Electrical connector system

Abstract

An electrical connector system may include a first conductor including a first conductive material; a second conductor comprising a first conductive material; a fastener configured to couple the first conductor to the second conductor; and a constant torque material comprising a second electrically conductive material. A constant torque material may be disposed in electrical communication with the first conductor and the second conductor. The constant torque material may include carbon nanotubes disposed on a substrate.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 567,386, filed on March 19, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to computer and / or telecommunications equipment cabinets, such as those used in data centers, and more particularly to power distribution systems for such equipment cabinets. Background Art

[0004] High-power copper busbars are commonly used in power distribution systems to carry high currents and efficiently transmit electrical energy. One primary method of connecting to these busbars is with bolted connections. The busbars are drilled to create holes at specific intervals, and bolts, nuts, and washers are used to fasten the busbars together. Bolted connections provide good mechanical strength and can handle high currents.

[0005] Bolted bridge bars are also often used to connect to these busbars. Bridge bars are short sections of busbars that bridge the gap between two busbars. They are typically bolted or welded to adjacent busbars, creating a continuous electrical path. Proper torque and suitable hardware are important to ensure a reliable connection, both with direct bolting and with bridge bars.

[0006] Various factors contribute to the need to properly torque and periodically re-torque the bolted connections to the busbars and the connections that join them together. For example, when high power is applied to a copper bus, temperature changes can cause physical movement between the various substructures that are connected. Additionally, high-current connections, particularly DC connections, can pulse due to magnetic fields when power levels change, particularly during fault conditions where current changes rapidly. Physical systems can also move from time to time.

[0007] Periodically re-torquing bolted connections increases maintenance costs and complexity. Periodically re-torquing bolted connections also typically requires system downtime, as power is typically shut down during any re-torquing process, potentially disrupting business operations and requiring planning and coordination. Without frequent, periodic re-torquing, bolted connections can become loose, leading to a loss of conductivity. This loss of conductivity can lead to an increase in heat in the connection, further compounding the problem. Summary of the Invention

[0008] The present applicant has created novel and useful devices, systems and methods for power distribution systems for computer equipment cabinets. The use of constant voltage material can ensure that bolts installed according to torque specifications remain within the specified torque range without the need for frequent periodic re-torquing, thereby reducing maintenance costs and complexity and reducing system downtime. In at least one embodiment, the constant voltage material can be permanently (or semi-permanently) elastic and can rebound uniformly when the bolt expands and contracts, for example due to thermal changes that may be caused by current changes, thereby eliminating (or at least greatly reducing) the need to re-torque the bolted connection. In at least one embodiment, the constant voltage material can be electrically conductive and can be advantageously arranged to support electrical communication between two or more conductors or between two or more conductors. In at least one embodiment, the constant voltage material can be or include carbon nanotubes. In at least one embodiment, the carbon nanotubes can be configured to provide a permanent (or at least long-lasting) elastic spring force or biasing force, such as to resist the back-off of the bolted connection.

[0009] In at least one embodiment, an electrical connector system may include two or more conductors such as bus bars and a conductive constant torque material coupled together in electrical communication with each other. In at least one embodiment, the two or more conductors may include or be made of one or more conductive materials, and the one or more conductive materials may be the same material or different materials from one conductor to another. In at least one embodiment, a fastener may be arranged to couple the two or more conductors together, and the constant torque material may be arranged to electrically communicate with the conductors. In at least one embodiment, the constant torque material may be or include a conductive material and may be arranged to support electrical communication between or between two or more conductors, fasteners, and / or other components.

[0010] In at least one embodiment, the constant torque material may be disposed on a substrate, which may include the constant torque material being formed on the substrate, being formed elsewhere and transferred to the substrate, or any combination of the foregoing. In at least one embodiment, the constant torque material may be or include carbon nanotubes. In at least one embodiment, a plurality of carbon nanotubes may be aligned at least substantially perpendicular to the face or other surface of one or more conductors. In at least one embodiment, the substrate may be coupled to at least a portion of a first conductor, such as to one or more faces or other surfaces of the first conductor. In at least one embodiment, the substrate may be coupled to at least a portion of a second conductor, such as to one or more faces or other surfaces of the second conductor. In at least one embodiment, two or more substrates comprising constant torque material may be coupled to any one or more of a plurality of conductors and / or to each other.

