Compression connector and mold

Abstract

An electrical compression connector for connecting a plurality of conductors, the compression connector comprising a connector body made of a compressible material, the connector body adapted to be inserted into a crimping tool having two opposing mold surfaces for compressing the connector body, the connector body includes a first conductor portion and a second conductor portion. The first conductor portion includes: a pair of sidewalls including a first sidewall and a second sidewall, the pair of sidewalls being joined by a bottom wall; and a first conductor opening between the pair of sidewalls and the bottom wall; and at least one insulating piercing member. The second conductor portion includes at least one second conductor opening that extends at least partially through the connector body.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is based on and claims priority to U.S. Provisional Application Serial No. 63 / 353,516, filed on June 17, 2022, entitled “COMPRESSION CONNECTORS,” and U.S. Provisional Application Serial No. 63 / 405,254, filed on September 9, 2022, entitled “COMPRESSION CONNECTORS AND PROTECTIVE COVERS,” the contents of each of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure generally relates to electrical compression connectors for connecting one or more solid or stranded wires or conductors to one or more wires or conductors. More specifically, the present disclosure relates to compression-type electrical connectors for connecting one or more extension wires or conductors to one or more tap wires or conductors. Background Art

[0004] Electrical connectors, and in particular compression connectors, exist in various forms, including terminals, joints, and extension and tap joints. Tap connectors have been used to establish electrical connections between continuous extension conductors or main power conductors and tap conductors or branch conductors. Existing compression connectors are generally adapted to receive branch conductors or tap conductors to engage the continuous extension conductors and are compressed with the aid of a crimping tool to achieve the desired connection.

[0005] However, with existing tap connectors, end users are often burdened with having to deal with the problem of keeping multiple wires in place within the connector while keeping the connector in place within the crimping tool during the crimping process. With existing tap connectors, prior to or during the crimping process, before the crimping tool can be activated and the connector compressed, one or more of the wires, conductors, or wire bundles "pop out" of their respective slots in the connector, and / or the connector itself is displaced from its proper position in the crimping tool.

[0006] There is a need for connectors and dies that ease the burden on end users who use electrical compression connectors and ensure secure mechanical and electrical connections between conductors and each of the connectors. Summary of the invention

[0007] An electrical compression connector for connecting a plurality of conductors, the compression connector comprising a connector body made of a compressible material, the connector body being adapted to be inserted into a crimping tool having two opposing die surfaces for compressing the connector body, the connector body comprising a first conductor portion and a second conductor portion. The first conductor portion comprises: a pair of side walls, the pair of side walls comprising a first side wall and a second side wall, the pair of side walls being connected by a bottom wall; and a first conductor opening located between the pair of side walls and the bottom wall; and at least one insulation piercing member. The second conductor portion comprises at least one second conductor opening, the at least one second conductor opening extending at least partially through the connector body.

[0008] An electrical compression connector for connecting multiple conductors, the compression connector comprising a connector body made of a compressible material, the connector body being adapted to be inserted into a crimping tool having two opposing die surfaces for compressing the connector body, the connector body having a first conductor portion and a second conductor portion. The first conductor portion comprises: a pair of side walls, the pair of side walls comprising a first side wall and a second side wall, the pair of side walls being connected by a bottom wall; and a first conductor opening located between the pair of side walls and the bottom wall; and at least one insulation piercing member. The second conductor portion comprises at least one second conductor opening, the at least one second conductor opening extending along at least one of the side walls of the connector body.

[0009] An electrical compression connector for connecting a plurality of conductors, the compression connector comprising a connector body made of a compressible material, the connector body being adapted to be inserted into a crimping tool having two opposing die surfaces for compressing the connector body, the connector body having a first conductor portion and a second conductor portion. The first conductor portion comprises: a pair of side walls, each of the pair of side walls comprising a first portion having a first thickness and a second portion having a second thickness different from the first thickness and being connected by a bottom wall; and a first conductor opening located between the pair of side walls and the bottom wall. The second conductor portion comprises at least one second conductor opening. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings depict embodiments for illustrative purposes only. Those skilled in the art will readily appreciate from the following description that alternative embodiments of the structures shown herein may be employed without departing from the principles described herein, wherein:

[0011] Figure 1 is a perspective view of an exemplary embodiment of a compression connector according to the present disclosure, showing a body having an extension conductor portion having a plurality of insulation piercing members and elongated arms formed into the body and a branch conductor portion having a plurality of branch conductor openings located on a bottom of the body;

[0012] Figure 1a According to an illustrative embodiment of the present disclosure, Figure 1 an enlarged view of a portion of the compression connector depicted in;

[0013] Figure 1b According to another illustrative embodiment of the present disclosure Figure 1 an enlarged view of a portion of a compression connector similar to the portion of the compression connector depicted in FIG.

[0014] Figure 2 yes Figure 1 A side view of a compression connector;

[0015] Figure 3 is an exploded perspective view of another exemplary embodiment of a compression connector according to the present disclosure, showing a body having an extension conductor portion having a plurality of insulation piercing members and elongated arms mountable to the body, and a branch conductor portion having a plurality of branch conductor openings located on a bottom of the body;

[0016] Figure 4 yes Figure 3 a side view of a compression connector showing an insulation piercing assembly mounted to a body of the compression connector;

[0017] Figure 5 is a perspective view of another exemplary embodiment of a compression connector according to the present disclosure, showing a body having an extension conductor portion having a plurality of insulation piercing members and elongated arms formed into the body and a branch conductor portion having a plurality of branch conductor openings located on a side of the body;

[0018] Figure 6 yes Figure 5 A side view of a compression connector;

[0019] Figure 7 is an exploded perspective view of another exemplary embodiment of a compression connector according to the present disclosure, showing a body having an extension conductor portion having a plurality of insulation piercing members and elongated arms mountable to the body, and a branch conductor portion having a plurality of branch conductor openings located on a side of the body;

[0020] Figure 8 yes Figure 7 a side view of a compression connector showing an insulation piercing assembly mounted to a body of the compression connector;

[0021] Fig. 9is a perspective view of another exemplary embodiment of a compression connector according to the present disclosure, showing a body having an extension conductor portion having a plurality of insulation piercing members and elongated arms formed into the body and a branch conductor portion having a plurality of branch conductor openings located on a bottom of the body;

[0022] Fig.10 yes Fig. 9 A side view of a compression connector;

[0023] Fig.11 is a perspective view of another exemplary embodiment of a compression connector according to the present disclosure, showing a body having an extension conductor portion having a plurality of insulation piercing members and elongated arms mountable to the body, and a branch conductor portion having a plurality of branch conductor openings located on a bottom of the body;

[0024] Fig.12 yes Fig.11 a side view of a compression connector showing an insulation piercing assembly mounted to a body of the compression connector;

[0025] Fig.13 is a perspective view of another exemplary embodiment of a compression connector according to the present disclosure, showing a body having an extension conductor portion having a plurality of insulation piercing members, elongated arms, and conductor retainer extensions integral to or mountable to the body, and a branch conductor portion having a plurality of branch conductor openings located on a side of the body;

[0026] Fig.14 yes Fig.13 a side view of a compression connector showing an insulation piercing assembly mounted to a body of the compression connector;

[0027] Fig.15 is a perspective view of another exemplary embodiment of a compression connector according to the present disclosure, illustrating an H-shaped body having a first conductor portion and a second conductor portion, wherein each conductor portion has a plurality of insulation piercing members and elongated arms extending from the body;

[0028] Fig.15a According to an illustrative embodiment of the present disclosure, Fig.15 an enlarged view of a portion of the compression connector depicted in;

[0029] Fig.15b According to another illustrative embodiment of the present disclosure Fig.15a an enlarged view of a portion of a compression connector similar to the portion of the compression connector depicted in FIG.

