 ( Figure 13 It can be accommodated in the cavity 136 of the cover member 122, such that the main sealant portion 162 of the sealant is disposed in the main cavity 136 and the port sealant portion 166 is disposed in the port sub-channel 136B.

[0081] According to some embodiments, a void 164 is pre-formed or defined in the sealant 160. According to some embodiments, the void 164 opens to the opening 130A. According to some embodiments, the sealant 160 completely surrounds the remainder of the void 164 so that the void 164 is spaced apart from the cover member 122 (by the sealant 160) on all sides except the top side. According to some embodiments, the sealant 160 fills the cover member cavity 136 (excluding the volume of the void 164) to a level close to but not completely reaching the peripheral edge 138. In other embodiments, the sealant 160 substantially completely fills the cover member cavity 136 of the cover member 122 until it reaches the peripheral edge 138 or any other desired level. According to some embodiments, the void 164 has sloping sidewalls that taper outward in the direction from the bottom wall 130 to the opening 130A.

[0082] According to some embodiments, the gap 164 is shaped to conform to the lower half of the connector 200. However, the gap 164 may have any other suitable shape.

[0083] Before use, sealant 170 ( Figure 13 It can be accommodated in the cavity 136 of the cover member 124, such that the main sealant portion 172 of the sealant is disposed in the main cavity 136 and the port sealant portion 176 is disposed in the port sub-channel 136B.

[0084] According to some embodiments, a void 174 is pre-formed or defined in the sealant 170. According to some embodiments, the void 174 opens to the opening 130A. According to some embodiments, the sealant 170 completely surrounds the remainder of the void 174 such that the void 174 is spaced apart from the cover member 124 on all sides except the top side. According to some embodiments, the sealant 170 fills the cavity 136 of the cover member 124 to a level close to but not completely reaching the peripheral edge 138. In other embodiments, the sealant 170 substantially completely fills the cavity 136 of the cover member (excluding the volume of the void 174) until it reaches the peripheral edge 138 or any other desired level.

[0085] Sealants 160 and 170 can be any suitable sealant. According to some embodiments, sealants 160 and 170 are gel sealants. As used herein, "gel" refers to a class of solid materials extended by a fluid extender. A gel can be a significantly diluted system that does not exhibit steady-state flow. See Ferry's "Viscoelastic Properties of Polymers," 3 rd As discussed in ed. p. 529 (J. Wiley & Sons, New York 1980), polymer gels can be cross-linked solutions, whether linked by chemical bonds, microcrystals, or some other type of linkage. The absence of steady-state flow can be considered a definition of solid-like properties, and significant dilution may be required to obtain a relatively low gel modulus. Solid properties can be achieved through a continuous network structure formed in the material, typically through cross-linking of polymer chains via some kind of linkage or the formation of domains of associated substituents of various polymer branches. Cross-linking can be physical or chemical, provided that the cross-linking sites can be maintained under the gel's operating conditions.

[0086] The gel used in this invention may be a silicone (organopolysiloxane) gel, such as the fluid expansion systems taught in U.S. Patent No. 4,634,207 to Debbaut (hereinafter referred to as “Debbaut '207”), U.S. Patent No. 4,680,233 to Camin et al., U.S. Patent No. 4,777,063 to Dubrow et al., and U.S. Patent No. 5,079,300 to Dubrow et al. (hereinafter referred to as “Dubrow '300”), the disclosure of each of these U.S. patents being incorporated herein by reference. These fluid-expanded silicone gels may be generated using non-reactive fluid extenders as described in the previously cited patents, or using an excess of a reactive liquid, such as a vinyl-rich silicone fluid, to act as an extender, as is commercially available from Dow-Corning Corporation of Midland, Michigan. The product is exemplified, or as disclosed in U.S. Patent No. 3,020,260 to Nelson. Because curing is typically involved in the preparation of these gels, they are sometimes referred to as thermosetting gels. The gel can be a silicone gel prepared from a mixture of divinyl-terminated polydimethylsiloxane, tetra(dimethylsiloxy)silane, platinum divinyltetramethyldisiloxane complex (commercially available from United Chemical Technologies, Bristol, Pennsylvania), polydimethylsiloxane, and 1,3,5,7-tetravinyltetramethylcyclotetrasiloxane (to provide a reaction inhibitor for sufficient fit time).

[0087] Other types of gels may also be used, such as polyurethane gels as taught in U.S. Patent No. 4,600,261 (hereinafter referred to as “Debbaut '261”) and U.S. Patent No. 5,140,476 (hereinafter referred to as “Debbaut '476”) to Debbaut, and gels based on styrene-ethylene-butene-styrene (SEBS) or styrene-ethylene-propylene-styrene (SEPS) using a cycloalkane or non-aromatic or low-aromatic hydrocarbon oil as an extender, as described in U.S. Patent No. 4,369,284 to Chen, U.S. Patent No. 4,716,183 to Gamarra et al., and U.S. Patent No. 4,942,270 to Gamarra. SEBS and SEPS gels comprise glassy styrene microphases interconnected by fluid-expanded elastomeric phases. The microphase-separated styrene domains act as binding points in the system. SEBS and SEPS gels are examples of thermoplastic systems.

[0088] Another type of gel that can be used is an EPDM rubber-based gel, as described in U.S. Patent No. 5,177,143 to Chang et al.

