Modular connection system and method

Abstract

A modular connection system, in particular a termination assembly for a heating cable, includes a first assembly connected to a first conductor of the heating cable and including a first cam rotatable about a first base frame to contact the first conductor from a first side and a second cam rotatable about the first base frame to contact the first conductor from a second side. The second assembly is connected to a second conductor of the heating cable and includes a third cam rotatable about a second base frame to contact the second conductor from the first side and a fourth cam rotatable about the second base frame to contact the second conductor from the second side. Each cam includes a tooth configured to pierce a sheath and core material of the heating cable when the respective cam is rotated, and a first end portion adjacent the tooth to contact the respective conductor. The invention further relates to a modular connection method.

Description

[0001] Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 602,940, filed Nov. 27, 2023, and U.S. Provisional Patent Application No. 63 / 602,918, filed Nov. 27, 2023, under 35 U.S.C § 119, the entire contents of which are incorporated herein by reference. Background of the Invention

[0003] Elongated cables such as power cables or heating cables often must be electrically connected to another elongated cable or a power source, for example, via an electrical plug. Connecting one such cable to a connector or plug may require lengthy and process-sensitive components as well as special tools to ensure a good electrical connection. For example, if such a connection is made in the field, the cable can be cut to an appropriate length for a particular application, and multiple layers along the cut end are stripped to expose the cable conductors. Stripping these layers can be difficult, may require special tools, and may not result in a completely "clean" conductor, making it difficult to achieve a good electrical connection with the plug. Additionally, the time required to strip the cable and assemble the plug can be relatively long.

[0004] In some cable applications, to address these inefficiencies, insulation displacement connector (IDC) systems have been developed. For example, a fixture for an IDC can include a wire guiding module having a channel for receiving a cable. When the cable is inserted into the channel and the mating IDC module and wire guiding module are engaged, the cable is pushed against teeth on the IDC such that the teeth pierce the cable to make electrical contact with the conductors.

[0005] However, current IDC systems require different components for different connection types. Many systems are also only suitable for factory-set terminations rather than for connections made in the field. Additionally, many IDC systems are too bulky for under-insulated installations, such as applications where insulation is required on the cable and the components to which the cable is installed. Accordingly, there is a need for a more simplified cable connection system that can be used in the field. Summary of the Invention

[0006] Some embodiments provide a termination assembly for a heating cable, the heating cable including a first conductor, a second conductor, a core material on the first and second conductors, and a sheath on the core material. The termination assembly includes a first component and a second component. The first component is connected to the first conductor of the heating cable and includes a first base having a first channel for receiving the heating cable. The first component further includes a first cam and a second cam, the first cam being rotatable about the first base to contact the first conductor from a first side when the first cam is in a closed position, and the second cam being rotatable about the first base to contact the first conductor from a second side when the second cam is in a closed position. The second component is connected to the second conductor of the heating cable and includes a second base having a second channel for receiving the heating cable. The second component further includes a third cam and a fourth cam, the third cam being rotatable about the second base to contact the second conductor from a first side when the third cam is in a closed position, and the fourth cam being rotatable about the second base to contact the second conductor from a second side when the fourth cam is in a closed position. Each of the first cam, the second cam, the third cam, and the fourth cam includes teeth and a first end portion, the teeth being configured to pierce the sheath and the core material when the respective cam rotates, and the first end portion being adjacent to the teeth to contact the respective conductor when the respective cam is in the closed position.

[0007] Some embodiments provide a method of terminating a heating cable via a termination assembly. The method includes aligning a first conductor of the heating cable with a first component and aligning a second conductor of the heating cable with a second component. The method further includes rotating a first cam of the first component from an open position to a closed position to cause the teeth of the first cam to pierce the sheath and the core material of the heating cable and to allow a first end portion of the first cam adjacent to the teeth to contact the first conductor from a first side of the heating cable, and rotating a second cam of the first component from an open position to a closed position to cause the teeth of the second cam to pierce the sheath and the core material of the heating cable and to allow a first end portion of the second cam adjacent to the teeth to contact the first conductor from a second side of the heating cable. The method further includes rotating a third cam of the second component from an open position to a closed position to cause the teeth of the third cam to pierce the sheath and the core material of the heating cable and to allow a first end portion of the third cam adjacent to the teeth to contact the second conductor from a first side, and rotating a fourth cam of the second component from an open position to a closed position to cause the teeth of the fourth cam to pierce the sheath and the core material of the heating cable and to allow a first end portion of the fourth cam adjacent to the teeth to contact the second conductor from a second side.

[0008] Some embodiments provide a termination assembly for a heating cable, the heating cable including a first conductor, a second conductor, a core material on the first and second conductors, and a sheath on the core material. The termination assembly includes a first assembly and a second assembly. The first assembly is connected to the first conductor of the heating cable and includes a first base frame, a first cam, and a first contact member. The first base frame includes a first channel for receiving the heating cable. The first cam is rotatable about the first base frame to contact the first conductor from a first side when the first cam is in a closed position. The first contact member is coupled to the first base frame to contact the first conductor from a second side when the first cam is in the closed position. The second assembly is connected to the second conductor of the heating cable and includes a second base frame, a second cam, and a second contact member. The second base frame includes a second channel for receiving the heating cable. The second cam is rotatable about the second base frame to contact the second conductor from a first side when the second cam is in a closed position. The second contact member is coupled to the second base frame to contact the second conductor from a second side when the second cam is in the closed position. Each of the first cam and the second cam includes teeth and a first end portion. The teeth are configured to pierce the sheath and the core material when the respective cam rotates. The first end portion is adjacent to the teeth to contact the respective conductor when the respective cam is in the closed position. Additionally, each of the first contact member and the second contact member includes an extension configured to pierce the sheath and the core material when the respective cam rotates, thereby pushing the respective conductor onto the respective contact member. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is an isometric cross-sectional view of a self-regulating heater cable.

[0010] Figure 2 is an isometric view of a cable coupled to an end termination plug according to some embodiments.

[0011] Figure 3 is an isometric view of a cable having an end termination plug and an end seal module configured to be coupled to the end termination plug according to some embodiments.

[0012] Figure 4 is an isometric view of a base module configured to be coupled to an end termination plug according to some embodiments.

[0013] Figure 5 is Figure 4 an isometric view of a base module that is to be coupled between two cables to form an electrical connection or splice.

[0014] Figure 6 is Figure 4 an isometric view of a base module that is to be coupled between three cables to form an electrical T-piece or tee splice.

[0015] Figure 7 Is Figure 4 An isometric view of a base module that is to be connected between four cables to form an X-shaped branch or an X-shaped joint.

[0016] Figure 8 A side view of a heating cable connected to a power cable via a base module, according to some embodiments.

[0017] Fig. 9 A side view of a heating cable, according to some embodiments, that includes an end termination plug connected to a power cable that includes a power termination plug.

[0018] Fig.10 A side view of a heating cable, according to some embodiments, that includes an end termination plug that is connected to a power termination plug of a tracing system component.

[0019] Fig.11 An isometric view of a cable having an end termination plug and a lighting end seal module, according to some embodiments, the lighting end seal module configured to be connected to the end termination plug.

[0020] Fig.12 An isometric view of two cables having end termination plugs and attachment modules, according to some embodiments, the attachment modules configured to be connected to the end termination plugs.

[0021] Fig.13 A schematic view of two cables having end termination plugs and attachment modules, according to some embodiments, the attachment modules configured to be connected to the end termination plugs.

[0022] Fig.14 A cross-sectional view of an exemplary blade configuration used in an end termination plug for a conductor for connection to a heating cable, according to some embodiments.

[0023] Fig.15 Is Fig.17 A partial isometric view of the blade configuration and a heating cable before insertion into a device.

[0024] Fig.16 Is Fig.17 An isometric view of the blade configuration and a heating cable before insertion into a device.

[0025] Fig.17 Is Fig.17 An isometric view of the blade configuration with a heating cable inserted therein.

[0026] Fig.18Isometric view of an exemplary spike configuration used in an end termination plug for a conductor for connection to a heating cable, according to some embodiments.

[0027] Fig.19 Is Fig.18 Isometric view of the spike configuration with a heating cable inserted therein.

[0028] Fig. 20 Is before electrical connection to the inserted heating cable Fig.18 Cross-sectional view of the spike configuration.

[0029] Fig.21 Is after electrical connection to the inserted heating cable Fig.18 Cross-sectional view of the spike configuration.

[0030] Fig. 22 Partial isometric view of a stamping configuration used in an end termination plug for a conductor for connection to a heating cable, according to some embodiments.

[0031] Fig.23 Is Fig. 22 Cross-sectional view of the stamping configuration.

[0032] Fig.24 Is Fig. 22 Isometric view of the stamping configuration with a heating cable inserted therein.

[0033] Fig.25 Isometric view of a cam configuration used in an end termination plug for a conductor for connection to a heating cable, according to some embodiments.