[0030] Fig.16 yes Fig.15 A side view of a compression connector;

[0031] Fig.17 is a perspective view of an exemplary embodiment of a die set according to the present disclosure, showing a first die having a forming surface on a bottom wall and a second die having a substantially flat surface on the bottom wall;

[0032] Fig.18 It was taken along line 18-18 Fig.17 A cross-sectional view of a first mold of a mold set;

[0033] Fig.19 is an exploded perspective view of a mold having a substantially flat surface on a bottom wall and a removable contact plate;

[0034] Fig. 20 yes Fig.19 A perspective view of the mold depicted in FIG. 1 having a removable contact plate mounted to a bottom wall;

[0035] Fig.21 yes Fig.19 A top view of the mold depicted in FIG. 1 having a removable contact plate mounted to a bottom wall;

[0036] Fig. 22 is a perspective view of another exemplary embodiment of a die set according to the present disclosure, showing a first die having a forming surface on a bottom wall and a second die having a substantially flat surface on the bottom wall;

[0037] Fig.23 It is taken along line 23-23 Fig. 22 A cross-sectional view of a first mold of a mold set;

[0038] Fig.24 yes Figure 1 Compression connectors and Figure 19-21 an exploded perspective view of a die set of FIG. 1 with a removable contact plate mounted to a bottom wall of a second die and showing an extension conductor and a plurality of branch conductors, the extension conductor being positioned for insertion between arms of a body of an extension conductor portion of a compression connector, the plurality of branch conductors being positioned for insertion into branch conductor openings in the branch conductor portion of the body, and showing the dies of the die set positioned in an open position with a first die positioned above a top end of the extension conductor portion of the body and a second die positioned below a bottom end of the branch conductor portion of the body so that the compression connector can be received between the dies and a wire clamp for holding the plurality of branch conductors in place;

[0039] Fig.25 yes Fig.24A perspective view of an exemplary embodiment of a wire clamp of , which shows one or more wire openings, wherein each wire opening has one or more wire clamps, the one or more wire clamps for clamping wires inserted into the one or more wire openings;

[0040] Fig.26 yes Fig.25 An end view of a wire clamp;

[0041] Fig. 27 is with Figure 1 A perspective view of a compression connector similar to the compression connector depicted in and showing a plurality of wires inserted into one or more wire openings of a wire clamp according to an illustrative embodiment of the present disclosure and one or more wire clamps clamping the wires;

[0042] Fig.28 It is along Fig. 27 A cross-sectional view taken along line 28-28 of FIG. 1 showing one or more wire clamps of a wire clamp clamping an electrical wire;

[0043] Fig.29 yes Fig.24 A perspective view of a compression connector and mold of , showing an exemplary embodiment of a wire clamp positioned in the mold aligned with a branch conductor opening located in a branch conductor portion of the compression connector;

[0044] Fig.30 According to an illustrative embodiment of the present disclosure Fig.29 an enlarged view of a portion of;

[0045] Fig.31 According to an illustrative embodiment of the present disclosure, Fig.24 A partially exploded rear perspective view of the compression connector and die set depicted in;

[0046] Fig.32 yes Fig.24 a side view of the compression connector and die showing the dies moving toward each other with the bottom end of the extended conductor portion of the body resting on the bottom wall of the second die and before the arms of the body contact the forming surface on the bottom wall of the first die;

[0047] Fig.33 yes Fig.32 a side view of the compression connector and die of FIG. 1 showing the dies moving toward each other with the bottom end of the branch conductor portion of the body resting on the bottom wall of the second die and the arms of the extension conductor portion of the body being folded by the forming surface located on the bottom wall of the first die before the distal ends of the arms pierce the insulating jacket surrounding the wire of the extension conductor;

[0048] Fig.34yes Fig.33 a side view of a compression connector and a die showing the die in a crimping position wherein the arms of the body are folded by the forming surface of the first die into the conductor between the dies such that the tips of the arms pierce the insulating jacket of the wire surrounding the conductor, and wherein the bottom wall of the second die compresses the branch conductor opening such that the branch conductor within the branch conductor opening is clamped to the compression connector;

[0049] Fig.35 yes Fig.34 A side view of another exemplary embodiment of a compression connector of , showing a single insulation piercing member located in the extended conductor portion of the body piercing the insulation jacket of the wire surrounding the conductor, and the distal end of the arm piercing the insulation jacket of the wire surrounding the conductor;

[0050] Fig.36 is a perspective view of a die withdrawn from a crimping position, releasing the compressed compression connector that has been mechanically and electrically connected to an extension conductor and a branch conductor;

[0051] Fig.37 is a perspective view of a mold set according to another illustrative embodiment of the present disclosure;

[0052] Fig.38 yes Fig.15 Compression connectors and Fig.37 a side view of a die set showing a first extension conductor positioned between a first set of arms of a body of a compression connector and a second extension conductor or branch conductor positioned between a second set of arms of the body of the compression connector, and showing the dies of the die set in an open position with the first die positioned above a top end of the body and the second die positioned below a bottom end of the body so that the compression connector can be received between the dies;

[0053] Fig.39 yes Fig.38 a side view of a compression connector, die, and conductor showing the dies moving toward each other with a first set of arms of a body positioned in a first die and a second set of arms of the body positioned in a second die, and before the arms of the body contact forming surfaces on the bottom walls of the first and second dies;

[0054] Fig.40 yes Fig.39 a side view of the compression connector, dies, and conductors of FIG. 1 showing the dies moving further toward each other, wherein a forming surface located on a bottom wall of the first die contacts and folds a first set of arms of the body, and wherein a forming surface located on a bottom wall of the second die contacts and folds a second set of arms of the body;

[0055] Fig.41 yes Fig.40a side view of a compression connector, die, and conductor of the present invention, showing the die in a crimping position, wherein a forming surface located on a bottom wall of a first die further folds a first set of arms of the body such that the tips of the first set of arms pierce an insulating jacket surrounding the wire of a first extension conductor, and wherein a forming surface located on a bottom wall of a second die further folds a second set of arms of the body such that the tips of the second set of arms pierce an insulating jacket surrounding the wire of a second extension conductor or branch conductor;

[0056] Fig.42 is similar to Fig.41 , but showing a single insulation piercing member in the first conductor portion of the body piercing the insulation jacket of the wire surrounding the first extension conductor, and the tips of the first set of arms of the body piercing the insulation jacket of the wire surrounding the first extension conductor, and showing a single insulation piercing member in the second conductor portion of the body piercing the insulation jacket of the wire surrounding the second extension conductor, and the tips of the second set of arms of the body piercing the insulation jacket of the wire surrounding the second extension conductor or branch conductor; DETAILED DESCRIPTION

[0057] The present disclosure provides embodiments of compression connectors for electrically connecting, for example, one or more branch conductors or tap conductors to one or more extension conductors or main conductors. For ease of description, the compression connector may be referred to as a "connector" in the singular and "connector" in the plural. The branch conductor or tap conductor may be referred to as a "branch conductor" in the singular and "branch conductors" in the plural. The main conductor or extension conductor may be referred to as an "extension conductor" in the singular and "extension conductors" in the plural. It should be noted that the extension conductor is generally larger in size than the branch conductor. In addition, the extension conductor and the branch conductor may be solid conductors, or they may be stranded conductors. Typically, the extension conductor and the branch conductor are stranded conductors. The port, slot, groove, orifice or other opening in the compression connector that receives the branch conductor may also be referred to as a "branch opening" in the singular and "branch openings" in the plural. The port, slot, groove, orifice or other opening in the compression connector that receives the extension conductor may also be referred to as a "extension opening" in the singular and "extension openings" in the plural.

[0058] Although for ease of reference, the present disclosure refers to branches and extensions and branch conductors and extension conductors, it should be understood that the various embodiments of the connectors described herein will be suitable for use in mechanically and electrically connecting any one conductor to any one or more other conductors regardless of the terminology assigned to them.

[0059] The present disclosure also provides an embodiment of a die set, which is configured to be mounted to a tool and receive a connector so that an extension conductor and a branch conductor can be crimped to the connector. The present disclosure also provides an embodiment of a cable positioner, which is used to hold and support an extension conductor and a branch conductor to be connected to the connector.

[0060] A compression connector according to an illustrative embodiment of the present disclosure is Figure 1-Figure 4 , and is referred to as a compression connector 10 or simply connector 10. In an exemplary embodiment, the connector 10 includes a body 20 having an extension conductor portion 22 and a branch conductor portion 24. The body 20 has a body length "BL" and a body width "BW". The extension conductor portion 22 includes two side walls 26 and 28 and a bottom wall 32 located between the two side walls 26 and 28, which forms or defines a portion of the extension opening 30. The thickness "T" of one or both of the walls 26 and 28 can be uniform along the length "L" of the wall, or the thickness of one or both of the walls 26 and 28 can be non-uniform along the length "L" of the wall. In the exemplary embodiment shown, the thickness of each wall 26 and 28 is non-uniform along the length of the wall. More specifically, the wall 26 has a first thickness "T1" along a first portion of the wall 26 and a second thickness "T2" along a second portion of the wall 26. As shown, in the exemplary embodiment, the first thickness "T1" is greater than the second thickness "T2". The transition zone 26a from the first portion of the wall 26 to the second portion of the wall 26 can be a sharp transition zone or a smooth transition zone. The transition zone from the first portion of the wall 26 to the second portion of the wall 26 can also be referred to as the "transition" of the wall 26. A sharp transition can be an immediate change from a first thickness to a second thickness. For example, a sharp transition can be a substantially flat boss in the wall 26. A smooth transition can be a gradual increase or decrease in thickness from a first thickness "T1" to a second thickness "T2". As a non-limiting example, a smooth transition can be a tapered edge, a bevel edge, or a curved edge that gradually increases or decreases the thickness of the wall 26 from a first thickness "T1" to a second thickness "T2". The length "L1" of the first portion of the wall 26 extends from the bottom of the extended conductor portion 22 to the transition zone 26a, and the length "L2" of the second portion of the wall 26 extends from the transition zone 26a to the end 26b of the wall 26.