[0089] Another class of gels that can be used are based on anhydride-containing polymers, as disclosed in PCT Publication No. WO96 / 23007. These gels have reportedly good heat resistance.

[0090] Gels may include a variety of additives, including stabilizers and antioxidants, such as hindered phenols (e.g., Irganox). tm 1076, available commercially from Ciba-Geigy in Tarrytown, New York, and phosphites (e.g., Irgafos). tm 168, available commercially from Ciba-Geigy in Tarryton, New York, and metal deactivators (e.g., Irganox). tm D1024 (from Ciba-Geigy, Tarryton, New York), and sulfides (e.g., Cyanox LTDP, available from American Cyanamid, Wayne, New Jersey), light stabilizers (e.g., Cyasorb UV-531, available from American Cyanamid, Wayne, New Jersey), and flame retardants such as halogenated paraffins (e.g., Bromoklor 50, available from Ferro, Hammond, Indiana) and / or phosphorus-containing organic compounds (e.g., Fyrol PCF and Phosflex 390, both available from Akzo Nobel Chemicals, Dobbs Ferry, New York), and acid removers (e.g., DHT-4A, available from Kyowa Chemical Industry, Inc. through Mitsui & Co., Cleveland, Ohio, and hydrotalcite). Other suitable additives include colorants, antimicrobial agents, thickeners, etc., as described in "Additives for Plastics, Edition 1" published by DATA Corporation of San Diego, California and International Plastics Selector.

[0091] Hardness, stress relaxation, and viscosity can be measured using a Texture Technologies texture analyzer or a similar machine, which features a load sensor for measuring force, a 5-gram trigger, and a ¼-inch (6.35 mm) stainless steel probe. To measure the hardness of, for example, a 20 mL glass vial containing 12 grams of gel, the probe is pushed into the gel at a speed of 0.2 mm / s to achieve a penetration distance of 4.0 mm. The hardness of the gel is the force (in grams) required to push the probe through the gel to the specified 4.0 mm at that speed. Higher numbers indicate a harder gel.

[0092] When the penetration speed was 2.0 mm / s and the probe was pushed into the gel to a penetration distance of approximately 4.0 mm, viscosity and stress relaxation were read from a stress curve generated by tracking the force versus time curve experienced by the load sensor. The probe was held at a penetration depth of 4.0 mm for 1 minute and then withdrawn at a speed of 2.00 mm / s. Stress relaxation is the resistance to the initial force (F) of the probe at the preset penetration depth. i Subtract the force resisting the probe after 1 minute (F) f Divide by the initial force F i The ratio is expressed as a percentage. That is, the stress relaxation percentage equals...

[0093]

[0094] Where F i and F f In grams. In other words, stress relaxation is the ratio of the initial force minus the force after 1 minute to the initial force. It can be considered a measure of the gel's ability to relax any induced compression placed on the gel. Viscosity can be considered as the magnitude of the resistance (in grams) on the probe as it is pulled out of the gel from a preset penetration depth at a speed of 2.0 mm / s.

[0095] An alternative method for characterizing the gel is based on the cone penetration (or cone depth) parameter of ASTM D-217, as proposed in Debbaut '261, Debbaut '207, Debbaut '746, and U.S. Patent No. 5,357,057 to Debbaut et al., each of which is incorporated herein by reference in its entirety. Cone penetration (“CP”) values ​​can range from approximately 70 (10) -1 (millimeters) to about 400 (10) -1 (mm). Stiffer gels typically have approximately 70 (10) mm. -1 (mm) to about 70 (10) -1 The CP value is approximately 200 (mm). Softer gels typically have a CP value of approximately 200 (mm). -1 (mm) to about 400 (10)-1 The CP value (in millimeters) is particularly preferred to be in the range of about 250 (10 mm). -1 (mm) to approximately 375 (10) -1 (mm). For a specific material system, the relationship between CP and Volland hardness can be established as proposed in U.S. Patent No. 4,852,646 to Dittmer et al.

[0096] According to some embodiments, the gel has a Volland hardness between about 5 and 100 gF, as measured by a texture analyzer. The gel may have an elongation at least 55%, as measured by ASTM D-638. According to some embodiments, the elongation is at least 100%. The gel may have a stress relaxation of less than 80%. The gel may have a viscosity greater than about 1 g.

[0097] Although, according to some embodiments, sealants 160 and 170 are gels as described above, other types of sealants may also be used. For example, sealants 160 and 170 may be silicone grease or hydrocarbon grease.

[0098] The housing assembly 100 may be formed in the following ways: Cover members 122, 124 and hinge 126 may be integrally formed. According to some embodiments, cover members 122, 124 and hinge 126 are integrally molded. According to some embodiments, the entire housing 120 is integrally molded. For example, housing 120 may be injection molded or vacuum-formed. According to other embodiments (e.g., if the cover members are not hinged), cover members 122, 124 are separately molded or otherwise formed. According to some embodiments, cover members 122, 124 and hinge 126 are integral.

[0099] If the sealants 160 and 170 are materials that require curing, such as curable gels, the sealants can be cured in situ. According to some embodiments, spacer inserts having shapes and sizes of pores 164 and 174, respectively, are placed in each cavity 136 of the cap members 122 and 124. Uncured liquid sealant is dispensed into the cavities 136 such that it fills the cavities 136 of the cap members 122 and 124 until the desired level is reached. The sealant can then be cured in situ. The spacer inserts are then removed to provide pores 164 and 174 within the sealants 160 and 170.