[0011] In at least one embodiment, a constant torque material can resist movement of two or more conductors relative to each other and / or relative to one or more other system components, such as a fastener or its components. In at least one embodiment, the fastener can include: a bolt having a head portion and a shaft portion; a nut configured to couple to the shaft portion of the bolt; and at least one washer configured to be positioned along the shaft portion. In at least one embodiment, the one or more washers can be or include Belleville washers and / or can be positioned between a portion of the fastener and the conductor. In at least one embodiment, the constant torque material can be coupled to a portion of the fastener.

[0012] In at least one embodiment, one or more conductors can be or include copper. In at least one embodiment, the system can include two or more bus bars and a constant torque material disposed on a substrate, the constant torque material configured to be compressed between the bus bars. In at least one embodiment, the substrate can include one or more openings configured to receive at least a portion of one or more fasteners therein and / or to receive at least a portion of one or more fasteners therethrough. In at least one embodiment, the constant torque material can be disposed in direct physical contact with the two or more conductors.

[0013] In at least one embodiment, an electrical connector, such as a wire or cable lug, may include: a conductor connection section that can be connected to a conductor; and a surface connection section that can be connected to another connector, such as a busbar, the surface connection section having a constant torque (or torque compensation) material applied thereto. In at least one embodiment, the constant pressure material may be or include carbon nanotubes. In at least one embodiment, the constant pressure material may be or include carbon nanotubes that are vertically aligned relative to the surface of the connector. In at least one embodiment, the constant pressure material may be applied to the top side and / or bottom side of the connector. In at least one embodiment, the constant pressure material may be applied to the conductor connection section and / or the surface connection section, and the conductor connection section and / or the surface connection section may be designed to be connected to a busbar, such as by means of a bolted connection. In at least one embodiment, the constant pressure material may be applied between the conductor connection section and the conductor.

[0014] In at least one embodiment, the connector may include a bus bar and / or bolts connecting the surface connection section to the bus bar. In at least one embodiment, a constant pressure material may be applied between the surface connection section and the bus bar. In at least one embodiment, the constant pressure material may be applied to the bus bar. In at least one embodiment, the constant pressure material may be applied to the surface of the bus bar opposite the connector.

[0015] In at least one embodiment, a constant pressure material may be applied between the surface connection section and the face of the bolt. In at least one embodiment, the constant pressure material may be applied to the face of the bolt. In at least one embodiment, the constant pressure material may be applied to the threads of the bolt. In at least one embodiment, the connector may include a nut that holds the connector between the bolt and the busbar. In at least one embodiment, the constant pressure material may be applied to the nut.

[0016] In at least one embodiment, the constant voltage material can be or include a coating on a surface of the connector. In at least one embodiment, the constant voltage material can be disposed on a substrate and disposed adjacent to one or more surfaces of the connector. For example, a first substrate comprising the constant voltage material can be disposed adjacent to the top of a surface connection section, such as between the face of a bolt and the connector, and a second substrate comprising the constant voltage material can be disposed adjacent to the bottom of the surface connection section, such as between the connector and a busbar.

[0017] In at least one embodiment, the electrical connector may be or include: a bus bar for coupling with a plurality of connectors, such as wire / cable lugs, and having a plurality of holes extending through the bus bar for receiving bolts to secure one of the lugs to the bus bar; and a constant voltage material that may be applied to the bus bar. In at least one embodiment, the constant voltage material may be or include carbon nanotubes, such as carbon nanotubes coupled to a substrate or transferred from a substrate to a surface of the bus bar. In at least one embodiment, the constant voltage material may be or include carbon nanotubes that are vertically aligned relative to the surface of the bus bar. In at least one embodiment, the constant voltage material may be applied to the top side and / or bottom side of the bus bar.