[0034] Fig.26 Is Fig.25 Isometric view of the cam configuration with a heating cable inserted therein.

[0035] Fig. 27 Is before electrical connection to the inserted heating cable Fig.25 Of the cam configuration along Fig.26 Cross-sectional view taken along line 27-27 in

[0036] Fig.28 Is after electrical connection to the inserted heating cable Fig.25 Cross-sectional view of the cam configuration.

[0037] Fig.29 Is Fig.25 Of the cam configuration along Fig.25 Cross-sectional view taken along line 29-29 of

[0038] Fig.30Is an isometric view of a wide cam configuration used in an end termination plug for a conductor for connection to a heating cable according to some embodiments.

[0039] Fig.31 Is Fig.30 A partial isometric view of the wide cam configuration with a heating cable inserted therein.

[0040] Fig.32 Is Fig.30 A cross-sectional view of the wide cam configuration of Fig.31 taken along line 32 - 32 of

[0041] Fig.33 Is an isometric view of a side cam configuration used in an end termination plug for a conductor for connection to a heating cable according to some embodiments.

[0042] Fig.34 Is Fig.33 A partial isometric view of the side cam configuration with a heating cable inserted therein.

[0043] Fig.35 Is Fig.33 A cross-sectional view of the side cam configuration of Fig.33 taken along line 35 - 35 of

[0044] Fig.36 Is an isometric view of an inclined cam configuration used in an end termination plug for a conductor for connection to a heating cable according to some embodiments.

[0045] Fig.37 Is Fig.36 A partial isometric view of the inclined cam configuration.

[0046] Fig.38 Is Fig.36 A cross-sectional view of the inclined cam configuration of Fig.37 taken along line 38 - 38, including the cable.

[0047] Fig.39 Is an isometric view of a lateral cam configuration used in an end termination plug for a conductor for connection to a heating cable according to some embodiments.

[0048] Fig.40 Is Fig.39 A partial isometric view of the lateral cam configuration with a heating cable inserted therein.

[0049] Fig.41 Is Fig.39 A cross-sectional view of the lateral cam configuration of Fig.39 taken along line 41 - 41 of

[0050] Fig.42Is an isometric view of a split cam construction used in an end termination plug for a conductor for connection to a heating cable.

[0051] Fig.43 Is Fig.42 A partial isometric view of the split cam construction.

[0052] Fig.44 Is Fig.42 An isometric view of a frame assembly of the split cam construction, including an inclined serrated extension.

[0053] Fig.45 Is according to some embodiments Fig.42 An isometric view of another frame assembly of the split cam construction, including a pin extension.

[0054] Fig.46 Is according to some embodiments Fig.42 An isometric view of another frame assembly of the split cam construction, including a lateral serrated extension.

[0055] Fig.47 Is according to some embodiments Fig.42 An isometric view of another frame assembly of the split cam construction, including an insulation displacement connector extension.

[0056] Fig.48 Is according to some embodiments Fig.42 An isometric view of another frame assembly of the split cam construction, including a single serrated extension.

[0057] Fig.49 Is according to some embodiments Fig.42 An isometric view of another frame assembly of the split cam construction, including a longitudinal serrated extension. Detailed Description

[0058] Before explaining in detail any embodiments of the present invention, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," or "having" and variations thereof herein is intended to cover the items listed thereafter and equivalents thereof as well as additional items. Unless otherwise specified or limited, the terms "mounted," "connected," "supported," and "coupled" and variations thereof are used broadly and encompass both direct and indirect mounting, connection, support, and coupling. Further, "connected" and "coupled" are not limited to physical or mechanical connection or coupling.

[0059] The following discussion is presented to enable a person skilled in the art to make and use embodiments of the present invention. Various modifications to the illustrated embodiments will be apparent to those skilled in the art, and the general principles herein can be applied to other embodiments and applications without departing from the embodiments of the present invention. Thus, the embodiments of the present invention are not intended to be limited to the embodiments shown, but rather to the broadest scope consistent with the principles and features disclosed herein. The following detailed description will be read with reference to the accompanying drawings, in which like elements in different drawings have like reference numerals. The drawings are not necessarily to scale, and they depict selected embodiments and are not intended to limit the scope of the embodiments of the present invention. Those skilled in the art will recognize that the examples provided herein have many useful alternatives and fall within the scope of the embodiments of the present invention.

[0060] Figure 1 An exemplary self-regulating heating cable 10 is shown. The cable 10 can include parallel conductor wires 12, a core 14, a primary sheath 16, an optional barrier layer 18, a ground plane 20 (such as but not limited to a wire braid, a wire wrap, and / or a foil wrap), and a final sheath 22. The conductor wires 12 can be made of nickel-plated copper (or tin-plated copper or another conductive material) and are surrounded by the core 14 (such as a semiconductive polymer material). For example, the core 14 can be extruded over and between the conductor wires 12 such that the conductor wires 12 are embedded within and separated by the core 14. In this way, the core 14 is considered to have an integral design. However, other self-regulating heating cables 10 can include separate, non-integral cores 14 surrounding the conductor wires 12. The core 14 can be surrounded by the primary sheath 16, which can be an electrically insulating polymer compound. On top of the primary sheath 16, the optional barrier layer 18 can serve as a barrier for the internal components (e.g., protecting them from water and / or chemicals). The barrier layer 18 can be a metal foil, such as aluminum foil. The ground plane 20 (e.g., tin-plated copper or other metal braid or wrap) then surrounds the aluminum foil 18 or the primary sheath 16 and serves as a ground path. On top of the ground plane 20, the final sheath 22 serves as a mechanical protection layer.

[0061] Typically, heating cables can be terminated to connect to a power source, another cable or multiple cables, a light, an end seal, and so on. For such connections, the end portion of the heating cable can be completely stripped back to expose the conductors 12 so that they can be electrically connected to a power source, the conductors of another cable, a light, or electrically terminated thereto. This can be done on-site or in the factory. Additionally, there are some systems for heating cables that include insulation displacement technology to allow connections without complete stripping or special tools. Such systems include specific connectors for each type of connection, e.g., T-branch connectors, single cable-to-cable connectors, X-branch connectors, power connectors connected to a single cable, power connectors connected to two cables, power connectors and T-branches, and so on. However, these systems are installed in the factory according to user specifications. For example, lengths of heating cables with specific factory-installed terminals or connectors are available, although such terminals are not fabricated on-site.

[0062] Some embodiments can provide a low-profile modular connection system that includes: a universal termination plug that can be installed on-site and provides a secure electrical connection to a cable (such as a self-regulating heating cable or a power cable); and various modules that can be directly coupled to the termination plug in the factory or on-site. Thus, the user can customize their connection by simply combining the modules and / or plugs required for their specific installation. An exemplary module includes a base module that allows in-line connection of any number of heating cables to create a power connection, a splice, or a branch circuit. Other exemplary modules include accessory modules, such as an end seal accessory module, a sensor accessory module, a broadcast accessory module, a light accessory module, or a combined accessory module, and so on. All of these modules include a unified mating connector that inserts into the universal termination plug.

[0063] For example, Figure 2 An example heating cable 10 including a universal termination plug 30 is shown in accordance with some embodiments. The universal termination plug 30 can provide a reliable electrical connection to the heating cable 10 and can be connected to the end of the cable 10. In some applications, the plug 30 can be coupled to the end of the heating cable 10 in a factory setting. In other applications, the plug 30 can be coupled to the end of the heating cable 10 on-site. Additionally, it should be noted that while the plug 30 may be referred to herein in relation to the heating cable 10 and more particularly to the self-regulating heating cable 10, the plug 30 and all other concepts discussed herein can also be applied to power cables.

[0064] Still referring to Figure 2 , the plug 30 can include an outer housing 32 that includes a body portion 34 and an end plug portion 36. The outer housing 32 (e.g., within the body portion 34) can include internal components that are electrically connected to one or more conductors 12 within the cable 10 ( Figure 2(not shown). Thus, based on these internal components, one type of plug 30 can be adapted to secure such an electrical connection to the conductor 12 within the heating cable 10, while another type of plug 30 can be adapted to secure such an electrical connection to one or more conductors within a power cable. However, externally, both types of plugs 30 can include a similar outer housing 32 or at least a similar end plug portion 36 with the same coverage.

[0065] In some embodiments, the plug 30 can include a connector 38 at the end plug portion 36. For example, the connector 38 can be a male plug connector. In other embodiments, the connector 38 can be a female socket connector. Additionally, when a mating plug is coupled to the end plug portion 36, the connector 38 can provide an electrical connection to one or more conductors 12 of the attached cable 10. For example, the connector 38 can include one or more terminals electrically connected to one or more conductors 12 of the attached cable 10 ( Figure 2 (not shown). In this way, when the mating plug is inserted into the end plug portion 36, one or more terminals within the mating plug can be mechanically and electrically connected to one or more terminals of the connector 38 to facilitate connection to one or more conductors 12 of the attached cable 10. In some embodiments, the end plug portion 36 and / or the connector 38 can include one or more mechanisms to substantially block, cover, or hide the electrical connection to one or more conductors 12 until the mating plug is received, such that an uninserted or "free" terminated plug 30 is not considered "live".