[0100] See Figures 20 to 27 The protective end cap 300 has an end cap longitudinal axis LL ( Figure 23 ), End cap height axis HH (perpendicular to axis LL) Figure 22 ), and the end cap depth axis DD (perpendicular to axes LL and HH). The end cap 300 has an inner side 302 and an opposite outer side 304.

[0101] The end cap 300 includes a base wall 310, an integrally formed upper sidewall 312, and an integrally formed lower sidewall 314. The sidewalls 312 and 314 extend along opposite lateral edges of the base wall 310 and project inwardly from the base wall 310. Each sidewall 312 and 314 has an inclined or tapered shoulder portion 316 to generally conform to the shape of the enclosed housing 120.

[0102] The end cap 300 also includes an integrally formed first mounting or insertion feature 330 and an integrally formed second mounting or insertion feature 332. Each insertion feature 330, 332 is in the form of a protrusion, a plug, or a pin. Insertion features 330 and 332 have distal terminal ends 330T and 332T, respectively.

[0103] Walls 310, 312, and 314 collectively define an end cap cavity 320 and an internal opening 322 communicating with the cavity 320 on the inner side 302. Walls 310, 312, and 314 also define a slot 324 communicating with the cavity 320. A removal or prying slot 326 is defined in the end of the end cap 300. A through hole 328 may also be formed in the end cap 300 to facilitate injection molding of the end cap 300.

[0104] Insertion features 330 and 332 can be constructed in substantially the same manner. Therefore, only insertion feature 330 will be described below, and it should be understood that the same description applies to insertion feature 332. In some embodiments and as shown, insertion features 330 and 332 are sized differently from each other to better fit the respective ports in the access ports A1-A4 into which they are suitable for insertion.

[0105] Insertion feature 330 has an insertion feature axis PP extending substantially parallel to axis DD. Figure 22 Insertion feature 330 includes a pair of opposing legs 350. The legs 350 together define a notch 360 and a cavity 362. The notch 360 has a notch axis QQ (…). Figure 24 The slot axis QQ extends substantially perpendicularly to the axes PP and LL.

[0106] See Figure 25 Each leg 350 has a base or proximal end 352A fixed to the base wall 310, and an opposite free end or distal end 352B. The legs 350 thus extend cantilevered from the base wall 310.

[0107] The distal end 352B of each leg 350 includes an end wall 354, a rounded distal portion of a shoulder 356, and an integrally formed latching feature or barb 358. The shoulders 356 of the two legs 350 together form an inclined, tapered, or truncated surface to facilitate the insertion of insertion features 330, 332 into the access ports A1-A4.

[0108] The opposing legs 350 are resiliently flexible at their connection with the base wall 310 and / or within each leg 350 to allow the legs 350 to be relatively displaced, bent, or deflected along the deflection axis VV in the convergence direction DC. Figure 27 The deflection axis VV is transverse to the slot axis QQ, and in some embodiments substantially perpendicular to the slot axis QQ. The outriggers 350 are resilient so that they exhibit a return force when deflected in the convergence direction DC, which tends to cause each outrigger 350 to move in the opposite return direction DR. Figure 27 ).

[0109] When the outrigger 350 is in its undeflected (relaxed) position, the barb 358 of the insertion feature 330 has an outer width or outer diameter D20 ( Figure 26 The barb 358 of the insertion feature 332 has an outer diameter D22 when its leg 350 is not deflected.

[0110] End cap 300 can be formed of any suitable material. According to some embodiments, end cap 300 is formed of an electrically insulating material. In some embodiments, end cap 300 is formed of a vacuum-formed or molded polymeric material. End cap 300 can be formed of polypropylene, nylon, polyethylene, ABS, and / or PMMA. End cap 300 can be formed of a flame-retardant material. The material of end cap 300 can be of any color or transparent.

[0111] Walls 310, 312, 314 and insertion features 330, 332 can be integrally formed. According to some embodiments, walls 310, 312, 314 and insertion features 330, 332 are integrally molded. According to some embodiments, the end cap 300 is integrally molded. For example, the end cap 300 can be injection molded or vacuum-formed. According to some embodiments, the end cap 300 is integral.

[0112] The encapsulated connection system 20 can be used according to the method of the invention to form an encapsulated connection 24 as follows. Typically, a connection 22 is first formed by mounting the connector 200 onto the cables 12, 14. Subsequently, a housing assembly 100 is mounted on the portion of the connection 22 and the cables 12, 14. Then, a protective end cap 300 is mounted on the housing assembly 100.

[0113] The connector 200 can be used according to the method of the invention to form a connection 22 as follows.

[0114] If necessary, the compression mechanism 270 releases or opens to allow the gripper portions 224, 234 and 225, 235 (and thereby allow the blade portions 252, 254) to separate. Cable 12 (where insulation layer 12B covers conductor 12A) is inserted into or between cable slots 224A, 234A, and cable 14 (where insulation layer 14B covers conductor 14A) is inserted into or between cable slots 225A, 235A. Cables 12, 14 can be inserted axially or laterally into the slots defined between the grippers.