[0061] Continue to refer Figure 1-Figure 4, similar to what is described above with reference to wall 26, wall 28 has a first thickness "T1" along a first portion of wall 28 and a second thickness "T2" along a second portion of wall 28. In this exemplary embodiment, the first thickness "T1" is greater than the second thickness "T2". The transition zone 28a from the first portion of wall 28 to the second portion of wall 28 can be a sharp transition zone or a smooth transition zone. The transition zone from the first portion of wall 28 to the second portion of wall 28 can also be referred to as the "transition" of wall 28. A sharp transition can be an immediate change from a first thickness to a second thickness. For example, a sharp transition can be a substantially flat boss in wall 28. A smooth transition can be a gradual increase or decrease in thickness from a first thickness "T1" to a second thickness "T2". As a non-limiting example, a smooth transition can be a tapered edge, a bevel edge, or a curved edge that gradually increases or decreases the thickness of wall 28 from a first thickness "T1" to a second thickness "T2". The length "L1" of the first portion of wall 28 extends from the bottom of the extended conductor portion 22 to the transition region 28a, and the length "L2" of the second portion of wall 28 extends from the transition region 28a to the end 28b of wall 28. Although the thicknesses "T1" and "T2" and lengths "L1" and "L2" of walls 26 and 28 are depicted as being the same or substantially the same for each wall, it should be understood that these thicknesses and / or lengths may be different for each of the walls.

[0062] The length "L2" and / or thickness "T2" of the second portion of the walls 26 and 28 is configured and dimensioned so that the walls 26 and 28 can be shaped so that the ends 26b and 28b of the walls 26 and 28 can pierce the insulating jacket of the extension conductor and contact the wires of the extension conductor during the crimping process, as will be described in more detail below. The increased thickness (T1) of the first portion of the wall 28 adds additional strength to the portion, thereby resisting deformation during the crimping process in areas that are not intended to bend. The increased thickness (T1) also facilitates providing a larger bend radius for the thinner L2 section during the crimping process.

[0063] exist Figure 1-Figure 4In the exemplary embodiment shown, the extension conductor portion 22 of the connector 10 is substantially a U-shaped structure, wherein the first portion of the walls 26 and 28 and the bottom wall 32 are configured, sized and shaped so that the extension opening 30 can receive the extension conductor. More specifically, the walls 26 and 28 and the bottom wall 32 form the extension conductor opening 30, and the length "L1" of the first portion of the walls 26 and 28 and the length "L3" of the bottom wall 32 can vary depending on the size of the extension conductor to be received in the extension conductor opening 30. As a non-limiting example, the size of the extension conductor can be in the range of from about 250Kcmil to about 750Kcmil. For a 250Kcmil extension conductor, the length "L1" of the first portion of the walls 26 and 28 and the length "L3" of the bottom wall 32 are configured, sized and shaped to form an extension conductor opening 30 sufficient to receive a 250Kcmil extension conductor. For a 750Kcmil extension conductor, the length "L1" of the first portion of the walls 26 and 28 and the length "L3" of the bottom wall 32 are configured, sized and shaped to form an extension opening 30 sufficient to receive a 750Kcmil extension conductor. The length "L2" of the second portion of the walls 26 and 28 may also vary depending on the desired penetration of different cable sizes.

[0064] The bottom wall 32 may include one or more insulation piercing members 40 extending into the extension opening 30. Each insulation piercing member 40 includes an insulation piercing tip 40a configured and dimensioned to pierce or cut through the insulation jacket of the extension conductor 700 to create an electrical path between the extension conductor and the connector 10. Non-limiting examples of multiple insulation piercing members 40 extending into the extension opening 30 are shown in FIG. Figure 1-Figure 4 A non-limiting example of a single insulation piercing member 40 extending into the extended opening 30 is shown in Fig.35 Shown. Figure 1-Figure 2 In an exemplary embodiment of the present disclosure, one or more insulation piercing members 40 may be integrally or monolithically formed into the bottom wall 32 such that the one or more insulation piercing members 40 extend into the extension opening 30. According to another illustrative embodiment of the present disclosure, the one or more insulation piercing members 40 may be attachable to the body 20 of the connector 10. In this embodiment, the insulation piercing members 40 may be made of a material that is different from the material of the body 20. For example, portions of the body 20 of the connector 10 need to be flexible and move during the compression process and may be made of a relatively soft material, such as tinned copper, aluminum, or similar metallic materials that deform appropriately when pressure is applied in standard mechanical, hydraulic, and pneumatic crimping tools and devices to crimp the conductor to the connector. On the other hand, the performance of the insulation piercing members 40 may be improved by using a relatively harder material. Thus, in Figure 3 , Figure 4 and Fig.35 In an exemplary embodiment of the present invention, one or more insulation piercing members 40 may be made of different materials (e.g., copper, tempered aluminum, stainless steel, etc.) and fixed or attached to the bottom wall 32 of the connector 10 so that the one or more insulation piercing members 40 extend into the extension opening 30. Figure 3 , Figure 4 and Fig.35 In an exemplary embodiment of the present invention, the insulation piercing member 40 is part of an insulation piercing assembly 42 that can be mounted or secured to the body 20 of the connector 10. As an example, the insulation piercing assembly 42 can have a body 44 having one or more insulation piercing members 40 extending from an upper surface of the body 44 and one or more mounting ribs 46 extending from a bottom surface of the body 44. The one or more mounting ribs 46 are configured and dimensioned to mate with one or more mounting channels 36 located in the bottom wall 32 of the body 20. It should be noted that, alternatively or in addition, the one or more mounting ribs 46 can be disposed on the bottom wall 32 of the body 20 and configured and dimensioned to mate with one or more mounting channels 36 located in the bottom surface of the body 44. It should also be noted that the one or more insulation piercing members 40 can extend from the inner surface of one or more walls 26 and 28.

[0065] The cross-sectional shape of the insulation piercing member shown is triangular. However, the insulation piercing member can have different shapes and sizes that are configured and dimensioned to pierce or cut through the insulation jacket of the wire surrounding the extension conductor, such as one or more tapered members and / or one or more members with sharp tips. In addition, one or more of the insulation piercing members 40 may include serrations 40b, such as in Figure 1a As seen in FIG. 1 , the serrations are located on one or both sides of the insulation piercing member 40. The serrations allow the crimped wire bundle to cold flow into the grooves of the serrations and can improve conductivity and cable retention. One or more of the insulation piercing members 40 may include a smooth, flat surface 40c, as shown in FIG. Figure 1b As shown in FIG. 1 , the smooth, flat surface is located on one or both sides of the insulation piercing member.

[0066] Continue to refer Figure 1-Figure 4, the branch connector portion 24 includes one or more raised semicircular areas or ridges 50e, which extend downward from the branch connector portion and may extend partially or completely along the width "BW" of the connector 10. One or more branch conductor openings 50 are formed above each semicircular area 50e. A portion of each branch conductor opening 50 can be configured and sized to receive one or more branch conductors. In the illustrated embodiment, the branch conductor portion 24 includes four branch conductor openings 50. Each branch conductor opening 50 extends along the width "BW" of the body 20, as shown. In this embodiment, when the connector 10 is crimped or compressed, the semicircular area 50e is folded, bent or deformed upward to close the opening 50 and crimp the branch conductor in the branch opening 50.