[0018] In at least one embodiment, the connector may include bolts coupling the connector to the bus bar. In at least one embodiment, a constant pressure material may be applied between the connector and the bus bar. In at least one embodiment, the constant pressure material may be applied to the connector. In at least one embodiment, the constant pressure material may be applied to a surface of the bus bar opposite the connector.

[0019] In at least one embodiment, a constant pressure material may be applied between the connector and the face of the bolt. In at least one embodiment, the constant pressure material may be applied to the face of the bolt. In at least one embodiment, the constant pressure material may be applied to the threads of the bolt. In at least one embodiment, the connector may include a nut that holds the connector between the bolt and the busbar. In at least one embodiment, the constant pressure material may be applied to the nut.

[0020] In at least one embodiment, the constant voltage material may be or include a coating on a surface of the bus bar. In at least one embodiment, the constant voltage material may be or include one or more washers disposed adjacent to one or more surfaces of the bus bar. For example, a first washer may be disposed adjacent to the top of the bus bar, such as between a connector and the bus bar, and a second washer may be disposed adjacent to the bottom of the bus bar, such as between a nut and the bus bar.

[0021] In at least one embodiment, the electrical connection block may include: a conductive body; a hole located in the body, the hole configured to receive a conductor therein; a clamping device configured to at least partially secure the conductor within the hole; a constant voltage material covering at least a portion of the clamping device; or any combination thereof. In at least one embodiment, the constant voltage material may be or include carbon nanotubes. In at least one embodiment, the constant voltage material may be or include carbon nanotubes that are vertically aligned relative to a surface and / or the body of the clamping device.

[0022] In at least one embodiment, the clamping device can be or include a threaded fastener threaded into the block. In at least one embodiment, the constant pressure material can cover at least a portion of the clamping device, such as a portion that engages the conductor and / or the body. In at least one embodiment, the constant pressure material can cover at least a portion of the threads of the clamping device. In at least one embodiment, the constant pressure material can cover at least a portion of the hole. In at least one embodiment, the constant pressure material can cover at least a portion of a surface, such as an end of the threaded fastener configured to engage the conductor.

[0023] In at least one embodiment, an electrical connector may include a first conductor, a second conductor, a fastener, and a constant voltage material. In at least one embodiment, the constant voltage material is in electrical contact with the first conductor and the second conductor. In at least one embodiment, the constant voltage material is made of a conductive material. In at least one embodiment, the constant voltage material is applied to at least a portion of the first conductor and at least a portion of the second conductor. In at least one embodiment, the constant voltage material is applied to at least a portion of the first conductor. In at least one embodiment, the constant voltage material is applied to at least a portion of the second conductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a perspective view of one of many embodiments of an electrical connector according to the present disclosure.

[0025] Figure 2 is a front view of a nut and bolt assembly according to the present disclosure.

[0026] Figure 3is a perspective view of one of many embodiments of an electrical connector according to the present disclosure.

[0027] Figure 4 is a perspective view of one of many embodiments of a bus bar assembly according to the present disclosure.

[0028] Figure 5 is a perspective view of one of many embodiments of an electrical connection block according to the present disclosure.

[0029] Figure 6 is a microscopic view of a portion of one of many embodiments of an electrical connector according to the present disclosure.

[0030] Figure 7 is a side cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure.

[0031] Figure 8 is an exploded cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure.

[0032] Figure 9 is an exploded cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure.

[0033] Figure 10 is an exploded cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure.

[0034] Figure 11 is an exploded cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure. DETAILED DESCRIPTION

[0035] The figures and the following written description of specific structure and function are not intended to limit the scope of the applicant's invention or the scope of the appended claims. Rather, the figures and written description are provided to teach any person skilled in the art how to make and use the invention for which patent protection is sought. Those skilled in the art will understand that, for the sake of clarity and understanding, not all features of a commercial embodiment of the present invention are described or illustrated. Those skilled in the art will also understand that the development of an actual commercial embodiment incorporating various aspects of the present invention will require numerous implementation-specific decisions to achieve the developer's ultimate goal for the commercial embodiment. Such implementation-specific decisions may include, but may not be limited to, compliance with system-related, business-related, governmental, and other constraints, which may vary depending on the specific implementation, location, and time. While the developer's effort may be complex and time-consuming in absolute terms, such effort will be a routine task for those skilled in the art having the benefit of this disclosure. It must be understood that the invention disclosed and taught herein is susceptible to numerous modifications and alternative forms, as well as various variations and alternative forms.