[0066] As described above, the terminated plug 30 can be a universal plug that can be connected to various modules. For example, Figure 3 An end seal module 40 according to some embodiments is shown. The end seal module 40 can be used as an end seal to terminate the cable 10. As Figure 3 shown, the end seal module 40 can include a housing 42 having a mating plug portion 44 and an end seal cover portion 46. Generally, the housing 42 can include a single opening at the mating plug portion 44, while the end seal cover portion 46 can be closed.

[0067] Thus, as Figure 3As shown, the mating plug portion 44 can be configured to be inserted into the end plug portion 36 of the plug 30. For example, in some embodiments, the mating plug portion 44 can include a female socket connector 48 within an opening that receives the male plug connector 38 of the plug 30. In other embodiments, the mating plug portion 44 can include a male plug connector 48 that is inserted into the female socket connector 38 of the plug 30. Additionally, in some embodiments, the connector 48 of the mating plug portion 44 can be configured to be electrically connected to the plug 30 such that when the components 30, 40 are mechanically coupled together (e.g., inserted into each other by a press fit, a threaded seal type fit, a snap type fit, etc.), an electrical connection is formed between one or more conductors 12 of the cable 10 and one or more components within the mating plug portion 44. However, generally speaking, the end seal cap portion 46 can include internal components to terminate at this electrical connection. Further, generally speaking, inserting the mating plug portion 44 of the end seal module 40 into the end plug portion 36 of the termination plug 30 can serve to both electrically and mechanically couple the two components. Additionally, in some embodiments, additional mechanical connections can be implemented, such as heat shrink tubing over the mating area, to further facilitate the mechanical coupling.

[0068] As another example, Figure 4 A base module 50 according to some embodiments is shown. The base module 50 can be used to provide in-line connections for any number of cables 10, e.g., each cable including a termination plug 30, to create power connectors, joints, or any number of branch circuits. As Figure 4 shown, the base module 50 can include a housing 52 having a body portion 54 and four mating plug portions 56 (specifically, mating plug portion 56A, mating plug portion 56B, mating plug portion 56C, and mating plug portion 56D). Figure 4 The mating plug portions 56 of the base module 50 can be substantially the same as the mating plug portions 44 of the Figure 3 end seal module 40, and thus, Figure 3 the above description of the mating plug portions 44 of the end seal module 40 can be applied to the mating plug portions 56 of the base module 50. That is, the housing 52 can include an opening at each mating plug portion 56 to provide access to a corresponding connector 58 at each opening.

[0069] Additionally, still referring to Figure 4, the housing 52 (e.g., at the main body portion 54) may include internal components that electrically connect the connector 58 of the mating plug portion 56 along the first end 60 of the base module 50 to the connector 58 of the mating plug portion 56 along the second end 62 of the base module 50. In this way, the base module 50 can facilitate various electrical connections between one or more cables 10 coupled (e.g., inserted) to the first end 60 and one or more cables 10 coupled (e.g., inserted) to the second end 62. For example, Figure 5-7 Three different connection configurations using the base module 50 are shown.

[0070] More particularly, Figure 5 An exemplary power connector or joint configuration using the base module 50 is shown. In this configuration, a first cable 10A including a plug 30 is inserted into a first mating plug portion 56A on the first end 60, and a second cable 10B is inserted into a second mating plug portion 56B on the second end 62, where the base module 50 serves to electrically connect or join the first cable 10A and the second cable 10B together. In addition, a first end seal cap 41A can be inserted into a third mating plug portion 56C on the first end 60, and a second end seal cap 41B can be inserted into a fourth mating plug portion 56D on the second end 62. In some embodiments, the end seal cap 41 can be a mechanical cap configured to cover the mating plug portion 56. In other embodiments, the end seal cap 41 can include electrical components (similar to those of the end seal module 40) that can be electrically connected to the connector 58 within the mating plug portion 56 to serve as electrical terminals at the respective connector 58.

[0071] Additionally, Figure 6 An exemplary power T-piece configuration using the base module 50 is shown. In this configuration, a first cable 10A is inserted into a first mating plug portion 56A on the first end 60, a second cable 10B is inserted into a second mating plug portion 56B on the second end 62, and a third cable 10C is inserted into a third mating plug portion 56C on the first end 60, where the base module 50 serves to electrically connect or join the first cable 10A, the second cable 10B, and the third cable 10C together, thereby forming a tee joint or power T-piece. In addition, a first end seal cap 41 can be inserted into a fourth mating plug portion 56D on the second end 62.

[0072] Furthermore, Figure 7An exemplary X-joint configuration using the base module 50 is shown. In this configuration, a first cable 10A is inserted into a first mating plug portion 56A on a first end 60, a second cable 10B is inserted into a second mating plug portion 56B on a second end 62, a third cable 10C is inserted into a third mating plug portion 56C on the first end 60, and a fourth cable 10D is inserted into a fourth mating plug portion 56D on the second end 62, wherein the base module 50 serves to electrically connect or join together the first cable 10A, the second cable 10B, the third cable 10C, and the fourth cable 10D, thereby forming an X-joint or an X-branch connector.

[0073] Additionally, although Figure 5-7 the base module 50 is shown connected between two or more cables 10, in some applications, the base module 50 can also facilitate the connection between the cable 10 and a power source. Figure 8 An exemplary configuration according to some embodiments is shown. That is, Figure 8 a heating cable 10 having a termination plug 30, a power cable 64 having a termination plug 30 coupled to a power source 66, and a base module 50 configured to connect the power cable 64 to the heating cable 10 are shown. Thus, referring to Figure 8 the base module 50, one of the mating plug portions 56A can be dedicated to receiving the termination plug 30 from the heating cable 10, and another mating plug portion 56B can be dedicated to receiving the termination plug 30 from the power cable 64. Alternatively, in some embodiments, the mating plug portions 56 can receive the termination plug 30 from the heating cable 10 or the power cable 64 in a universal manner. The internal components within the housing 52 of the base module 50 can facilitate the electrical connection from the power cable 64 to the heating cable 10. Additionally, in some applications, the base module 50 can include two mating plug portions 56, as Figure 8 shown, or can include three, four, or more mating plug portions 56 to enable the power cable 64 to be coupled to multiple heating cables 10.

[0074] Alternatively, in some applications, as Fig. 9 shown, the power cable 64 can be coupled to a dedicated power termination plug 68. The power termination plug 68 can be similar to the termination plug 30 in that it can include an outer housing 32 having a body portion 34. However, the outer housing 32 of the power termination plug 68 can also include a mating plug portion 56. In this way, the end termination plug 30 of the heating cable 10 can be directly coupled to (e.g., inserted into) the power termination plug 68 of the power cable 64. The internal components housed within the outer housing 32 of the power termination plug 68 can include the electrical connectors necessary to facilitate the electrical coupling between the heating cable 10 and the power cable 64.

[0075] In addition, in some embodiments, one or more components of the tracing system may be configured with a mating plug portion 56 to receive the termination plug 30 of the connected heating cable 10. For example, Fig.10 A tracing system component 70 including a mating plug portion 56 is shown. The tracing system component 70 can be, for example, a junction box, a controller, or another component that can be coupled to the tracing cable 10. The mating plug portion 56 of the tracing system component 70 can include a connector 58 that facilitates an electrical connection within the component 70 when the termination plug 30 of the tracing cable 10 is inserted into the mating plug portion 56. Thus, the modular system can reduce the need for field splicing any type of cable connection.

[0076] According to another example, Fig.11 A lighted end seal module 72 according to some embodiments is shown. The lighted end seal module 72 can be used in a manner similar to Figure 3 the end seal module 40, e.g., for terminating the cable 10. For example, the lighted end seal module 72 can include a housing 74 having a mating plug portion 76 and a lighted end seal cover portion 78. Fig.11 The mating plug portion 76 of the lighted end seal module 72 of Figure 3 can be the same or similar to the mating plug portion 44 of the end seal module 40 of Figure 3 , and thus, Figure 3 the above description of the mating plug portion 44 of the end seal module 40 of Fig.11 can be applied to the mating plug portion 76 of the lighted end seal module 72. Additionally, internally, the lighted end seal cover portion 78 can include components that terminate in electrical connections, similar to

[0077] As yet another example, Fig.12Shows an accessory module 84 according to some embodiments. The accessory module 84 can be connected between cables 10 and can include one or more internal accessories that, in some applications, can draw power from one or more of the cables 10 via an electrical connection. As Fig.12 shown, the accessory module 84 can include a housing 86 having a body portion 88 and two mating plug portions 90 configured to receive the end plug portion 36 of the termination plug 30.