[0067] refer to Figure 5 and Figure 6 , shows another exemplary embodiment of a compression connector 10 according to the present disclosure. This exemplary embodiment is substantially similar to Figure 1 and Figure 2 10, such that the same reference numerals are used for the same features of the connector 10. Figure 1 and Figure 2 The difference between the embodiments of the present invention is the positioning of the branch opening 50. As shown, the branch opening 50 is not located along the horizontal axis of the branch conductor portion 24 of the body 20, but is located along the vertical axis on one or both sides of the branch conductor portion 24 of the body 20 and the possible extension conductor portion 22. In the embodiment shown, one or more sides of the branch conductor portion 24 of the body include one or more slots 50a, so that one slot intersects with the branch opening 50, thereby creating a gap in the body 20 and forming one or more hinge portions 50b in the side of the branch conductor portion 24 of the body 20. The slot 50a can be configured so that ribs 50c and 50d are formed in the body 20. The ribs 50c and 50d help keep the branch conductor in the branch opening 50 until the connector 10 is compressed (e.g., crimped). The hinge portion 50b enables the ribs 50c and 50d to bend toward each other more easily when the connector 10 is compressed. In this embodiment, when the connector 10 is crimped or compressed, the hinge 50 b folds, bends or deforms to close the gap and crimp the branch conductor in the branch opening 50 .

[0068] refer to Figure 7 and Figure 8 , shows a compression connector 10 according to another exemplary embodiment of the present disclosure. This exemplary embodiment is substantially similar to Figure 3 and Figure 410, such that the same reference numerals are used for the same features of the connector 10. Figure 3 and Figure 4 The difference between the embodiments of the present invention is the positioning of the branch opening 50. As shown, the branch opening 50 is not located along the horizontal axis of the branch conductor portion 24 of the body 20, but is located along the vertical axis on one or both sides of the branch conductor portion 24 and possible extension conductor portion 22 of the body 20. In the embodiment shown, one or more sides of the branch conductor portion 24 of the body include one or more slots 50a, so that one slot intersects with the branch opening 50, thereby creating a gap in the body 20 and forming one or more hinge portions 50b in the side of the branch conductor portion 24 of the body 20. The slot 50a can be configured so that ribs 50c and 50d are formed in the body 20. The ribs 50c and 50d help keep the branch conductor in the opening 50 until the connector 10 is compressed (e.g., crimped). The hinge portion 50b enables the ribs 50c and 50d to bend toward each other more easily when the connector 10 is compressed. In this embodiment, when the connector 10 is crimped or compressed, the hinge 50 b folds, bends or deforms to close the gap and crimp the branch conductor in the branch opening 50 .

[0069] refer to Fig. 9 and Fig.10 , shows another exemplary embodiment of a compression connector 10 according to the present disclosure. This exemplary embodiment is substantially similar to Figure 1 , Figure 2 , Figure 5 and Figure 6 10, such that the same reference numerals are used for the same features of the connector 10. Figure 1 , Figure 2 , Figure 5 and Figure 6The difference between the embodiments of the present invention is the positioning of the branch openings 50. As shown, the branch openings 50 are not positioned along the same horizontal axis of the branch conductor portion 24 of the body 20, but are positioned along two different horizontal axes of the branch conductor portion 24 of the body 20. In the embodiment shown, the bottom surface of the branch conductor portion 24 of the body 20 has one or more extensions 52 extending from the bottom surface. The extension 52 can extend entirely or partially across the width "BW" of the body 20. In this embodiment, two branch openings 50 are positioned along a first horizontal axis, and two branch openings 50 are positioned along a second horizontal axis, wherein the second horizontal axis extends through one or more extensions 52. As described above, the branch conductor portion 24 of the body 20 includes one or more slots 50a, one of which intersects the branch opening 50, thereby creating a gap in the branch opening 50 and forming one or more hinges 50b in the branch conductor portion 24 of the body 20. The slots 50a can be configured so that ribs 50c and 50d are formed in the body 20. The ribs 50c and 50d help hold the branch conductors within the openings 50 until the connector 10 is compressed (e.g., crimped). The hinge portion 50b enables the ribs 50c and 50d to bend toward each other more easily when the connector 10 is crimped or compressed. In this embodiment, when the connector 10 is crimped or compressed, the hinge 50b folds, bends, or deforms to close the gap and crimp the branch conductors in the branch openings 50.

[0070] refer to Fig.11 and Fig.12 , shows another exemplary embodiment of a compression connector 10 according to the present disclosure. This exemplary embodiment is substantially similar to Figure 3 , Figure 4 , Figure 7 and Figure 8 10, such that the same reference numerals are used for the same features of the connector 10. Figure 3 , Figure 4 , Figure 7 and Figure 8The difference between the embodiments of the present invention lies in the positioning of the branch openings 50. As shown, one or more branch openings 50 are not positioned along the same horizontal axis of the branch conductor portion 24 of the body 20, but are positioned along two different horizontal axes of the branch conductor portion 24 of the body 20. In the embodiment shown, the bottom surface of the branch conductor portion 24 of the body 20 has one or more extensions 52 extending from the bottom surface. The extension 52 can extend through the width "BW" of the body 20 in whole or in part. In this embodiment, two branch openings 50 are positioned along a first horizontal axis, and two branch openings 50 are positioned along a second horizontal axis, wherein the second horizontal axis extends through the extension 52. As described above, the branch conductor portion 24 of the body 20 includes one or more slots 50a, one of which intersects the branch opening 50, thereby creating a gap in the branch opening 50 and forming one or more hinges 50b in the branch conductor portion 24 of the body 20. The slots 50a can be configured so that ribs 50c and 50d are formed in the body 20. The ribs 50c and 50d help hold the branch conductors within the openings 50 until the connector 10 is compressed (e.g., crimped). The hinge portion 50b enables the ribs 50c and 50d to bend toward each other more easily when the connector 10 is compressed or crimped. In this embodiment, when the connector 10 is compressed or crimped, the hinge 50b folds, bends, or deforms to close the gap and crimp the branch conductors in the branch openings 50.

[0071] refer to Fig.13 and Fig.14 , shows another exemplary embodiment of a compression connector 10 according to the present disclosure. This exemplary embodiment is substantially similar to Figure 7 and Figure 8 10, such that the same reference numerals are used for the same features of the connector 10. Figure 7 and Figure 8The difference between the embodiments of the present invention is that one or both side walls 26 and / or 28 of the extension conductor portion 22 of the body 20 include a movable conductor retainer 27, which is coupled to or formed into one or both side walls 26 or 28 of the connector body 20 via a living hinge 27a. In the illustrated embodiment, the conductor retainer 27 is coupled to the side wall 26 via a living hinge 27a. When the extension conductor is positioned within the extension opening 30 of the connector body 20, the conductor retainer 27 can be moved, such as rotated or pivoted, until the free end 27b of the conductor retainer 27 is adjacent to the end 28b of the side wall 28 to at least temporarily retain the extension conductor within the extension opening 30 until the connector 10 is crimped. Additionally, the side wall 26 or 28 without the movable conductor retainer 27 may include a living hinge 29 positioned to permit the side wall 26 or 28 to move in a direction away from the opposing side wall 26 or 28 to at least temporarily increase the size of the extension opening 30 .