[0115] Then, nut 276 is driven to compress compression mechanism 270 along sliding axis BB, thereby driving jaws 224, 234 and 225, 235 together along clamping axes parallel to sliding axis BB. Nut 276 is driven until a predetermined torque is applied. Shear nut 276 is driven via shear head 276A until the predetermined torque is applied, at which point shear head 276A will break off at shear section 276C, thereby helping to ensure that proper load is applied to blade components 252, 254, 256.

[0116] Therefore, the insulation piercing features 252B and 254B of the opposing paired blade components 252 and 254 are driven to converge on the cables 12 and 14 and capture the cables between them. More specifically, the teeth 252C and 254C of each blade component 252 and 254 are pushed through the insulation layer 12B and form mechanical and electrical contact with the conductors 12A and 14A. The teeth 252C and 254C are embedded in the insulation layers 12B and 14B and make electrical and mechanical contact or engagement with the conductors 12A and 12B. In the aforementioned manner, the connector 200 is operatively connected to the cables 12 and 14, and the conductors 12A and 14A are electrically connected to each other without stripping the insulation layers 12B and 14B.

[0117] According to some embodiments, teeth 252C and 254C are embedded in conductors 12A and 14A. According to some embodiments, teeth 252C and 254C are embedded in conductors 12A and 14A by a distance of at least about 0.5 mm.

[0118] Connection 22 is formed in the manner described above. Blade components 252 and 254 provide electrical continuity (i.e., a path for current flow) between conductors 12A and 14A of cables 12 and 14. Connector 200 mechanically secures cables 12 and 14 relative to each other.

[0119] Once connection 22 is configured as described above, housing assembly 100 is mounted on connection 22 and cables 12, 14. Housing assembly 100 can be held in place as follows: Figure 12The fully or partially open position is shown, and connection 22 can be inserted between cover members 122, 124. The cover assembly 100 is then closed by advancing one or both of the cover members 122, 124 into engagement about hinge 126, as shown. Figure 1 As shown, this causes the latch finger 182 and the latch opening 183 to interlock in the closed position.

[0120] Then, the safety latch component 185 is in the direction FP (around hinge 185A) Figure 2 ) pivot upwards until the barbs of their latching fingers 186 interlock with the latching flange 189, as Figure 1 As shown in the image.

[0121] A closed housing 120 defines a housing cavity 106, which includes a main housing cavity 106 and an adjacent port channel 109 (commonly defined by a port extension 140). A connector 200 is received within voids 164 and 174 of sealants 160 and 170. A connection 22 is encapsulated within sealants 160 and 170, and the sealants 160 and 170 and the connection 22 are in turn encapsulated within the housing 120 (i.e., within the housing cavity 106). The portions of cables 12 and 14 that extend from and through the connection 22 and through the port channel 109 to the vulnerable wall 142 are also encapsulated within sealants 160 and 170.

[0122] The connector 22 is oriented relative to the cover parts 122, 124 such that the lower part 200A of the connector 200 is received and placed in the gap 164, and the upper part 200B of the connector 200 is received in the gap 174.

[0123] Before or during the enclosure assembly 100, cables 12, 14 may cause the vulnerable wall 142 to break or expand outward so that cables 12, 14 pass through it and are generally surrounded by it. The walls 142 may be angled outward so that they tend to expand outward through cables 12, 14.

[0124] According to some embodiments and as illustrated, the volume and configuration of the sealants 160 and 170 are selected to ensure that when the housing assembly 100, in which the connection 22 is arranged, transitions from an open position to a closed position, the connection 22 displaces at least one of the sealants 160 and 170, and according to some embodiments, displaces both of the sealants.

[0125] According to some embodiments, the combined volume of the connector 200, the portion of the cables 12, 14 in the housing cavity 106, and the sealants 160, 170 is greater than the volume of the housing cavity 106.

[0126] According to some embodiments, when the housing assembly 100 is installed as described herein, the cover members 122, 124 forcibly displace the sealant 160, 170 around the connector 200 around the closure of the connection 22, such that the sealant 160, 170 flows around the connector 200 and, in some cases, enters the orifices within the connector 200. According to some embodiments, the sealant 160, 170 substantially completely encapsulates the connector 200. According to other embodiments, the sealant 160, 170 only partially surrounds the connector 200 (e.g., in cases where the voids 164, 174 extend to the bottom wall 130).

[0127] As will be appreciated from the description herein, sealants 160 and 170 engage portions of cables 12 and 14 to form a seal around them. Sealants 160 and 170 also form sealing blocks surrounding connector 200, thereby sealing connector 200. It is noteworthy that in the illustrated housing assembly 100, sealant mass blocks 160 and 170 are connected to each other to encapsulate connector 200 and cables 12 and 14.

[0128] The housing assembly 100 can be customized in size and configuration to accommodate and seal connectors 200 and cables 12, 14 in multiple or a range of sizes.

[0129] The cover assembly 100 and connector 200 are re-entrant and removable so that the system can be disconnected, maintained, or repaired. In some embodiments, the cover assembly 100 and connector 200 are intended to be replaced rather than reused.