[0078] Additionally, still referring to Fig.12 , the body portion 88 can include internal components that electrically connect the connector 92 of the mating plug portion 90 along the first end 94 of the accessory module 84 to the connector 92 of the mating plug portion 90 along the second end 96 of the accessory module 84. In this way, the accessory module 84 can incorporate one or more accessories that draw power from the electrical connection between the cables 10 coupled to (e.g., inserted into) the first end 94 and the second end 96, and / or sense one or more variables related to the characteristics of the cables 10 and / or the surrounding environment. For example, in some applications, in the case where a user desires to locate the accessory module 84, a single cable 10 can be cut, the two cut ends can be terminated with corresponding termination plugs 30, and the accessory module 84 can be connected between the termination plugs 30. As another example, two cables 10 can be connected by the accessory module 84, each cable including a termination plug 30. In some embodiments, the accessories within the accessory module can include, but are not limited to, sensors, broadcast components, light sources, controllers, and the like.

[0079] For example, Fig.13 shows an exemplary schematic diagram of an accessory module 84 according to some embodiments. As Fig.13 shown, the accessory module 84 can include a sensor 98, a controller 100, a power supply 102, a broadcast component 104, and / or a light source 80. It should be noted that in some applications, one type of accessory module 84 can include one or more accessories or a combination of accessories (e.g., sensors, broadcast modules, and / or lights, etc.), while another type of accessory module 84 can include one or more other accessories or another combination of accessories. However, externally, all types of accessory modules 84 can include the same mating plug portions 90 for connection between the cables 10. Additionally, in some embodiments, all accessory modules 84 can be the same size. However, in other embodiments, some accessory modules 84 can be longer or shorter (or larger or smaller) than other accessory modules. Additionally, although Fig.12 and Fig.13 show the accessory module 84 connected between two cables 10, in some applications, the accessory module 84 can facilitate the connection between the cable 10 and the power supply 66 or the power cable 64.

[0080] Still referring to Fig.13 Fig.13 , in some embodiments, the sensor 98 can be a temperature sensor configured to monitor temperature, a current sensor configured to monitor the current through the cable 10, or another type of sensor. In some embodiments, the sensor 98 can draw power directly from the connected cable 10. However, in other embodiments, the sensor 98 can draw power from a separate power source, such as the power supply 102 or an external power source (not shown). Additionally, the sensor 98 and the power supply 102 can be connected to the controller 100. That is, the controller 100 can be powered by the cable 10, the power supply 102, or an external power source, and can obtain data from the sensor 98. In embodiments where the controller 100 and the sensor 98 are configured to draw power from an external power source, the accessory module 84 may not include the internal power supply 102, or may still include the power supply 102 as an alternative power source.

[0081] Additionally, still referring to Fig.13 Fig.13 , the accessory module 84 can include a broadcast component 104 connected to the controller 100. For example, the broadcast component 104 can include components that facilitate wireless communication, such as a WiFi component, a Bluetooth component, or other components. In such embodiments, the controller 100 can obtain data from the sensor 98 and communicate with an external source via the broadcast component 104 based on that data. In some embodiments, the controller 100 can send the raw data from the sensor 98, can process the data and send the processed data, or can process the data and send a communication based on the data, such as an alert, a marker, a report, etc. For example, in some embodiments, the external source can include an electronic heat tracing (EHT) controller of a heat tracing system (not shown), a supervisor or management system of the heat tracing system, or another source. In another example, the external source can include a mobile phone, a tablet, or other computing devices configured to communicate with the controller 100 via a Bluetooth component (e.g., via Bluetooth pairing) or a WiFi component (e.g., via a local area network, a wide area network, etc.). Thus, in some applications, the accessory module 84 can be field - joined into the cable 10 to allow monitoring and reporting of variables related to the cable 10 and / or the surrounding environment at a location (e.g., at the "edge" or at the accessory module 84) or in a control room or another location.

[0082] Furthermore, still referring to Fig.13, in some embodiments, the accessory module 84 may include a light source 80 that draws power from the connected cable 10 or from the power supply 102. Thus, in some embodiments, the accessory module 84 may perform the same functions as the above-described light-emitting end seal module 72, e.g., emitting light in response to current drawn by heating the cable 10. In additional embodiments, the accessory module 84 may perform additional functions using the light source 80. For example, the controller 100 may control when the light source 80 emits light based on, e.g., the drawn current or another variable sensed by the sensor 98. Additionally, in some embodiments, the light-emitting end seal module 72 itself may be considered an accessory module. Further, in some applications, any of the above accessories may be incorporated into the base module 50 (including two or more mating plug portions 56) or the end seal module 40 (including a single mating plug portion 44) to form an accessory module.

[0083] Accordingly, in view of the foregoing, some embodiments provide a connection system for one or more cables 10 that may include a universal termination plug connected to the cut end of the cable and one or more of the above-described modules. Due to the "plug and play" nature of the modular connection, the connection system may allow for easy field termination without the need for commercial knowledge or special permits. For example, in some embodiments, the cable 10 may include a factory-installed termination plug 30 at its end, allowing the user to easily install the cable 10 using various modules. Additionally, the user may additionally connect a termination plug 30 to the cut end of the cable 10 in the field for additional modular connections. The connection system may also allow a heat-tracing cable system with termination plugs to be prefabricated on a pipe or roofing material and quickly connected in the field via the desired modules. Such prefabrication may significantly reduce the man-hours in the field and the associated costs of having personnel with trade knowledge perform the field connections. Additionally, the connection system (e.g., the termination plug 30 and associated modules) may have a low-profile form factor. For example, as Figure 3-9 and Figure 11-12 shown, the modules may include a substantially low profile to allow for insulated installation. However, in some applications, one or more modules, such as the light-emitting end seal module 72 or the accessory module 84, may include a light source 80 that extends outside of the low-profile form factor to provide a convenient alert or warning system for nearby users.

[0084] In addition, a connection system (e.g., termination plug 30 and associated modules) can provide users with the ability to customize their systems by using accessory modules, and can provide new features to the system through new accessory modules or other modules, without a full system redesign. More particularly, the connection system can allow users to adapt the system to their needs through different modules, and will also allow for future upgrades as needed. That is, new features can be introduced into the system through small modular packages (all modules include mating plug portions 44, 56, 76, 90 for easy connection to termination plug 30 in the system), without having to upgrade or redesign the existing "base" system. The unified nature of termination plug 30 for both heating cable 10 and power cable 64 can allow for the implementation of various electrical connections and accessories in the connection system through easy-to-use plug-and-play modules. In addition, any number of electrical connections between cables 10 can be facilitated through a single base module 50, and any number of accessories can be provided within the coverage of accessory module 84.

[0085] Return reference Figure 2 , as described above, the termination plug 30 of some embodiments can include a housing 32 having a body portion 34 and an end plug portion 36. The body portion 34 can include internal components ( Figure 2 not shown in the figure) that allow for electrical connection to one or more conductors 12 within cable 10. Some existing connectors for joining or terminating heating cable 10 require the complete stripping of the cable down to the conductors 12 and fastening to the conductors 12 by mechanical means, such as crimping or threaded terminals. According to some embodiments, the solution provided requires minimal cable preparation and stripping, minimizes or eliminates the tools required for making the connection, and provides a better electrical connection that can handle higher current loads than standard insulation displacement connectors.

[0086] For example, some embodiments provide a method of making an electrical connection to the electrical tracing parallel conductors 12 without removing the main sheath 16 or the core material 14. Such electrical connection can be achieved by different ways of a termination mechanism that pierces or cuts through the main sheath 16 and the core 14 and contacts the conductor 12. According to some embodiments, different configurations for achieving such electrical connection are shown in Figure 14-49 and any one of these configurations described herein can be implemented as a termination assembly within the body portion 34 of the termination plug 30 shown in Figure 2 . That is, any termination assembly configuration shown and described below with reference to Figure 14-49 can serve to electrically connect the conductors 12 of cable 10 to the connector 38 within the termination plug 30.

[0087] Therefore, Fig.14 、 15, 16, and 17 illustrate an exemplary blade configuration 110 in accordance with some embodiments. The blade configuration 110 may include first and second blade arrays 112 made of a conductive material, and the first and second arrays may be spaced apart by a distance that is generally equal to the distance between the conductors 12 of the heating cable 10. As Fig.16 and Fig.17 shown, the blade configuration 110 may also include an insertion channel 114 to align the conductors 12 of the heating cable 10 with the blade arrays 112. The heating cable 10 (e.g., having a final sheath 22 and a braid layer 20 that are peeled back) may be longitudinally inserted through the channel 114, and by pushing the heating cable 10 through the blade arrays 112, each blade array 112 cuts through the primary sheath 16 and the core material 14 and makes contact with the conductors 12.