[0036] The use of singular terms such as, but not limited to, "one" is not intended to be a restriction on the number of items. In addition, the use of relational terms such as, but not limited to, "top", "bottom", "left", "right", "top", "bottom", "lower", "up", "side" is used in written description for clarity when specifically referring to the accompanying drawings, and is not intended to limit the scope of the present invention or the appended claims. The terms "including" and "such as" are illustrative, rather than restrictive. The terms "connect", "connected", "connected", "connecting piece" and similar terms are widely used in this article and can include for fixing, combining, bonding, fastening, attaching, engaging, inserting therein, forming thereon or therein, communicating one or more components or otherwise such as mechanically, magnetically, electrically, chemically, in an operable manner, directly or indirectly by an intermediate element any method or device associated together with one or more components, and can also include but not limited to forming a functional component integrally with another functional component in an integral manner. Connection can occur in any direction, including occurring in the direction of rotation. Furthermore, all parts and components of the present disclosure that are inherently capable of being physically implemented include both imaginary and real features, whether or not such features are explicitly described herein, including but not limited to features such as axes, ends, inner and outer surfaces, interior spaces, tops, bottoms, sides, boundaries, dimensions (e.g., height, length, width, thickness), mass, weight, volume, and density.

[0037] Applicants have created novel and useful devices, systems, and methods for power distribution systems used in computing equipment cabinets. The use of constant-voltage materials, such as carbon nanotubes, can ensure that bolts installed to torque specifications remain within the specified torque range without the need for periodic re-torquing, thereby reducing maintenance costs and complexity and reducing system downtime. The use of constant-voltage materials, such as carbon nanotubes, can eliminate (or at least significantly reduce) the long-term conductivity loss typically expected in bolted connections and can advantageously support electrical communication between two or more components, such as busbars.

[0038] Figure 1 is a perspective view of one of many embodiments of an electrical connector according to the present disclosure. Figure 2 is a front view of a nut and bolt assembly according to the present disclosure. Figure 3 is a perspective view of one of many embodiments of an electrical connector according to the present disclosure. Figure 4 is a perspective view of one of many embodiments of a bus bar assembly according to the present disclosure. Figure 5 is a perspective view of one of many embodiments of an electrical connection block according to the present disclosure. Figure 6 is a microscopic view of a portion of one of many embodiments of an electrical connector according to the present disclosure. Figure 7 is a cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure. Figure 8 is an exploded cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure. Figure 9 is an exploded cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure. Figure 10 is an exploded cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure. Figure 11 is an exploded cross-sectional view of one of many embodiments of an electrical connector according to the present disclosure. Figures 1 to 11 are described in conjunction with each other.

[0039] In at least one embodiment, an electrical connector system 50 according to the present disclosure may include one or more electrical connectors 100 and / or one or more other components for providing an electrical connection. In at least one embodiment, an electrical connector 100 according to the present disclosure, such as a wire or cable lug, may include: one or more conductor connection segments 110, the one or more conductor connection segments 110 being crimped to a conductor 120; and one or more surface connection segments 130, the one or more surface connection segments 130 having a constant pressure (or torque compensation) material 200 applied thereto or otherwise arranged in contact therewith. In at least one embodiment, the constant pressure material 200 may be or include carbon nanotubes. In at least one embodiment, the constant pressure material 200 may be or include carbon nanotubes that are aligned vertically (or at least substantially vertically) relative to one or more surfaces of the connector 100, such as a top surface, a bottom surface, or another surface. In at least one embodiment, the constant voltage material 200 can be or include carbon nanotubes aligned at another angle or multiple angles relative to one or more surfaces of the connector 100, and the other angle or multiple angles can be or include any angle sufficient to achieve one or more of the advantages or objectives discussed herein according to the implementation of the present disclosure.