[0130] The enclosed housing assembly 100 includes a lateral side 103L of the housing 120. Figure 1 The housing 120 has a first set or pair of chamber ports CP1, CP2 on the housing 120 and a second set or pair of chamber ports CP3, CP4 on the opposite side 103R of the housing 120. Chamber port CP1 is aligned with the opposite chamber port CP4, and chamber port CP2 is aligned with the opposite chamber port CP3. This port arrangement provides for installation in which cables 12, 14 extend completely through the housing assembly 100. In this case, cable 14 will extend continuously through chamber port CP4, housing cavity 106 (in which cable 14 is connected to connector 200), and chamber port CP1. Cable 12 may similarly extend through chamber port CP3, housing cavity 106, and chamber port CP2. Because cables 12, 14 fill or occupy ports CP1, CP2, CP3, CP4, and cable conductors 12A, 14A are covered by cable insulators 12B, 14B, the risk of accidental intrusion into the housing 120 and contact with live components therein is significantly eliminated or reduced.

[0131] However, in some installations, the protected connection assembly 24 is installed at the terminal ends 12E, 14E of the cables 12, 14 (e.g., main cable 12 and branch cable 14). Figure 6 and Figure 13 In this configuration, the terminal ends 12EC and 14EC of cable conductors 12A and 14A are not covered by cable insulators 12B and 14B, and chamber ports CP1 and CP2 are not occupied by cables. This arrangement presents the risk that an object (e.g., a probe) could be inserted into the housing 120 through one of the chamber ports CP1 and CP2 and come into contact with the live parts of cable conductors 12A and 14A or connector 200. Figure 2 An exemplary or illustrative object P is shown that can be probed, penetrated, or attempted to penetrate the housing 120 through chamber ports CP1, CP2. An exemplary intruding object may include a tool (e.g., a screwdriver) or other object small enough to fit through chamber ports CP1, CP2. It will be appreciated that if the intruding object is conductive, contact between that object and a cable conductor or connector in the housing 120 may risk injury (e.g., electric shock) or other undesirable or destructive electrical transmissions that could lead to damage to the electrical system.

[0132] The protective end cap 300 is used to prevent or inhibit accidental insertion of objects through either of the chamber ports CP1 or CP2. During use, the user inserts the object along the end cap in the insertion direction I (…). Figure 1 The end cap 300 is pushed onto the enclosed housing assembly 100, causing insertion features 330 and 332 to be inserted into housing ports EP1 and EP2, respectively. More specifically, insertion feature 330 is inserted into inlet port A1, and insertion feature 332 is inserted into inlet port A2. The end cap 300 (especially insertion features 330 and 332) thereby prevents entry into chamber ports CP1 and CP2.

[0133] Each insertion feature 330, 332 slides along its axis PP and the corresponding port axis UU. Figure 7 The outer diameter D20 of the barb 358 in the insertion part 330 is larger than the inner diameter D21 of the corresponding entry port A1. Figure 26 The outer diameter D22 of the barb 358 of the insertion part 332 ( Figure 26 () is greater than the inner diameter D23 of the corresponding inlet port A2 () Figure 26 Therefore, when the insertion portions 330, 332 slide into their entry ports A1, A2, the legs 350 of each insertion portion 330, 332 deflect inward (along the convergence direction DC); Figure 27The barbs 358 jump over the rear edge of the strain-relieving wall 152 until they reach their relaxed position. The legs 350 then allow a springback return or rapid retraction toward their relaxed position (in the return direction DR), thereby interlocking or latching the barbs 358 onto the inner surface or face 157 of the strain-relieving wall 152. The inserts 330, 332 are thus locked in the entry ports A1, A2 and thereby in the housing ports EP1, EP2. The end cap 300 is thus interlocked, locked, anchored, or secured to the housing assembly 100, as shown below. Figures 1 to 11 As shown in the image.

[0134] In some embodiments, and as shown, when the end cap 300 is mounted on the housing assembly 100 as described, the distal terminal end 330T of the insertion portion 330 is disposed in the gap 155 between the chamber port CP1 and the inlet port A1, so that the insertion portion 330 does not displace or open the port wall 142 of the chamber port CP1. Similarly, the distal terminal end 332T of the insertion portion 332 is disposed in the gap 155 between the chamber port CP2 and the inlet port A2, so that the insertion portion 332 does not displace or open the port wall 142 of the chamber port CP2. In this way, the end cap 300 allows the port walls 142 of the chamber ports CP1 and CP2 to remain closed and prevents or resists the extrusion of sealant through the chamber ports CP1 and CP2. In some embodiments, the distal terminal ends 332T are positioned to contact or closely adjacent to their respective port walls 142. The distal terminal ends 330T and 332T thus reinforce the port walls 142 to similarly resist the extrusion of sealant through the chamber ports CP1 and CP2.

[0135] With the end cap 300 mounted on the housing assembly 100 as described, the insertion portions 330 and 332 are disposed in and block the entry ports A1 and A2. The insertion portions 330 and 332 thereby protect the chamber ports CP1 and CP2 and block or prevent objects or probes from entering through the chamber ports CP1 and CP2.

[0136] When the end cap 300 is mounted on the housing assembly 100 as described above, the base wall 310 covers a portion of the side wall 132 and port wall 142 of the housing 120. Specifically, the base wall 310 covers the dividing line or mating interface (or interface) between the cover components 122 and 124. Figure 11 The end cap 300 thereby prevents or inhibits the insertion of an object or probe between the cap parts 122 and 124 at that location.