[0088] More particularly, as Fig.14 , 16 and 17 shown, the blade configuration 110 may include a first or upper insulating housing 116 and a second or lower insulating housing 118 that are joined together by fasteners 120. The insulating housings 116, 118 may be made of an electrically insulating material and may form the insertion channel 114 and two blade channels 122, 124 when joined together, where each blade channel 122, 124 may accommodate a corresponding blade array 112. With respect to the blade arrays 112, as Fig.14 and 15 best shown, each blade array 112 may include four blades 126, two blade retaining clips 128, and two blade wedges 130. The blade retaining clips 128 may be joined together (e.g., with fasteners 132) to clamp together two upper blades 126 and two lower blades 126, with a blade wedge 130 between the two upper blades and a blade wedge 130 between the two lower blades, such that the blades 126 form an "X" shape. Additionally, in some embodiments, each blade array 112 may include more than four blades 126 that form an X shape and are radially arranged around the corresponding conductor 12. The four (or more) blades 126 that form an X shape may help center the conductor 12 within the configuration 110 to help ensure good electrical contact with the conductor 12.

[0089] As Figure 14-17As shown, the blades 126 extend outwardly from the blade holding clip 128 and can receive the cable 10 inserted through the insertion channel 114. The blades 126 are positioned close enough to each other such that when the cable 10 is pushed into the blades 126 towards the blade holding clip 128, the blades 126 can cut into the main sheath 16 and the core material 14 of the cable 10 and contact the conductor 12. Thus, this configuration 110 can provide a length of contact between the blades 126 and the conductor 12 from both above and below the conductor 12 (e.g., as compared to a single contact point). Additionally, this contact is provided by the user pushing the cable 10 through the insertion channel 114, without the need for additional tools to make the connection between the blades 126 and the conductor 12.

[0090] In some embodiments, the blades 126, the blade holding clip 128, and / or the blade wedges 130 can be made of a conductive material, such as brass, bronze, steel, stainless steel, or other suitable materials, to form an electrical connection with the conductor 12. Additionally, as Figure 15-17 shown, the conductive ring terminals 134 can be coupled to at least one blade holding clip 128 of each blade array 112. Thus, Figure 15-17 the configuration 110 includes two ring terminals 134, but in some embodiments can include additional ring terminals 134. When the blade configuration 110 is assembled within the termination plug 30, the ring terminals 134 can receive a plug or wire from within the body portion 34 of the plug 30 to facilitate connection between the connector 38 of the plug 30 and the conductor 12 of the cable 10 via the ring terminals 136, the blade holding clip 128 (and / or the blade wedges 130), and the blades 126. Alternatively, in some embodiments, the wire can be directly brazed to the blade holding clip 128, eliminating the need for the ring terminals 134. Thus, wherever the ring terminals 134 are shown and described herein, such ring terminals 134 can be replaced by a direct wire connection.

[0091] Fig.18 、 19 Figures 20 and 21 illustrate another exemplary connection configuration 140 (e.g., a spike configuration) according to some embodiments. Generally speaking, the spike configuration 140 can include a plurality of sharp spikes that pierce the main sheath 14 and the core material 14 to clamp the corresponding conductor 12 from at least two sides. According to one example, as Figure 18-21 shown, the spike configuration 140 can include two pivot assemblies 142 that are to be positioned parallel to the flat surface of the oblong electrical heating cable 10. Each of the pivot assemblies 142 can include a set of two sharp spikes or protrusions 144 (in Fig. 20 and 21shown, wherein each protrusion 144 is aligned with one of the conductors 12 of the inserted heating cable 10. More particularly, the pivot assembly 142 can be angularly disposed relative to the heating cable 10 before and during cable insertion, as Fig. 20 shown. In this way, the heating cable 10 can be longitudinally inserted into the channel 146 formed between the two pivot assemblies 142. Once the cable 10 is seated, the pivot assemblies 142 rotate to close downwardly onto the heating cable 10 until they are parallel to the heating cable 10, and thus, the sharp protrusions 144 pierce the main sheath 16 and the core 14 of the heating cable 10 to contact the conductor 12.

[0092] More particularly, as Figure 18-21 shown, the spike configuration 140 can include a housing 148, a seat 150, a threaded member 152, and two pivot assemblies 142. For example, the seat 150 can be translated within the housing 148 along a track 154 when controlled by rotation of the threaded member 152 extending through the rear of the housing 148. That is, the housing 148 can include an upper track 154A and a lower track 154B defined within its inner surface. As Fig. 20 and 21 shown, the seat 150 can include an upper portion 156 that slides along the upper track 154A and a lower portion 158 that slides along the lower track 154B. The seat 150 can also include a base 160 located between the upper portion 156 and the lower portion 158 that contacts the threaded member 152. Additionally, each pivot assembly 142 (e.g., an upper pivot assembly and a lower pivot assembly) can include a pivot member 162, two side-by-side protrusions 144, and a roller mount 164 fixed to the housing 148. The protrusions 144, such as threaded members, can be made of a conductive material to form an electrical connection with the conductor 12 and can each include a corresponding annular terminal 134 coupled thereto.

[0093] In Fig.18 and 20 the "open" position shown, the seat 150 can be located at its most rearward position adjacent the rear of the housing 148. This seat position allows the pivot member 162 to retract into the housing 148, where the rear end 166 of the pivot member 162 rotates outwardly toward the corresponding upper portion 156 or lower portion 158 of the seat 150. Accordingly, the protrusions 144 extend out of the channel 146, allowing the cable 10 to be inserted into the channel 146 until it abuts the seat 150.

[0094] Then, the user can rotate the threaded member 152 to move the seat 150 toward the "closed" position, where the seat 150 is located at its most forward position adjacent the front of the housing 148, as Fig.19 and Fig.21As shown. This seat position extends the pivot member 162 out of the housing 148, and through translational movement, the pivot member 162 contacts each roller mount 164 in such a way that the end 166 of the pivot member 162 rotates towards a position parallel to the cable 10. Thus, when the pivot member 162 reaches the closed position, the protrusion 144 rotates into the cable 10, piercing the main sheath 16 and the core 14 of the heating cable 10 and contacting the conductor 12 (note that for clarity, the cable 10 is removed from Fig.21 the view). Thus, this contact is provided by the user pushing the cable 10 through the insertion channel 146 and rotating the threaded member 152, allowing the user to make the connection to the conductor 12 manually (e.g., without tools) or using a tool for rotating the threaded member. Thus, when the spike configuration 140 is assembled within the termination plug 30 in the closed position, the annular terminal 134 can facilitate the connection between the connector 38 of the plug 30 and the conductor 12 of the cable 10 via the annular terminal 134 and the protrusion 144. Additionally, through this translational and rotational movement, a cleat 168 on the front end of each pivot member 162 can contact the cable 10, for example, to provide strain relief.

[0095] Fig. 22 , 23 Figures 22, Fig.23 23, Fig.23 24 show yet another exemplary connection configuration 170 (e.g., a stamping configuration) according to some embodiments. The stamping configuration 170 can include multiple sets of shear members 172 aligned with the parallel conductors 12 of the cable 10 (as

[0096] shown). Each set of shear members 172 can pierce only one side of the cable 10 (e.g., from above the cable 10, as Figure 22-24 shown), or the shear members 172 can pierce both sides of the cable 10. The parallel heat - tracing cables 10 are longitudinally inserted into the channel 174. Manually (e.g., without tools) or with mechanical assistance via a tool, the shear members 172 are pushed towards the cable 10, piercing the main sheath 16 and the core 14 and contacting the conductor 12.

[0096] More particularly, as Figure 22-24 shown, the stamping configuration 170 can include an insulating housing 176 (as Fig.24 shown) and two shear assemblies 178. As Fig. 22 shown in 23As shown, each shear assembly 178 can include one or more shear pieces 172, threaded members 180, and a shear housing 182, as well as an annular terminal 134 coupled to the shear housing 182. The shear housing 182 can support the shear pieces 172 and the threaded members 180, and can each define a half-channel 184 that together define a channel 174 for receiving the cable 10. In some embodiments, some or a portion of the shear assembly 178, including the shear pieces 172, the threaded members 180, and / or the shear housing 182, can be made of a conductive material to form an electrical connection with the conductor 12, while the insulating housing 176 can be made of an insulating or non-conductive material. Additionally, in some embodiments, as Fig. 22 and 23 shown, the shear assemblies 178 can be physically and / or electrically separated.

[0097] Still referring to Figure 22-24 , in the "open" position, the threaded member 180 (or another mechanical component capable of moving the shear piece 172) can be rotated in a manner that positions the shear piece 172 outside of the channel 174, thereby allowing the cable 10 to be inserted therein. In the "closed" position, the threaded member 180 can be manipulated to press the shear piece 172 down onto the cable 10 such that the shear piece 172 enters the channel 174 and pierces the main sheath 16 and the core 14 of the heating cable 10 and contacts the conductor 12. Thus, when the stamping structure 170 is assembled within the termination plug 30 in the closed position, the annular terminal 134 can facilitate the connection between the connector 38 of the plug 30 and the conductor 12 of the cable 10 via the annular terminal 134 and the shear assembly 178.