[0072] A compression connector according to another illustrative embodiment of the present disclosure is Fig.15 and Fig.16, and is referred to as connector 100. In the exemplary embodiment, connector 100 is an H-shaped member having a body 102 having a first conductor portion 104 and a second conductor portion 106. First conductor portion 104 includes two side walls 110 and 112, a first opening 114 located between side walls 110 and 112, and a bottom wall 116 located between side walls 110 and 112, which defines a portion of first opening 114. The thickness "T" of one or both of walls 110 and 112 may be uniform along the length "L" of the wall, or the thickness of one or both of walls 110 and 112 may be non-uniform along the length "L" of the wall. In the exemplary embodiment shown, the thickness of each wall 110 and 112 is non-uniform along the length of the wall. More specifically, wall 110 has a first thickness "T1" along a first portion of wall 110 and a second thickness "T2" along a second portion of wall 110. As shown, in this exemplary embodiment, the first thickness "T1" is greater than the second thickness "T2". The transition zone 110a from the first portion of the wall 110 to the second portion of the wall 110 can be a sharp transition zone or a smooth transition zone. The transition zone 110a from the first portion of the wall 110 to the second portion of the wall 110 can also be referred to as the "transition" of the wall 110. A sharp transition can be an immediate change from the first thickness to the second thickness. For example, the sharp transition can be a substantially flat boss in the wall 110. A smooth transition can be a gradual increase or decrease in thickness from the first thickness "T1" to the second thickness "T2". As a non-limiting example, the smooth transition can be a tapered edge, a bevel edge, or a curved edge that gradually increases or decreases the thickness of the wall 110 from the first thickness "T1" to the second thickness "T2". The length "L1" of the first portion of the wall 110 extends from the bottom of the first conductor portion 104 to the transition zone 110a, and the length "L2" of the second portion of the wall 110 extends from the transition zone 110a to the end 110b of the wall 110. Similarly, the wall 112 has a first thickness "T1" along a first portion of the wall 112 and a second thickness "T2" along a second portion of the wall 112. As shown, in the exemplary embodiment, the first thickness "T1" is greater than the second thickness "T2". The transition zone 112a from the first portion of the wall 112 to the second portion of the wall 112 can be a sharp transition zone or a smooth transition zone. The transition zone from the first portion of the wall 112 to the second portion of the wall 112 can also be referred to as the "transition" of the wall 112. A sharp transition can be an immediate change from a first thickness to a second thickness. For example, a sharp transition can be a substantially flat boss in the wall 112. A smooth transition can be a gradual increase or decrease in thickness from a first thickness "T1" to a second thickness "T2". As a non-limiting example, a smooth transition can be a tapered edge, a bevel edge, or a curved edge that gradually increases or decreases the thickness of the wall 112 from a first thickness "T1" to a second thickness "T2".The length "L1" of the first portion of the wall 112 extends from the bottom of the first conductor portion 104 to the transition region 112a, and the length "L2" of the second portion of the wall 112 extends from the transition region 112a to the end 112b of the wall 112. Although the thicknesses "T1" and "T2" and the lengths "L1" and "L2" of the walls 110 and 112 are depicted as being the same or substantially the same for each wall, it is understood that the thickness and / or length of the walls may be different.

[0073] Continue to refer Fig.15 and Fig.16 , the first conductor portion 104 of the connector 100 also includes one or more insulation piercing members 40 extending from the inner surface of one or more walls 110, 112 and / or 116. In the illustrated embodiment, a plurality of insulation piercing members 40 extend from the bottom wall 116 into the opening 114. The insulation piercing members 40 may extend partially or completely along the width "W" of the body 102. In the exemplary embodiment, the insulation piercing members 40 extend along the width "W" of the body 102, as shown. Each insulation piercing member 40 may include an insulation piercing tip 40a that is configured and dimensioned to pierce or cut through an insulation jacket surrounding a conductor (e.g., an extension conductor) when the connector 100 is compressed or crimped so that a wire located within the conductor contacts the insulation piercing member 40 to create an electrical path between the connector 100 and the wire located within the conductor.

[0074] The second conductor portion 106 includes two side walls 130 and 132, a second opening 134 located between the side walls 130 and 132, and a bottom wall 136 located between the side walls 130 and 132, which defines a portion of the second opening 134. The thickness "T" of one or both of the walls 130 and 132 may be uniform along the length "L" of the wall, or the thickness of one or both of the walls 130 and 132 may be non-uniform along the length "L" of the wall. In the exemplary embodiment shown, the thickness of each wall 130 and 132 is non-uniform along the length of the wall. More specifically, the wall 130 has a first thickness "T1" along a first portion of the wall 130 and a second thickness "T2" along a second portion of the wall 130. As shown, in the exemplary embodiment, the first thickness "T1" is greater than the second thickness "T2". The transition region 130a from the first portion of the wall 130 to the second portion of the wall 130 may be a sharp transition region or a smooth transition region. The transition zone from the first portion of the wall 130 to the second portion of the wall 130 may also be referred to as the "transition" of the wall 130. A sharp transition may be an immediate change from a first thickness to a second thickness. For example, a sharp transition may be a substantially flat boss in the wall 130. A smooth transition may be a gradual increase or decrease in thickness from a first thickness "T1" to a second thickness "T2". As a non-limiting example, a smooth transition may be a tapered edge, a bevel edge, or a curved edge that gradually increases or decreases the thickness of the wall 130 from a first thickness "T1" to a second thickness "T2". The length "L1" of the first portion of the wall 130 extends from the top of the second extended conductor portion 106 to the transition zone 130a, and the length "L2" of the second portion of the wall 130 extends from the transition zone 130a to the end 130b of the wall 130. Similarly, the wall 132 has a first thickness "T1" along the first portion of the wall 132 and a second thickness "T2" along the second portion of the wall 132. As shown, in this exemplary embodiment, the first thickness "T1" is greater than the second thickness "T2". The transition zone 132a from the first portion of the wall 132 to the second portion of the wall 132 can be a sharp transition zone or a smooth transition zone. The transition zone from the first portion of the wall 132 to the second portion of the wall 132 can also be referred to as the "transition" of the wall 132. A sharp transition can be an immediate change from the first thickness to the second thickness. For example, a sharp transition can be a substantially flat boss in the wall 132. A smooth transition can be a gradual increase or decrease in thickness from the first thickness "T1" to the second thickness "T2". As a non-limiting example, a smooth transition can be a tapered edge, a bevel edge, or a curved edge that gradually increases or decreases the thickness of the wall 132 from the first thickness "T1" to the second thickness "T2". The length "L1" of the first portion of the wall 132 extends from the top of the second extended conductor portion 106 to the transition zone 132a, and the length "L2" of the second portion of the wall 132 extends from the transition zone 132a to the end 132b of the wall 132.Although the thicknesses "T1" and "T2" and lengths "L1" and "L2" of walls 130 and 132 are depicted as being the same or substantially the same for each wall, it is understood that the thickness and / or length of the walls may be different.

[0075] Continue to refer Fig.15 and Fig.16 , the second conductor portion 106 of the connector 100 also includes one or more insulation piercing members 40 extending from the inner surface of one or more walls 130, 132 and / or 136. In the illustrated embodiment, a plurality of insulation piercing members 40 extend from the bottom wall 136 into the opening 134. The insulation piercing members 40 may extend partially or completely along the width "W" of the body 102. In the exemplary embodiment, the insulation piercing members 40 extend along the width "W" of the body 102, as shown, and each includes an insulation piercing tip 40a that is configured and dimensioned to pierce or cut through an insulation jacket surrounding a conductor (e.g., an extension conductor) when the connector 100 is crimped such that a wire located within the conductor contacts the insulation piercing members 40 to create an electrical path between the connector 100 and the wire located within the conductor.

[0076] It should be noted that Figure 15-16 In the exemplary embodiment shown, the first conductor portion 104 and the second conductor portion 106 are substantially U-shaped structures in which the walls are shaped to receive conductors (e.g., extension conductors and / or branch conductors). The configuration of the openings 114 and 134 can vary depending on the size of the conductor to be crimped. As a non-limiting example, the conductor can be in the range of from about 250Kcmil-750Kcmil. It should also be noted that the insulation piercing member 40 can have different shapes. For example, the cross-sectional shape of the insulation piercing member 40 shown is triangular. However, the insulation piercing member can have different shapes and sizes that are configured and sized to pierce or cut through the insulation jacket of the wire surrounding the conductor, such as one or more tapered members and / or one or more members having a sharp tip. In addition, as in Fig.15a As shown in FIG. 1 , one or more of the sides of the insulation piercing member 40 may include serrations 40 b. The serrations allow the crimped wire bundle to cold flow into the grooves of the serrations and may improve conductivity and cable retention. Fig.15b As shown in FIG. 4 , one or more of the sides of the insulation piercing member 40 may include a smooth, flat surface 40c.

[0077] The connectors described in the present disclosure may be manufactured from one or more materials or combinations of materials, and may include, for example, copper, tinned copper, aluminum, steel, or similar metallic materials that deform appropriately when pressure is applied in standard mechanical, hydraulic, and pneumatic crimping tools and devices to crimp the conductor to the connector. In addition, the branch conductor openings disclosed and described herein may also include one or more insulation piercing members similar to the insulation piercing members described herein, which are configured and sized to pierce the insulating jacket surrounding the branch conductor. As described above, the insulation piercing members described herein may be made of the same or different material as the other parts of the compression connector, and, in particular, may be made of a harder material than the other parts of the compression connector to more easily penetrate the conductor.