[0137] Additionally, sidewalls 312 and 314 extend beyond cap members 122 and 124 in a direction parallel to the end cap insertion direction I, thereby wrapping around the top and bottom of housing 120. This arrangement prevents objects or probes from being inserted into chamber ports CP1 and CP2 or into chamber 106 from an angled (or inclined) or indirect direction through interface JL. Specifically, sidewalls 312 and 314 prevent entry into chamber ports CP1 and CP2 from above or below through the gap 155 between port wall 142 and strain relief wall 152. The geometry 314 of the end cap 300 with sidewall 312 also reinforces housing 120 to resist opening or deformation of housing 120.

[0138] The housing 120 is configured such that the cover components 122 and 124 can be accessed along the separation axis MM in the separation direction N ( Figure 11 They are separated by relatively moving one or both of them. The separation direction N and axis MM are approximately perpendicular to the plane of the interface JL between the axis of hinge 126 and the cover parts 122, 124. The deflection axis VV of each insertion part is... Figure 9 and Figure 27 Laterally (and in some embodiments, and as shown, substantially perpendicular to) the separation direction N and the axis MM. That is, the return direction DR of the outrigger 350 (which is perpendicular to the slot axis QQ); Figure 21 () laterally or perpendicular to the separation axis MM.

[0139] Therefore, the force exerted by the inserted object or probe will primarily be directed in direction DR. These forces are thus resisted by the fixed wall portion of each cover member 122, 124 on either side of the insertion portions 330, 332 (i.e., the strain-relieving wall portion 152 adjacent to each leg 350). On the other hand, if the deflection axis VV is instead oriented parallel to the separation axis MM, the force exerted by the probe in the insertion cavity 362 will displace the leg 350 in the separation direction N. The housing 120 will provide minimal resistance to the opening of the leg 350, with the effect that the leg 350 can be opened more easily to allow the probe to pass through the distal ends of the insertion portions 330, 332.

[0140] Furthermore, the orientation of the return direction DR tends to be such that the spring return force of the guide leg 350 is perpendicular to the separation axis MM. This reduces any tendency for the spring return force or the force applied by the inserted object or probe to push the cover parts 122, 124 apart.

[0141] In addition, due to the orientation of the return direction DR, the interlock between the barb 358 and the strain relief wall 152 is less susceptible to displacement caused by deformation or displacement between the cover components 122 and 124.

[0142] If necessary, the end cap 300 can be removed from the housing assembly 100. A prying tool (e.g., a flathead screwdriver) can be inserted into the pry slot 326 and used to pry open the end cap 300.

[0143] When the sealants 160 and 170 are gels, as assembly 100 transitions from the open to the closed position, cables 12 and 14 and housing 120 can apply compressive forces to the sealants 160 and 170. The gel can thus be stretched and generally deformed and substantially conformed to the outer surfaces of connector 200, cables 12 and 14, and the inner surface of housing 120. Some shearing of the gel may also occur. At least some of the gel deformation can be elastic. The restoring force in the gel caused by this elastic deformation generally causes the gel to operate as a spring, which applies an outward force between housing 120 and connector 200 and cables 12 and 14. The compressive loading and restoring force are maintained by the closing of cover components 122 and 124.

[0144] The various properties of the gel described above ensure that the gel sealants 160 and 170 maintain a reliable and durable seal between the housing 120 and connector 200 and cables 12 and 14. The elastic memory and retaining or restoring forces within the elongated, elastically deformable gel typically cause the gel to bear mating surfaces against the inner surfaces of connector 200, cables 12 and 14, and housing 120. Furthermore, the viscous nature of the gel provides adhesion between the gel and these surfaces. Even when cold-applied, the gel is generally able to flow around connector 200, cables 12 and 14, and housing 120 to accommodate their irregular geometries.

[0145] According to some embodiments, sealants 160 and 170 are self-healing or self-fusion gels. This property, combined with the aforementioned compressive forces between the connector 200, cables 12 and 14, and housing 120, allows sealants 160 and 170 to reform into a continuous form if the gel is sheared by inserting cables 12 and 14 into the housing assembly 100. The gel can also reform if the connector 200 and cables 12 and 14 are removed from it.

[0146] The sealants 160 and 170, especially when formed from gels as described herein, provide a reliable moisture barrier for cables 12 and 14 and connector 200, even when the housing assembly 100 is subjected to extreme temperatures and temperature variations. The housing 120 may be made of an abrasion-resistant material that resists perforation due to abrasive forces.

[0147] The gel sealant can also prevent or inhibit corrosion of the connection 22 by depositing an oil layer from the gel on the exposed surfaces of the connector 200 and conductor portions 12A, 14A within the housing cavity 106. Even after the gel is removed from the connection 22, the oil can be retained to coat the connection surface as a moisture barrier.

[0148] As will be appreciated from the description herein, the housing assembly according to the invention can be provided as a pre-formed and fully assembled unit having a pre-cured gel or other sealant as described above, which can be cold-applied around the joint to form a seal.

[0149] Although, according to some embodiments, the housing 120 is formed integrally and monolithically, the housing may also be formed in other ways according to some aspects of the invention. For example, the cover parts 122, 124 and / or hinge 126 may be separate parts connected together by hinges or other means. For example, the cover parts 122, 124 may be separate parts that are fixed together by straps, buckles, latches, etc. and / or not hinged.

[0150] According to some embodiments, the cover assembly 100, as described herein, can be formed without sealant gaps 164, 174 (i.e., cover parts 122, 124 are entities filled up to the desired level).