[0098] Generally, the insulating housing 176 can house the shear assemblies 178 and hold them in position relative to each other, thereby supporting the shear assemblies 178 to hold the cable 10 in the closed position. In some embodiments, the insulating housing 176 can be assembled onto the shear device 178 either before or after the cable 10 is connected to the shear device 172. More particularly, according to one method of installation, the insulating housing 176 is first assembled onto the shear assembly 178. The cable 10 is inserted into the channel 174, and the two shear assemblies 178 can be manipulated into the closed position such that the shear pieces 172 contact the conductor 12 of the cable 10.

[0099] According to another installation method, each shearing assembly 178 can be individually installed onto the cable 10, and the insulating housing 176 can be assembled onto the shearing assembly 178. More particularly, the cable 10 can be positioned within a half-channel 184 of a shearing housing 182 of a shearing assembly 178 (e.g., the cable 10 can longitudinally move through the half-channel 184 or laterally move into the half-channel 184). Then, the shearing assembly 178 can be manipulated to a closed position such that one or more shearing members 172 contact a conductor 12 of the cable 10. Before or after this manipulation, the cable 10 can be further positioned within a half-channel 184 of a shearing housing 182 of another shearing assembly 178 (e.g., the cable 10 can longitudinally move through the half-channel 184 or laterally move into the half-channel 184). The second shearing assembly 178 can also be manipulated to a closed position such that one or more shearing members 172 contact another conductor 12 of the cable 10. Once both shearing assemblies 178 are in their closed positions, the insulating housing 176 can be assembled onto the shearing assemblies 178.

[0100] Additionally, still referring to Figure 22-24 , in some embodiments, by having separate shearing assemblies 178, the configuration 170 can accommodate heating cables 10 having different distances between the conductors 12. For example, in some embodiments, the insulating housing 176 can accommodate shearing assemblies 178 spaced apart at different distances. Alternatively, in some embodiments, the stamping configuration 170 can further include one or more additional features or components to accommodate heating cables 10 having different distances between the conductors 12. For example, in some embodiments, the shearing members 172 can be open fork-shaped members to connect to the conductors 12 within a certain distance range. In another example, in some embodiments, the configuration 170 can include a spring or other component (not shown) that can allow the shearing members 172 to move closer together or further apart to accommodate the distance range between the conductors 12.

[0101] Fig.25 , 26 Figures 27, 28, and 29 illustrate yet another exemplary connection configuration 190 (e.g., a cam configuration) according to some embodiments. The cam configuration 190 can include one or more cams 192 aligned with each parallel conductor 12, and the portion of each cam 192 closest to the conductor 12 has ridges or teeth 194. For example, the cams 192 can be positioned on a side of the cable 10 adjacent to the conductor 12, or the cams 192 can be positioned on both sides of the cable 10 adjacent to the conductor 12, such as above and below the conductor 12. In use, the traced cable 10 can be longitudinally inserted into the channel 196. Then the cams 192 are rotated (e.g., manually or with mechanical assistance) such that the teeth 194 cut through the primary sheath 16 and the core 14, thereby allowing the cams 192 to contact the conductors 12.

[0102] More particularly, as Figure 25-29 shown, the cam structure 190 may include an insulating housing 198 (as Fig.25 , 27 and 28 shown) and two frame assemblies 200, each frame assembly including a base frame 202 (as Figure 26-29 shown) and a frame plate 204 (as Fig.26 and Fig.29 shown). The insulating housing 198 may hold the frame assemblies 200 and may include an opening defining a channel 196 for receiving the cable 10 and an opening defining a cam channel 206 to allow rotation of each cam 192. As Fig.26 shown (wherein for clarity the insulating housing 198 has been removed), each frame assembly 200 may include a respective base frame 202 coupled to the frame plate 204, for example, using fasteners (not shown). When coupled together, each frame assembly 200 may further define a cam channel 206 to allow rotation of the upper cam 192 and the lower cam 192, and may each define a half-channel 214, the two half-channels together defining the channel 196 for receiving the cable 10. In some embodiments, as Fig.26 and Fig.29 shown, the frame assemblies 200 may be physically and / or electrically separated.

[0103] Referring to Figure 26-29 , the respective cam 192 may be positioned between the base frame 202 and the frame plate 204 within the cam channel 206 and may rotate about a pivot member 208 that may be anchored to the base frame 202 and the frame plate 204. Thus, the cam 192 rotates relative to the base frame 202. Additionally, in some embodiments, one or more shims 218 ( Fig.29 shown) may be positioned around the pivot member 208 between the cam 192 and the base frame 202 and / or the frame plate 204. Each cam 192 may be in the Fig.25 and 27 shown first "fully open" position and the Fig.26 , 28 and 29 shown second "fully closed" position. That is, in the Fig.25 and 27 shown fully open position, each cam 192 may rotate such that the first end 210 of the cam 192 may be outside or away from the cable channel 196. Additionally, the opposite second end 212 of the cam 192 may be positioned outside the cam channel 206. In Fig.26 and Fig.28In the fully closed position shown, the cam 192 is rotatable such that the first end 210 is positioned within the cable channel 196 and the second end 212 is positioned within the cam channel 206 (e.g., the cam channel defined by the frame assembly 200 and / or the insulating housing 198).

[0104] In use, the cam configuration 190 can be placed in the fully open position and the cable 10 can be inserted into the channel 196, as Fig.25 shown. Once the cable 10 is inserted, the user can manually or by means of a tool (not shown) press the second end 212 of each cam 192 to rotate the cam 192 about the respective pivot member 208 until the fully closed position is reached. This rotation causes the first end 210 of the cam 192, and more particularly the teeth 194, to enter the channel 196, pierce the primary sheath 16 and the core 14 of the heating cable 10, and allow the first end 210 of the cam 192 to contact the conductor 12, as Fig.28 and Fig.29 shown. Although the teeth 194 can contact the conductor 12, in some embodiments, the first end 210 can include a substantially smooth portion that contacts the conductor 12 when in the fully closed position to help ensure good electrical contact between the cam 192 and the conductor 12. In some embodiments, the cable 10 can be fully inserted into the channel 196 until it abuts against the inner wall 216 of the frame assembly 200 (as Fig. 27 and Fig.28 shown) before the cam 192 rotates to its respective closed position. For example, the channel 196 terminates at the inner wall 216 and the inner wall 216 can act as a stop to prevent further translation of the cable 10 within the channel 196 as the cam 192 rotates, thus allowing the teeth 194 of the cam 192 to pierce the primary sheath 16 and the core 14 rather than pushing the cable 10 further into the channel 196.

[0105] In some embodiments, the cam 192, the frame assembly 200, the gasket 218, and / or the pivot member 208 can be made of a conductive material to form an electrical connection with the conductor 12. Additionally, as Fig.25 and Fig.26 shown, an annular terminal 134 can be coupled to each frame assembly 200, e.g., to each base frame 202. Thus, Figure 25-29 the cam configuration 190 can include two annular terminals 134, but in some embodiments can include additional annular terminals 134. Accordingly, when the cam configuration 190 is assembled within the termination plug 30 in the closed position, the annular terminals 134 can facilitate connection between the connector 38 of the plug 30 and the conductor 12 of the cable 10 via the annular terminals 134 and the frame assembly 200, the gasket 218, and / or the pivot member 208, and the cam 192.

[0106] Generally, the insulating housing 198 can accommodate the frame assemblies 200 and hold them in position relative to each other to support the frame assemblies 200 to hold the cable 10 in a closed position. In some embodiments, the insulating housing 198 can be assembled onto the frame assemblies 200 before or after the cable 10 is connected to the cam 192. More particularly, according to one mounting method, the insulating housing 198 is first assembled onto the frame assemblies 200. The cable 10 can be inserted into the channel 196, and the cam 192 can be rotated to the closed position such that the first end 210 of the cam 192 contacts the conductor 12 of the cable 10.

[0107] According to another mounting method, each frame assembly 200 can be individually mounted onto the cable 10, and the insulating housing 198 can be assembled onto the frame assemblies 200. More particularly, the cable 10 can be positioned in the half-channel 214 defined by one frame assembly 200 (e.g., the cable 10 can move longitudinally through the half-channel 214 or laterally into the half-channel 214). Then, the corresponding cams 192 of the frame assembly 200 can be manipulated to the closed position such that the first end 210 of each cam 192 contacts the conductor 12 of the cable 10. Before or after this manipulation, the cable 10 can be further positioned in the half-channel 214 of another frame assembly 200 (e.g., the cable 10 can move longitudinally through the half-channel 214 or laterally into the half-channel 214). The corresponding cams 192 of the second frame assembly 200 can also be manipulated to the closed position such that the first end 210 of the cam 192 contacts the other conductor 12 of the cable 10. Once all the cams 192 are in their closed positions, the insulating housing 198 can be assembled onto the frame assemblies 200.