[0078] Now go to Figure 17-Figure 23 , shows an exemplary embodiment of a die set that can be used to secure a conductor to Figure 1-Figure 16 Connector. Figure 17-Figure 18 In an exemplary embodiment of the present invention, the die set 200 includes a first die 210 and a second die 230. The first die 210 includes a tool connection portion 212 and a contact or impact portion 214, the tool connection portion is configured and sized to match with a tool, and the contact or impact portion is configured and sized to contact or impact a connector. For ease of description, the contact or impact portion 214 may also be referred to as a contact portion 214 herein. In this embodiment, the contact portion 214 has a pair of side walls 216 and a bottom wall 218 located between the side walls 216. The bottom wall 218 has a contact or impact surface 220, which is a forming surface in this embodiment. For ease of description, the contact or impact surface 220 may also be referred to as a contact surface 220 herein. The second die 230 includes a tool connection portion 232 and a contact or impact portion 234, the tool connection portion is configured and sized to match with a tool, and the contact or impact portion is configured and sized to contact or impact a connector. For ease of description, the contact or impact portion 234 may also be referred to as a contact portion 234 herein. In one embodiment, the contact portion 234 has a pair of side walls 236 and a bottom wall 238 located between the walls 236. In one embodiment, the bottom wall 238 has a contact or impact surface 240, which is a substantially flat surface in this embodiment. For ease of description, the contact or impact surface 240 may also be referred to herein as the contact surface 240.

[0079] refer to Figure 19-21 , shows another exemplary embodiment of the second mold 230 of the mold set. This exemplary embodiment is substantially similar to Fig.17230, such that the same reference numerals are used for the same features of the mold 230. Fig.17 The difference between the embodiments is the addition of a contact or impact plate 239. The second mold 230 includes a tool connection portion 232 and a contact portion 234, the tool connection portion being configured and sized to mate with a tool, the contact portion being configured and sized to contact or impact the connector. In one embodiment, the contact portion 234 has a pair of side walls 236 and a bottom wall 238 located between the side walls 236. The side walls have a first end face 235 and a second end face 237. The interior surfaces of the side walls 236 and the bottom wall 238 define an opening 233, which is configured and sized to receive a branch conductor portion of a connector, such as the branch conductor portion 24 of the connector 10, as will be described below with reference to FIG. Fig.24 In this embodiment, the bottom wall 238 has a substantially flat surface having one or more mounting holes 247, as in Fig.19 The contact or impact plate 239 can be secured to the bottom wall 238 of the second mold 230 via mounting holes 247 using fasteners 243. Figure 19-21 As shown in FIG, the contact plate 239 has one or more mounting apertures 245 that are positioned to align with one or more mounting holes 247 in the bottom wall 238 so that one or more fasteners (e.g., grub screws or set screws 243) can pass through the contact plate 239 and engage the one or more mounting holes 247. Figure 19-21 As shown in , the contact plate 239 may include one or more contact or impact rods 241 extending from the contact plate 239 and along the longitudinal axis of the contact plate. When the contact plate 239 is attached to the second mold 230, the contact or impact rods 241 extend at least partially along the bottom wall 238 of the second mold 230. For ease of description, the contact or impact rods 241 may also be referred to as contact rods 241 herein. Each of the one or more contact rods 241 may have, for example, a tapered side edge, a rounded side edge, or a straight edge. Figure 19-21 In the illustrated embodiment, one or more contact bars 241 have tapered side edges. One or more contact bars 241 are provided to improve deformation of the branch conductor portion of the connector contacted by the die and facilitate crimping of smaller sized wires to the connector.

[0080] Continue to refer Figure 19-21According to one embodiment, one or more of the side walls 236 include a stopper 244 extending from an end face 237 of the side wall 236 toward the opening 233. The stopper 244 may be integrally or monolithically formed into each side wall 236, or the stopper 244 may be fixed to the side wall 236 using, for example, fasteners or welding. The stopper 244 is configured to align a connector (e.g., connector 10) in the opening 233 so that one or more contact bars 241 of the contact plate 239 contact the branch conductor portion of the connector and ensure that the contact bar contacts the connector at a controlled position.

[0081] According to another exemplary embodiment of the present disclosure, a mold set is Fig. 22 and Fig.23 2 and is referred to as a die set 250. The die set 250 includes a first die 260 and a second die 280. The first die 260 includes a tool connection portion 262 and a contact or impact portion 264, the tool connection portion is configured and sized to match the tool, and the contact or impact portion is configured and sized to contact or impact the connector. For ease of description, the contact or impact portion 264 may also be referred to as the contact portion 264 herein. In this embodiment, the contact portion 264 has a pair of side walls 266 and a bottom wall 268 located between the side walls 266. The bottom wall 268 has a contact or impact surface 270, which is a forming surface in this embodiment. For ease of description, the contact or impact surface 270 may also be referred to as the contact surface 270 herein. The second die 280 includes a tool connection portion 282 and a contact or impact portion 284, the tool connection portion is configured and sized to match the tool, and the contact or impact portion is configured and sized to contact or impact the connector. For ease of description, the contact or impact portion 284 may also be referred to herein as the contact portion 284. According to the illustrated embodiment, the contact portion 284 has a pair of side walls 286 and a bottom wall 290 located between the side walls 286. According to the illustrated embodiment, the bottom wall 290 has a contact or impact surface 290, which is a substantially flat surface in this embodiment. For ease of description, the contact or impact surface 290 may also be referred to herein as the contact surface 290. Similar to the above reference Figure 19-21 In the depicted embodiment, although not shown, the bottom wall 288 may have a substantially planar surface with one or more mounting holes 247 for mounting the contact or strike plate 239 using, for example, flat head machine screws or other fasteners. Fig. 22 and Fig.23 The shaped contact or impact surface 270 depicted in FIG. 1 includes two angled surfaces 270a and 270b extending from the side wall 286. Thus, the die set 250, and in particular the first die 260, may be particularly suitable for crimping compression connectors (such as in the above-mentioned Figure 5-Figure 14), the compression connector having branch openings along the side or lower side of the compression connector 10.

[0082] When crimping a conductor to a connector (e.g., connector 10), it may be challenging for a technician to hold the tool, conductor, and connector in place between the dies. To reduce the burden on the technician, a wire clamp may be used to temporarily hold one or more branch conductors in one or more branch conductor openings in the connector and / or to temporarily hold the connector in place on the first die or the second die of the die set. The wire clamp according to an exemplary embodiment of the present disclosure is Figure 24-Figure 30 , and may be referred to herein as a wire clamp 350 or simply a clamp 350. In the illustrated embodiment, the wire clamp 350 is used to temporarily retain one or more branch conductors 720 in one or more branch conductor openings 50 in the connector 10 during the crimping process, and may also be used to temporarily fix the connector 10 in place on the second die 230 of the die set 200. The wire clamp 350 has a body 352 and one or more biasing arms 354 extending from the body 352. In the exemplary embodiment, the body 352 is a rectangular member having a top side 356, a bottom side 358, an inner side 360 ​​and an outer side 362, a first end 364 and a second end 366. The body 352 is substantially hollow with one or more partition walls 368 that may extend from the top side 356 to the bottom side 358 and at least partially from the inner side 360 ​​to the outer side 362. The top side 356, the bottom side 358, the inner side 360, the outer side 362, the first end 364, the second end 366 and one or more partitions 368 define one or more wire compartments 370, which are accessible from the inner side 360 ​​or the outer side 362 or from the inner side 360 ​​and the outer side 362. In each wire compartment 370, there is one or more wire clamps 372, which are used to clamp the bare wires of the branch conductor 720, as in Fig.28 One or more wire grippers 372 may extend from the top side 356 into the wire compartment 370 and / or from the bottom side 358 into the wire compartment 370. In another embodiment, one or more wire grippers 372 may additionally or alternatively extend from a baffle 368 or a plurality of baffles 368 into the compartment 370.

[0083] exist Figure 24-Figure 30In the illustrated embodiment, the top side 356, the bottom side 358, the inner side 360, the outer side 362, the first end 364, the second end 366, and one or more partitions 368 define four wire compartments 370. Each wire compartment 370 has two wire grippers 372, wherein a first wire gripper extends from an inner wall of the top side 356 and a second wire gripper extends from an inner wall of the bottom side 358. As shown, at rest, the wire grippers 372 have a gap "G" ( Fig.26 ), the gap is sufficient to allow the bare wire of the branch conductor 720 to pass between them and to allow the wire clamp 372 to flex as the bare wire of the branch conductor 720 continues to pass between the wire clamps 372. Fig.28 When the wire clamp 350 is inserted into the wire clamp 350 in the direction indicated by the middle arrow "B", the wire clamp 372 can be flexed to allow the bare wire of the branch conductor 720 to enter the wire compartment 370 from the inner side 360 ​​of the main body 352. The distal end portion 372a of the wire clamp 372 effectively clamps the bare branch conductor wire and limits or prevents the bare wire of the branch conductor 720 from being pulled out from the inner side 360 ​​of the main body 352.