[0151] In other embodiments, the connector system and method described herein may include different types of electrical connectors instead of IPC connector 200. These other types of electrical connectors may be IPC connectors with different designs or non-insulated puncture connectors.

[0152] According to some embodiments, housings and protective end caps (e.g., housing 120) as disclosed herein can be used to encapsulate connections including IPC connectors (e.g., connection 22) or other types of connectors (e.g., non-IPC connectors) without providing a sealant therein (e.g., sealant 160, 170). Such a sealant-free housing provides touch protection.

[0153] According to some embodiments, the housing assembly 100, connector 200, and protective end cap 300 are pre-constructed or packaged as mating kits. However, the housing assembly 100 and connector 200 do not necessarily need to be provided as kits. For example, the housing assembly 100 and protective end cap 300 can be retrofitted to a connector 200 that has been previously installed, even years ago.

[0154] According to some embodiments, cables 12 and 14 are power transmission conductors. According to some embodiments, cables 12 and 14 are suspended power transmission conductors. According to some embodiments, cable 12 is a trunk conductor cable, while cable 14 is a branch conductor cable.

[0155] According to some embodiments, the protected connection component 24 conforms to Underwriters Laboratories standard UL6703 (issued August 2, 2011). According to some embodiments, the protected connection component 24 can be directly buried underground according to Underwriters Laboratories standard UL486D (issued June 19, 2015) (without requiring an additional enclosure).

[0156] It will be appreciated that the housing according to the invention may have components (e.g., cover parts, walls, etc.) and cavities or chambers having shapes, constructions and / or dimensions different from those shown and described herein.

[0157] The foregoing is illustrative of the invention and should not be construed as limiting it. Although some exemplary embodiments of the invention have been described, those skilled in the art will readily recognize that many modifications can be made to these exemplary embodiments without substantially departing from the novel teachings and advantages of the invention. Therefore, all such modifications are intended to be included within the scope of the invention. It should be understood that the foregoing is illustrative of the invention and should not be construed as limiting it to the specific embodiments disclosed, and modifications to the disclosed embodiments and other embodiments are intended to be included within the scope of the invention.

Claims

1. An encapsulated connection system for mechanically and electrically connecting a first cable and a second cable, each of the first cable and the second cable comprising an elongated electrical conductor covered by an insulating layer, the encapsulated connection system comprising: An electrical connector configured to form a connection with a first cable and a second cable, wherein the conductors of the first cable and the second cable are electrically connected through the electrical connector; A housing configured to receive and cover the connection and to protect the electrical connector, the housing including a plurality of housing ports, each configured to receive a cable; and A protective end cap configured to selectively cover at least a selected housing port among the housing ports; in: The housing includes a first cover component and a second cover component that respectively define a first cover component cavity and a second cover component cavity; The first cover component and the second cover component are pivotally connected by a hinge; The first cover component and the second cover component are pivotable relative to each other about the hinge between a closed position and an open position for receiving the connection, wherein the first cover component and the second cover component define a housing cavity to accommodate the connection, such that the electrical connector is encapsulated in the first cover component and the second cover component; The protective end cap includes an insertion feature; The protective end cap includes opposing sidewalls; The protective end cap is configured to be mounted on the housing such that: The insertion feature is received through the selected housing port; and The opposing sidewalls overlap with the first cover component and the second cover component, thereby resisting the first cover component and the second cover component from moving from the closed position toward the open position.

2. The enclosed connection system of claim 1, wherein, The electrical connector is an insulating puncture connector, which includes: At least one conductive puncture component; and A clamping mechanism configured and operable to push the at least one piercing member through the insulation of the first and second cables and to electrically engage with the conductors of the first and second cables to form the connection.

3. The encapsulation connection system according to claim 1, characterized in that: The protective end cap is configured to be mounted on the housing such that the insertion feature blocks the selected housing port.

4. The encapsulation connection system according to claim 3, characterized in that: The protective end cap includes a second insertion feature; as well as The protective end cap is configured to be mounted on the housing such that the second insertion feature blocks the second housing port in the housing port.

5. The encapsulation connection system according to claim 1, characterized in that: The housing cavity is configured to receive the electrical connector and the first and second cables; The selected housing port includes an inlet port, a chamber port between the inlet port and the housing cavity, and a gap defining the inlet port and the chamber port; as well as The protective end cap is configured to be mounted on the housing such that the insertion feature extends through the entry port and into the gap.

6. The encapsulation connection system according to claim 5, characterized in that: The insertion feature has a distal terminal end; and The protective end cap is configured to be mounted on the housing such that the distal terminal end is located in the gap and between the chamber port and the inlet port.

7. The encapsulation connection system according to claim 6, characterized in that: The enclosure includes a fragile port wall extending across the chamber port; as well as The protective end cap is configured to be mounted on the housing such that the distal terminal end is located in the gap and between the vulnerable port wall and the inlet port.

8. The encapsulation connection system according to claim 7, characterized in that, The encapsulation connection system includes a flowable sealant disposed within the housing cavity to provide a seal around the electrical connector.

9. The encapsulation connection system according to claim 5, characterized in that: The enclosure includes a strain-relieving wall; The inlet port is located within the strain relief wall; as well as The insertion feature includes an integrally formed latching feature configured to interlock with the strain relief wall to secure the protective end cap to the housing.