[0108] Figure 30-49 There is shown an additional configuration that can be considered a variant of the cam configuration 190 described above with respect to Figure 25-29 Thus, unless otherwise indicated, like elements can be numbered accordingly, and any description herein corresponding to one cam configuration also applies to the other cam configuration. According to some embodiments, in each of the cam configurations described herein, when in the closed position, at least two electrical contact points are formed for each conductor 12 of the cable 10. For example, looking back at Fig.29 the configuration 190 shown, each conductor 12 is contacted by the upper and lower cams 192 on opposite sides. Further, in each of the cam configurations described herein, the frame assemblies can be individually or jointly coupled to the cable 10 before or after the insulating housing 198 is assembled onto the frame assemblies, as described above.

[0109] Now referring to Figure 30-32 , there is shown a wide cam configuration 220 according to some embodiments. The wide cam configuration 220 can be similar to Figure 25-29The cam construction 190 shown includes an insulating housing 198 ( Fig.30 shown) and two frame assemblies 200 ( Fig.31 and Fig.32 shown), each frame assembly including a base frame 202 and a frame plate 204. The insulating housing 198 can hold the frame assemblies 200 and can include an opening defining a channel 196 for receiving the cable 10 and an opening defining a cam channel 206 to allow the cam 222 to rotate. As Fig.31 shown (wherein for clarity the insulating housing 198 has been removed), each frame assembly 200 can include a respective base frame 202 coupled to the frame plate 204, for example, using fasteners (not shown). When joined together, each frame assembly 200 can further define a cam channel 206 to allow the upper cam 222 and the lower cam 222 to rotate, and can each define a half-channel 214, the two half-channels together defining the channel 196 for receiving the cable 10. In some embodiments, as Fig.31 and Fig.32 shown, the frame assemblies 200 can be physically and / or electrically separated.

[0110] Referring Fig.31 and Fig.32 , the cams 222 of the wide cam construction 220 can be significantly wider than the cams 192 of the cam construction 190 of Figure 25-29 . For example, as Fig.29 shown, the width of each cam 192 of the cam construction 190 can be approximately equal to the diameter of the conductor 12. However, as Fig.32 shown, the width of each wide cam 222 of the wide cam construction 220 can be wider than the diameter of the conductor 12. In one embodiment, each wide cam 222 can include a width of approximately 0.5 inches. In other embodiments, each wide cam 222 can include a width between approximately 0.15 inches and 0.75 inches. The wide cams 222 can allow the construction 220 to accommodate cables 10 having different widths or thicknesses or cables 10 having conductors 12 with different diameters, and can help maintain a strong electrical connection with the conductor 12, even when the cable 10 is misaligned or moves within the channel 196.

[0111] Now referring Figure 33-35 , a side cam construction 230 is shown in accordance with some embodiments. The side cam construction 230 can be similar to the cam construction 190 shown in Figure 25-29 , including an insulating housing 198 (as Fig.33 shown) and two frame assemblies 232 (as Fig.34 and Fig.35as shown). The insulating housing 198 can hold the frame assembly 232 and can include an opening defining a channel 196 for receiving the cable 10 and an opening defining a cam channel 206 to allow rotation of the cams 192, 238. As Fig.34 shown (wherein for clarity, the insulating housing 198 has been removed), each frame assembly 232 can include a respective base frame 234 coupled to three cam holders 236. Each cam holder 236 can further define a cam channel 206 to allow rotation of the respective upper cam 238, lower cam 238, and side cam 192, and the cam holders 236 of each frame assembly 232 can jointly define a semi-channel 214 that partially defines the channel 196 for receiving the cable 10. In some embodiments, as Fig.34 and Fig.35 shown, the frame assemblies 232 can be physically and / or electrically separated.

[0112] As Fig.35 shown, the side cam configuration 230 can provide three contact points against each conductor 12 of the cable 10 via the upper cam 238, lower cam 238, and side cam 192. In this configuration 230, the side cam 192 can help center the cable 10 within the channel 196, thereby facilitating better alignment between the upper and lower cams 238 and the conductor 12. Additionally, in some embodiments, as Fig.35 shown, at least the upper cam 238 and lower cam 238 can include inclined surfaces 239 adjacent to the teeth 194. These inclined surfaces 239 can allow for better contact with the conductor 12 and can also avoid interference with other cam surfaces that contact the conductor 12 when in the closed position.

[0113] Now referring to Figure 36-38 , an inclined cam configuration 240 is shown in accordance with some embodiments. The inclined cam configuration 240 can be similar to Figure 33-35 the side cam configuration 230 shown, including an insulating housing 198 ( Fig.36 shown) and two frame assemblies 242 ( Fig.37 and Fig.38 shown). The insulating housing 198 can hold the frame assemblies 242 and can include an opening defining a channel 196 for receiving the cable 10 and an opening defining a cam channel 206 to allow rotation of the cam 192. As Fig.37 shown (wherein for clarity, the insulating housing 198 has been removed), each frame assembly 242 can include two base frames 244 that are coupled together to further define a cam channel 206 to allow rotation of the respective upper cam 192, lower cam 192, and side cam 192. The base frames 244 can also jointly define a semi-channel 214 that partially defines the channel 196 for receiving the cable 10. In some embodiments, as Fig.37 and Fig.38 As shown, the frame assembly 242 can be physically and / or electrically separated.

[0114] As Fig.38 shown, the angled cam configuration 240 can provide three contact points against each conductor 12 of the cable 10 via the upper cam 192, the lower cam 192, and the side cam 192. In this configuration 240, the side cam 192 can help center the cable 10 within the channel 196, thereby facilitating better alignment between the upper and lower cams 192 and the conductor 12. Additionally, compared to Fig.35 the side cam configuration 230 shown, in the angled cam configuration 240, the upper and lower cams 192 can approach the conductor 12 at an angle. More particularly, the upper and lower cams 238 of the side cam configuration 230 can be substantially parallel to each other and rotate along the same plane, while the upper and lower cams 192 of the angled cam configuration 230 can be non - parallel to each other and rotate along different planes.

[0115] Now referring to Figure 39-41 , a lateral cam configuration 250 according to some embodiments is shown. The lateral cam configuration 250 can be similar to Figure 25-29 the cam configuration 190 shown, including an insulating housing 198 (shown in Fig.39 ) and two frame assemblies 252 (shown in Fig.40 and 41 ). The insulating housing 198 can hold the frame assemblies 252 and can include an opening defining a channel 196 for receiving the cable 10 and an opening defining a cam channel 206 to allow the cam 192 to rotate. As Fig.40 shown (where the insulating housing 198 has been removed for clarity), each frame assembly 252 can include two base frames 254 that are joined together to further define the cam channel 206, thereby allowing rotation of the corresponding upper and lower cams 192. The base frames 244 can also jointly define a half - channel 214 that also defines the channel 196 for receiving the cable 10. In some embodiments, as Fig.40 shown, the frame assemblies 252 can be physically and / or electrically separated. For example, in one embodiment, the frame assemblies 252 can be spaced approximately 0.25 inches apart.

[0116] As Fig.40As shown, the lateral cam structure 250 can provide two contact points on each conductor 12 of the cable 10 via the upper cam 192 and the lower cam 192. In this structure 250, the cams 192 are along a plane perpendicular to the direction in which the cable 10 is inserted through the channel 196 (e.g., perpendicular to the length of the cable 10, as opposed to the previous structures 190, 220, 230, 240 where the cams 192 rotate parallel to the length of the cable 10). Thus, each cam 192 can rotate across the width of the cable 10 rather than along the length of the cable 10. Accordingly, the first end 210 of the cam 192 can contact the wider conductor 12, the narrower conductor, or the misaligned conductor within the channel 196 of the cable 10.

[0117] Now referring to Figure 42-44 , a split cam structure 260 according to some embodiments is shown. The split cam structure 260 can be similar to Figure 25-29 the cam structure 190 shown, including an insulating housing 198 (shown in Fig.42 ) and two frame assemblies 262 (shown in Fig.43 and Fig.44 ). The insulating housing 198 can hold the frame assemblies 262 and can include an opening defining a channel 196 for receiving the cable 10 and an opening defining an upper cam channel 206 to allow the upper cam 192 to rotate. As Fig.43 shown (where the insulating housing 198 has been removed for clarity), each frame assembly 262 can include a base 264 anchored to a respective upper cam 192. The bases 264 can also each define a semi-channel 214 which together define the channel 196 for receiving the cable 10. In some embodiments, as Fig.43 shown, the frame assemblies 262 can be physically and / or electrically separated.