[0084] As in Fig.29 and Fig.30 As shown in FIG. 1 , when the wire clamp 350 and the branch conductor portion of the connector (e.g., the branch conductor portion 24 of the connector 10) are positioned into the opening 233 of the mold of the mold set (e.g., the second mold 230 of the mold set 200), the biasing arm 354 of the wire clamp 350 contacts the bottom wall 238 of the second mold 230 to bias the body 352 toward the stopper 244 extending from the side wall 236 of the mold 230 to provide resistance to the connector exiting the second mold 230. The biasing arm 354 can also provide resistance to the side of the contact plate 239, thereby providing resistance to the connector exiting the mold. The biasing arm 354 can also apply force to the body 352 in the direction of the arrow "T", and when the top side 356 of the body 352 contacts the stopper 244, the wire clamp 350 is held in place between the stopper 244 and the bottom wall 238 of the mold 230. Thus, the wire clamp may hold the connector 10 and / or branch conductors in place within the opening 233 of the second die 230 prior to the crimping operation of the tool.

[0085] Reference now Figure 31-Figure 36, the use of the die set 200 to fix the extension conductor and the branch conductor to the connector 10 will be described. First, the rear portion 212 of the first die 210 of the die set 200 and the rear portion 232 of the second die 230 of the die set 200 are matched with the working head of a standard crimping tool (not shown) (such as a hydraulic 12-ton or 15-ton handheld power tool). An example of a hydraulic power tool is PAT46-18V manufactured by Burndy, LLC. Then, the connector 10 is placed between the first and second dies 210, 230 so that the bottom surface of the branch conductor portion 24 rests on the contact surface 240 of the second die 230, as shown. The extension conductor 700 is positioned in the extension opening 30 of the connector 10, and the end portion of the branch conductor 720 is stripped and positioned in the branch opening 50 of the connector 10. It should be noted that one or more of the extension conductor 700 and / or the branch conductor 720 can be positioned in the connector 10 before or after the connector is positioned in the die. When the tool is actuated, the first mold 210 moves toward the second mold 230 so that the walls 26 and 28 of the connector 10 contact the contact surface 220 of the first mold 210. It should be noted that the second mold 230 can move toward the first mold 210, or the molds 210 and 230 can move toward each other. As the first mold 210 continues to move toward the second mold 230, the compressive force applied to the mold by the tool is transmitted to the connector 10 so that the walls 26 and 28 of the connector 10 follow the shape of the contact surface 220 of the first mold 210, as in Fig.32 and Fig.33 As the first die 210 continues to move toward the second die 230, the compressive force applied by the tool to the die drives the end 26b of the wall 26 and the end 28b of the wall 28 to pierce the insulating jacket 702 of the wire surrounding the extension conductor 700, as shown in Fig.34 . The compressive force applied by the tool to the dies 210, 230 also drives the ends of one or more insulation piercing members 40 of the connector 10 through the insulating jacket 702 of the wire surrounding the extension conductor 700. When the tool compresses the connector 10, the ends 26b of the wall 26, the ends 28b of the wall 28, and the insulation piercing members 40 contact the wire of the extension conductor 700, creating a conductive path between the extension conductor 700 and the connector 10. In addition, when the tool compresses the connector 10, due to the unique geometric relationship between the connector 10 and the die set 200, the branch opening 50 receives a direct compressive load, causing the branch opening 50 to deform or compress to crimp the branch conductor 720 to the connector 10. More specifically, as Figure 32-Figure 34, the raised semicircular area or ridge 50e of the connector 10 contacts the contact surface 240, directing the compressive force directly to the branch opening 50 of the connector 10, in which the branch conductor 720 is located, and thus firmly crimping the branch conductor 720 to the connector 10. After the crimping process is completed, the conductors 700 and 720 disposed in their respective openings will be fixed in place, i.e., crimped to the connector 10.

[0086] As described above, according to an embodiment of the present disclosure, one or more insulation piercing members may be provided on the connector 10 . Fig.35 An embodiment is depicted in which only one insulation-piercing member 40 is provided. The insulation-piercing member 40 can be made as a single integral or unitary structure with the connector 10. Alternatively, the insulation-piercing member 40 can be part of a separate insulation-piercing assembly 42 component that can be mounted or secured to the body of the connector 10. As an example, the insulation-piercing assembly 42 has a body having one or more insulation-piercing members 40 extending from an upper surface of the body and one or more mounting ribs 46 extending from a bottom surface of the body. The one or more mounting ribs 46 are configured and dimensioned to mate with one or more mounting slots 36 located in the bottom wall 32 of the body of the connector 10.

[0087] refer to Fig.36 After the crimping process is completed, the crimping tool is opened and the pressure is released by moving the first die 210 away from the second die 230 so that the crimped connector 10a can be removed. It should be noted that the second die 230 can be moved away from the first die 210, or the dies 210 and 230 can be moved away from each other. Fig.36 The crimp connector 10 a depicted in FIG. 1 provides a secure and durable mechanical and electrical connection to the extension conductor 700 and the branch conductor 720 .

[0088] According to another illustrative embodiment of the present disclosure, a mold set is Fig.37 , and is referred to as die set 300. Fig.37In an exemplary embodiment of the present invention, the mold set 300 includes a first mold 310 and a second mold 320. The first mold 310 includes a rear portion 312 and a front portion 314, the rear portion is configured and sized to match the tool, and the front portion is configured and sized to contact the connector. In this embodiment, the front portion 314 has a pair of side walls 316 and a bottom wall 318 located between the side walls 316. The bottom wall 318 has a contact surface 320, which is a forming surface in this embodiment. The second mold 330 includes a rear portion 332 and a front portion 334, the rear portion is configured and sized to match the tool, and the front portion is configured and sized to contact the connector. In this embodiment, the front portion 334 has a pair of side walls 336 and a bottom wall 338 located between the walls 336. The bottom wall 338 has a contact surface 340, which is a forming surface in this embodiment.

[0089] Will refer to Figure 38-Figure 42 Describe the use of the above reference Fig.37 The mold assembly 300 described above fixes the first conductor and the second conductor to the above reference Fig.15 and Fig.16The process of the connector 100 described above. First, the rear portion 312 of the first die 310 of the die set 300 and the rear portion 332 of the second die 330 of the die set 300 are matched with the working head of a standard crimping tool (not shown) (such as a hydraulic 12-ton or 15-ton hand-held power tool). An example of a hydraulic power tool is the PAT46-18V manufactured by Burndy, LLC. The first conductor (which can be an extension conductor 700 or a branch conductor 720) is positioned between the walls 110 and 112 of the first conductor portion 104 of the connector 100, and the second conductor (which can be an extension conductor 700 or a branch conductor 720) is positioned between the walls 130 and 132 of the second conductor portion 106 of the connector 100. Then, the connector 100 and the conductors 700, 720 are placed between the first and second dies 310, 330. In this way, the walls 110 and 112 of the first conductor portion 104 are positioned between the walls 316 of the first die 310, and the walls 130 and 132 of the second conductor portion 106 are positioned between the walls 336 of the second die 330. When the tool is actuated, the first die 310 moves toward the second die 330, so that the walls 110 and 112 of the first conductor portion 104 of the connector 100 will contact the contact surface 320 of the first die 310. Similarly, when the first die 310 moves toward the second die 330, the walls 130 and 132 of the second conductor portion 106 of the connector 100 will contact the contact surface 340 of the second die 330. It should be noted that the second die 330 can move toward the first die 310, or the dies 310 and 330 can move toward each other. As the first die 310 continues to move toward the second die 330, the compressive force applied by the tool to the die is transmitted to the connector 100, causing the walls 110 and 112 of the first conductor portion 104 to conform to the shape of the contact surface 320 of the first die 310, as in Fig.39 and Fig.40 In addition, the compressive force applied by the tool to the mold causes the walls 130 and 132 of the second conductor portion 106 to conform to the shape of the contact surface 340 of the second mold 330, as also seen in FIG. Fig.39 and Fig.40 As seen in Fig.41 and Fig.42As depicted in FIG. 1 , as the first die 310 continues to move toward the second die 330, the compressive force applied to the die by the tool drives the end 110b of the wall 110 and the end 112b of the wall 112 to pierce the insulating jacket of the conductor (e.g., the insulating jacket 702) and penetrate sufficiently to form good electrical contact with the wires of the first conductors 700, 720. The compressive force applied to the die 310, 330 by the tool also drives the end of the insulation piercing member 40 of the first conductor portion 104 of the connector 100 to penetrate the insulating jacket of the conductor (e.g., the insulating jacket 702) and penetrate sufficiently to form good electrical contact with the wires of the first conductors 700, 720. In addition, the compressive force applied to the die by the tool drives the end 130b of the wall 130 and the end 132b of the wall 132 to pierce the insulating jacket (e.g., the insulating jacket 702) and penetrate sufficiently to form good electrical contact with the wires of the second conductors 700, 720. The compressive force applied by the tool to the dies 310 , 330 also drives the tip of the insulation piercing member 40 of the second conductor portion 106 of the connector 100 through the insulating jacket (e.g., insulating jacket 702 ) and penetrates sufficiently to make good electrical contact with the wires of the second conductors 700 , 720 .