10. The encapsulation connection system according to claim 1, characterized in that: The insertion feature has a latching feature, which includes opposing legs that can be deflected relative to each other along a deflection axis; The protective end cap is configured to be mounted on the housing such that the deflection axis extends transversely to the separation axis of the first cover component and the second cover component.

11. The encapsulation connection system according to claim 1, characterized in that, The housing includes: A flowable sealant is disposed in the at least one cover component to provide a seal around the electrical connector.

12. The encapsulation connection system according to claim 11, characterized in that, The sealant is a gel.

13. The encapsulation connection system according to claim 11, characterized in that, The housing includes: A first flowable sealant disposed in the first cover component cavity and a second flowable sealant disposed in the second cover component cavity; Wherein, the first cover component and the second cover component define the housing cavity to receive the connection, such that the electrical connector is encapsulated in the first flowable sealant and the second flowable sealant; and The housing is configured such that when the first cover component and the second cover component move around the electrical connector from the open position to the closed position, the electrical connector will displace the first flowable sealant and the second flowable sealant.

14. The encapsulation connection system according to claim 13, characterized in that, The first flowable sealant and the second flowable sealant are a first gel and a second gel adapted to be elongated and elastically deformed in the closed position when the electrical connector is disposed in the housing cavity.

15. The encapsulation connection system according to claim 13, characterized in that: The electrical connector has a connector volume; The first flowable sealant and the second flowable sealant respectively include a first gap and a second gap pre-defined therein for receiving the electrical connector, the first gap and the second gap having a first gap volume and a second gap volume, respectively; and The sum of the first gap volume and the second gap volume is less than the connector volume.

16. The encapsulation connection system according to claim 15, characterized in that, The sum of the first gap volume and the second gap volume is between 60% and 100% of the connector volume.

17. The encapsulation connection system according to claim 1, characterized in that: The electrical connector is an insulating puncture connector, which includes: At least one conductive puncture component; and A clamping mechanism configured and operable to push the at least one piercing member through the insulation layer of the first cable and the second cable and to electrically engage with the conductors of the first cable and the second cable to form a connection including the insulating piercing connector and the first cable and the second cable, wherein the conductors of the first cable and the second cable are electrically connected to each other through the at least one piercing member. The insertion feature has a distal terminal end; The connection includes a flowable sealant disposed in the housing cavity to provide a seal around the insulating puncture connector; The housing cavity is configured to receive the insulating piercing connector and the first cable and the second cable; The selected housing port includes an inlet port, a chamber port between the inlet port and the housing cavity, and a gap defining the inlet port and the chamber port; The enclosure includes a fragile port wall extending across the chamber port; The protective end cap is configured to be mounted on the housing such that: The insertion feature blocks the selected housing port and extends through the entry port and into the gap; and The distal terminal end is located in the gap and between the vulnerable port wall and the entry port; The enclosure includes a strain-relieving wall; The inlet port is located within the strain relief wall; and The insertion feature includes an integrally formed latching feature configured to interlock with the strain relief wall to secure the protective end cap to the housing.

18. A method for forming an encapsulated connection assembly around a first cable and a second cable, each of the first cable and the second cable comprising an elongated electrical conductor covered by an insulating layer, the method comprising: The first cable and the second cable are connected to an electrical connector to form a connection, wherein the conductors of the first cable and the second cable are electrically connected through the electrical connector; The connection is enclosed in a housing to protect the electrical connector, wherein the housing includes a plurality of housing ports, each configured to receive a cable; and At least selected housing ports are covered by protective end caps; in: The housing includes a first cover component and a second cover component that respectively define a first cover component cavity and a second cover component cavity; The first cover component and the second cover component are pivotally connected by a hinge; The first cover component and the second cover component are pivotable relative to each other about the hinge between a closed position and an open position for receiving the connection, wherein the first cover component and the second cover component define a housing cavity to accommodate the connection, such that the electrical connector is encapsulated in the first cover component and the second cover component; The protective end cap includes an insertion feature; The protective end cap includes opposing sidewalls; The protective end cap is configured to be mounted on the housing such that: The insertion feature is received through the selected housing port; and The opposing sidewalls overlap with the first cover component and the second cover component, thereby resisting the first cover component and the second cover component from moving from the closed position toward the open position.

19. An encapsulated connection assembly, comprising: A first cable and a second cable, each comprising an elongated electrical conductor covered by an insulating layer; An electrical connector that forms a connection with the first cable and the second cable, wherein the conductors of the first cable and the second cable are electrically connected through the electrical connector; A housing that receives and covers the connection to protect the electrical connector, the housing including a plurality of housing ports, each configured to receive a cable; and A protective end cap that covers at least a selected housing port among the housing ports; in: The housing includes a first cover component and a second cover component that respectively define a first cover component cavity and a second cover component cavity; The first cover component and the second cover component are pivotally connected by a hinge; The first cover component and the second cover component are pivotable relative to each other about the hinge between a closed position and an open position for receiving the connection, wherein the first cover component and the second cover component define a housing cavity to accommodate the connection, such that the electrical connector is encapsulated in the first cover component and the second cover component; The protective end cap includes an insertion feature; The protective end cap includes opposing sidewalls; The protective end cap is configured to be mounted on the housing such that: The insertion feature is received through the selected housing port; and The opposing sidewalls overlap with the first cover component and the second cover component, thereby resisting the first cover component and the second cover component from moving from the closed position toward the open position.

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