[0118] As Fig.43 and Fig.44 shown, the split cam structure 260 can provide two contact points on each conductor 12 of the cable 10 via the upper cam 192 and the lower contact member 266. In this structure 260, the two upper cams 192 rotate in different directions along the same plane to achieve the closed position. However, in other embodiments, the structure 260 can include two upper cams 192 that rotate in the same direction, similar to Figure 25-29The cam structure 190. Additionally, the lower contact member 266 may be coupled to the base frame 264 and may include an extension extending into the channel 196, such as the inclined serrations 268. In use, when the user rotates each upper cam 192 to the closed position, the corresponding upper cam 192, particularly the teeth 194, may pierce the main sheath 16 and the core 14 of the heating cable 10 to contact the conductor 12, and may also force the cable 10 against the lower contact member 266, where the extension (here the inclined serrations 268) may also pierce the main sheath 16 and the core 14 of the heating cable 10 to contact the conductor 12.

[0119] Figure 45-49 Additional examples of the lower contact member 266 according to some embodiments are shown. For example, Fig.45 A contact member 266 with an extension in the form of a pin 270 is shown. Fig.46 A contact member 266 with an extension in the form of lateral serrations 272 is shown. Fig.47 A contact member 266 with an extension in the form of an insulation displacement connector 274 (e.g., including two pointed teeth) is shown. Fig.48 A contact member 266 with an extension in the form of a single serration 276 is shown. Fig.49 A contact member 266 with an extension in the form of longitudinal serrations 278 is shown.

[0120] In view of the above, some embodiments provide a configuration for electrical connection to the parallel conductors of a heat tracing cable, which can be incorporated into a common end termination plug of a connection system for a heating cable. Such a termination assembly configuration can be connected to the end of the heating cable in the field without tools or with minimal tools, and does not require the conductors of the heating cable to be fully exposed. Instead, the termination assembly configuration is capable of forming good electrical contact with the conductors after piercing the core material and the main sheath of the heating cable. Due to contacting the conductors from multiple sides of the heating cable and / or providing a larger contact surface area against the conductors, the configurations of some embodiments can provide sufficient electrical connection to the conductors. For example, compared to typical insulation displacement connection methods, this sufficient electrical connection can handle the high current load of the heating cable.

[0121] Those skilled in the art will understand that although the present invention has been described above in conjunction with specific embodiments and examples, the present invention need not be so limited, and many other embodiments, examples, uses, modifications, and departures from the embodiments, examples, and uses are intended to be covered by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated herein by reference as if each such patent or publication were incorporated herein independently by reference. The various features and advantages of the present invention are set forth in the following claims.

Claims

1. A termination assembly for a heating cable, the heating cable comprising a first conductor, a second conductor, a core material on the first conductor and the second conductor, and a sheath on the core material, the termination assembly comprising: A first component connected to the first conductor of the heating cable, the first component comprising: a first base frame comprising a first channel for receiving the heating cable, a first cam rotatable about the first pedestal to contact the first conductor from a first side when the first cam is in a closed position, and a second cam rotatable about the first pedestal to contact the first conductor from a second side when the second cam is in a closed position; and A second component connected to the second conductor of the heating cable, the second component comprising: a second base frame including a second channel for receiving the heating cable, a third cam rotatable about the second pedestal to contact the second conductor from the first side when the third cam is in a closed position, and a fourth cam rotatable about the second pedestal to contact the second conductor from the second side when the fourth cam is in a closed position, wherein each of the first cam, the second cam, the third cam, and the fourth cam includes a tooth and a first end portion, the tooth being configured to pierce the sheath and the core material when the corresponding cam is rotated, and the first end portion being adjacent to the tooth to contact the corresponding conductor when the corresponding cam is in a closed position.

2. The termination assembly according to claim 1, wherein: Each of the first cam, the second cam, the third cam, and the fourth cam includes a width greater than a diameter of the first conductor and the second conductor.

3. The termination assembly according to claim 1, wherein: The first cam is rotatable about the first pedestal via a first pivot member, and wherein the first cam, the first pedestal, and the first pivot member are made of an electrically conductive material to form an electrical connection with the first conductor. 4 . The termination assembly according to claim 3 , further comprising a housing for accommodating the first assembly and the second assembly, the housing being made of an electrically insulating material.

5. The termination assembly according to claim 1, wherein: The first cam and the third cam rotate in the same direction from an open position to a closed position.

6. The termination assembly according to claim 1, wherein: The first cam and the third cam rotate in opposite directions from an open position to a closed position.

7. The termination assembly according to claim 6, wherein: The first cam and the third cam both rotate perpendicular to the length of the heating cable.

8. The termination assembly according to claim 6, wherein: The first cam and the third cam both rotate parallel to the length of the heating cable.

9. The termination assembly of claim 1, wherein: The first assembly further includes a fifth cam rotatable about the first pedestal to contact the first conductor from a third side when the fifth cam is in a closed position; and The second assembly also includes a sixth cam rotatable about the second base to contact the second conductor from a fourth side when the sixth cam is in a closed position.

10. The termination assembly according to claim 1, wherein: The first end portion includes an inclined surface that contacts the corresponding conductor when the corresponding cam is in the closed position.

11. The termination assembly according to claim 1, wherein: The first channel terminates at an inner wall of the first base frame, the inner wall being configured to prevent translational movement of the heating cable when the first cam is rotated to a closed position.

12. A method of terminating a heating cable via a termination assembly, the method comprising: aligning a first conductor of the heating cable with a first component and aligning a second conductor of the heating cable with a second component; rotating a first cam of the first assembly from an open position to a closed position so that teeth of the first cam pierce the jacket and core material of the heating cable and allow a first end portion of the first cam adjacent the teeth to contact the first conductor from a first side of the heating cable; rotating a second cam of the first assembly from an open position to a closed position so that the teeth of the second cam pierce the jacket and core material of the heating cable and allow a first end portion of the second cam adjacent the teeth to contact the first conductor from a second side of the heating cable; rotating a third cam of the second assembly from an open position to a closed position so that teeth of the third cam pierce the jacket and core material of the heating cable and allow a first end portion of the third cam adjacent the teeth to contact the second conductor from the first side; as well as The fourth cam of the second assembly is rotated from an open position to a closed position so that the teeth of the fourth cam pierce the jacket and core material of the heating cable and allow a first end portion of the fourth cam adjacent to the teeth to contact the second conductor from the second side.

13. The method according to claim 12, further comprising: rotating a fifth cam of the first assembly from an open position to a closed position so that the teeth of the fifth cam pierce the jacket and core material of the heating cable and allow a first end portion of the fifth cam adjacent the teeth to contact the first conductor from a third side of the heating cable; as well as The sixth cam of the second assembly is rotated from an open position to a closed position so that the teeth of the sixth cam pierce the jacket and core material of the heating cable and allow a first end portion of the sixth cam adjacent to the teeth to contact the second conductor from a fourth side of the heating cable.

14. The method according to claim 12, wherein: Aligning the first and second conductors includes inserting the heating cable through a passageway of the termination assembly such that the first conductor of the heating cable is aligned with the first assembly and the second conductor of the heating cable is aligned with the second assembly.

15. The method of claim 12, further comprising installing a housing on the first assembly and the second assembly after the first cam, the second cam, the third cam, and the fourth cam are rotated to a closed position.

16. A termination assembly for a heating cable, the heating cable comprising a first conductor, a second conductor, a core material on the first conductor and the second conductor, and a jacket on the core material, the termination assembly comprising: A first component connected to the first conductor of the heating cable, the first component comprising: a first base frame comprising a first channel for receiving the heating cable, a first cam rotatable about the first pedestal to contact the first conductor from a first side when the first cam is in a closed position, and a first contact member coupled to the first pedestal to contact the first conductor from a second side when the first cam is in a closed position; and A second component connected to the second conductor of the heating cable, the second component comprising: a second base frame including a second channel for receiving the heating cable, a second cam rotatable about the second pedestal to contact the second conductor from the first side when the second cam is in a closed position, and a second contact member coupled to the second pedestal to contact the second conductor from the second side when the second cam is in a closed position, wherein each of the first cam and the second cam includes a tooth configured to pierce the jacket and the core material when the corresponding cam is rotated and a first end portion adjacent to the tooth to contact the corresponding conductor when the corresponding cam is in a closed position, and Wherein each of the first contact member and the second contact member includes an extension configured to pierce the sheath and the core material when the corresponding cam is rotated, thereby pushing the corresponding conductor onto the corresponding contact member.

17. The termination assembly according to claim 16, wherein: The extension includes one of: a single serration, a plurality of serrations, an insulation displacement connector, or a plurality of pins.

18. The termination assembly according to claim 16, wherein: The first cam, the second cam, the first contact member, and the second contact member are made of a conductive material to form an electrical connection with the first conductor and the second conductor.

19. The termination assembly of claim 18, further comprising a housing for accommodating the first assembly and the second assembly, the housing being made of an electrically insulating material.

20. The termination assembly of claim 16, wherein: The first cam and the second cam rotate in opposite directions from an open position to a closed position.

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