[0090] As described above with reference to other embodiments of the present disclosure, one or more insulation piercing members may be provided on the connector 100. For example, Fig.42 An embodiment is depicted in which only one insulation piercing member 40 is provided in the first conductor portion 104 of the connector 100 and one insulation piercing member 40 is provided in the second conductor portion 106. The insulation piercing member 40 can be made as a single integral or unitary structure with the connector 100. Alternatively, the insulation piercing member 40 can be part of a separate insulation piercing assembly 42 that can be mounted or secured to the body of the connector 100. As an example, the insulation piercing assembly 42 has a body having one or more insulation piercing members 40 extending from an upper surface of the body and one or more mounting ribs 46 extending from a bottom surface of the body. The one or more mounting ribs 46 are configured and dimensioned to mate with one or more mounting slots 36 located in a bottom wall of the body of the connector 100.

[0091] After the crimping process is completed, the crimping tool is opened and the pressure is released by moving the first die 310 away from the second die 330 so that the crimped connector 100a can be removed. It should be noted that the second die 330 can be moved away from the first die 310, or the dies 310 and 330 can be moved away from each other. The crimped connector 100a provides a strong and durable mechanical and electrical connection to the extension conductor 700 and the branch conductor 720.

[0092] The present disclosure relates to insulating jackets disposed on conductors and piercing such insulating jackets. It should be noted that conductors are typically provided with insulating jackets that, in addition to providing insulation, provide protection for additional insulation provided between the insulating jacket and the conductor. As used herein, the phrases "insulating jacket" or "jacket" are intended to include any of various types of coverings surrounding a conductor, including but not limited to the insulating jacket and any additional insulation that may be present between the insulating jacket and the conductor. "Insulating jacket" may also refer to a separate insulating layer surrounding a conductor.

[0093] For purposes of this disclosure, the term "compressible" refers to being ductile or capable of permanent deformation when sufficient force is applied. The terms "compress," "compressed," and "compressing" refer to an object being subjected to a generally inwardly directed force, which may cause the object to be compacted. For clarity, portions or regions of an object may also be subjected to different types of stresses, such as compression, tension, shear, and / or bending.

[0094] It should be noted that each mold of each mold group contemplated by the present disclosure can be made into a single one-piece or integral structure, so that the tool connection portion and the contact or impact portion are a single structure. In another embodiment, each mold of each mold group contemplated by the present disclosure can be made of multiple structures, so that the tool connection portion and the contact or impact portion are connected together to form a mold. As shown in all the accompanying drawings, the same figure numbers represent the same or corresponding parts. Although illustrative embodiments of the present disclosure have been described and shown above, it should be understood that these are exemplary embodiments of the present disclosure and should not be considered restrictive. Additions, deletions, substitutions and other modifications may be made without departing from the spirit or scope of the present disclosure. Therefore, the present disclosure should not be considered to be limited by the foregoing description.

Claims

1. An electrical compression connector for connecting a plurality of conductors, the compression connector comprising: a connector body made of a compressible material, the connector body being adapted to be inserted into a crimping tool having two opposing die surfaces for compressing the connector body, the connector body comprising a first conductor portion and a second conductor portion; wherein the first conductor portion comprises: a pair of side walls, the pair of side walls comprising a first side wall and a second side wall, the pair of side walls being connected by a bottom wall; and a first conductor opening located between the pair of side walls and the bottom wall; and at least one insulation piercing member; and The second conductor portion includes at least one second conductor opening, and the at least one second conductor opening at least partially extends through the connector body.

2. The electrical compression connector according to claim 1, wherein: The at least one second conductor opening extends at least partially across a width of the connector body.

3. The electrical compression connector of claim 2, wherein: The at least one second conductor opening extends completely across the width of the connector body.

4. The electrical compression connector of claim 1, further comprising a raised ridge located on the connector body adjacent the at least one second conductor opening.

5. The electrical compression connector of claim 1, further comprising a wire clamp adapted to retain at least one second conductor in the at least one second conductor opening.

6. The electrical compression connector of claim 1, wherein: The second conductor portion includes a hinge portion adjacent to the second conductor opening and the connector body, such that when the crimping tool applies force to the connector body, the hinge portion of the connector body first bends to secure one or more second conductors positioned in the at least one second conductor opening to the connector body, and when the crimping tool applies additional force to the connector body, the connector body is compressed around the at least one first conductor positioned in the first conductor opening.

7. The electrical compression connector of claim 1, wherein: The distal end portion of each of the pair of side walls is adapted to pierce an insulation covering the first conductor when the crimping tool applies a force to the connector body.

8. The electrical compression connector of claim 1, wherein: The at least one insulation piercing member extends from at least one of the first side wall, the second side wall, and the bottom wall into the first conductor opening.

9. The electrical compression connector of claim 8, wherein: The at least one insulation piercing member is integrally and monolithically formed to at least one of the first side wall, the second side wall, and the bottom wall.

10. The electrical compression connector of claim 8, wherein: The at least one insulation piercing member is attachable to at least one of the first side wall, the second side wall, and the bottom wall.

11. An electrical compression connector for connecting a plurality of conductors, the compression connector comprising: a connector body made of a compressible material, the connector body being adapted to be inserted into a crimping tool having two opposing die surfaces for compressing the connector body, the connector body having a first conductor portion and a second conductor portion; wherein the first conductor portion comprises: a pair of side walls, the pair of side walls comprising a first side wall and a second side wall, the pair of side walls being connected by a bottom wall; and a first conductor opening located between the pair of side walls and the bottom wall; and at least one insulation piercing member; and The second conductor portion includes at least one second conductor opening extending along at least one of the side walls of the connector body.

12. The electrical compression connector of claim 11, wherein: The second conductor opening includes a hinge portion adjacent to the second conductor opening and the connector body, so that when the crimping tool applies force to the connector body, the hinge portion of the connector body first bends to secure one or more second conductors positioned in the at least one second conductor opening to the connector body, and when the crimping tool applies additional force to the connector body, the connector body is compressed around the at least one first conductor positioned in the first conductor opening.

13. The electrical compression connector of claim 11, wherein: The at least one insulation piercing member extends from at least one of the first side wall, the second side wall, and the bottom wall into the first conductor opening.

14. The electrical compression connector of claim 13, wherein: The at least one insulation piercing member is integrally and monolithically formed to at least one of the first side wall, the second side wall, and the bottom wall.

15. The electrical compression connector of claim 13, wherein: The at least one insulation piercing member is attachable to at least one of the pair of first side walls, the second side wall, and the bottom wall.

16. The electrical compression connector of claim 11, further comprising a wire clamp adapted to retain at least one second conductor in the at least one second conductor opening.

17. The electrical compression connector of claim 11, wherein: The distal end portion of each of the pair of side walls is adapted to pierce an insulation covering the first conductor when the crimping tool applies a force to the connector body.

18. An electrical compression connector for connecting a plurality of conductors, the compression connector comprising: a connector body made of a compressible material, the connector body being adapted to be inserted into a crimping tool having two opposing die surfaces for compressing the connector body, the connector body having a first conductor portion and a second conductor portion; wherein the first conductor portion comprises: a pair of side walls, each of the pair of side walls comprising a first portion having a first thickness and a second portion having a second thickness different from the first thickness, and connected by a bottom wall; and a first conductor opening located between the pair of side walls and the bottom wall; and Wherein, the second conductor portion includes at least one second conductor opening.

19. The electrical compression connector of claim 18, wherein: The first portion is thicker than the second portion.

20. The electrical compression connector of claim 19, wherein: The second portion includes a distal end portion.

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