[0040] In at least one embodiment, the constant voltage material 200 may be or include one or more coatings located on or applied to a surface of the connector 100. For example, the constant voltage material 200 may include or be coupled to a substrate 210, and the constant voltage material 200 may be transferred to a surface of the connector 100 and / or the substrate 210 may be disposed in operable communication with a surface of the connector 100. In at least one embodiment, the substrate 210 may be or include a sheet, plate, panel, disk, gasket, or other structure having the constant voltage material 200 spread or otherwise disposed thereon, and one or more substrates 210 may be disposed adjacent to one or more surfaces of the connector 100. For example, the base plate 210 can be disposed adjacent to the top of the surface connection section 130, such as between the face 310 of the bolt 300 and the connector 100, the base plate 210 can be disposed adjacent to the bottom of the surface connection section 130, such as between the connector 100 and the bus bar 400, the base plate 210 can be disposed adjacent to the bottom of the bus bar 400, such as between the bus bar 400 and the nut 320 that holds the bolt 300 in place, or any combination thereof. As used herein, the term "bolt" can be or include any threaded fastener or similar coupling (e.g., a screw, a threaded rod, etc.) according to an implementation of the present disclosure.

[0041] In at least one embodiment, the constant voltage material 200 may be or include carbon nanotubes, and the substrate 210 may be or include aluminum and / or any other material (whether currently known or developed in the future) on which the carbon nanotubes can be generated, propagated, or otherwise coupled to. In at least one embodiment, the constant voltage material 200 may be or include carbon nanotubes arranged to be transferred from the substrate 210 to one or more other system components, such as to one or more surfaces of bolts, washers, nuts, bus bars, conductors, or other components. In at least one embodiment, the constant voltage material 200 and / or the substrate 210 may be conductive and may be advantageously arranged and disposed on, in contact with, or otherwise cooperate with two or more other system components to support electrical communication between or among these components.

[0042] In at least one embodiment, constant pressure material 200 can dissipate heat, thereby minimizing any temperature variations and resulting physical movement between connectors / connectors 100, 400, 500. In at least one embodiment, constant pressure material 200 can flex and / or otherwise compensate for physical movement between connectors / connectors 100, 400, 500, thereby maintaining the torque of bolt 300 within specifications (which may be or include any specifications required or desired according to implementations of the present disclosure) during or despite any such movement.

[0043] In at least one embodiment, the constant voltage material 200 can be applied to the top side and / or the bottom side of the connector 100. In at least one embodiment, the constant voltage material 200 can be applied to the conductor connection section 110 and / or the surface connection section 130. The conductor connection section 110 and / or the surface connection section 130 can be designed to be coupled to the bus bar 400, such as by bolted connections. In at least one embodiment, the constant voltage material 200 can be applied between the conductor connection section 110 and the conductor 120.

[0044] In at least one embodiment, the connector system 50 may include one or more bus bars 400 and / or one or more bolts 300 for coupling the surface connection sections 130 of one or more electrical connectors 100 to the bus bars 400. In at least one embodiment, a constant voltage material 200 may be applied between the surface connection sections 130 and the bus bars 400. In at least one embodiment, the constant voltage material 200 may be applied to the bus bars 400. In at least one embodiment, the constant voltage material 200 may be applied to the surface of the bus bars 400 opposite the connector 100.

[0045] In at least one embodiment, a constant pressure material 200 can be applied to or otherwise disposed between the surface connection section 130 and the face 310 of the bolt 300. In at least one embodiment, the constant pressure material 200 can be applied to or otherwise disposed in contact with the face 310 of the bolt 300. In at least one embodiment, the constant pressure material 200 can be applied to or otherwise disposed in contact with the threads 330 of the bolt 300. In at least one embodiment, the connector system 50 can include a nut 320 for retaining the connector 100 between the bolt 300 and the bus bar 400. In at least one embodiment, the constant pressure material 200 can be applied to or otherwise disposed in contact with the nut 320.

[0046] In at least one embodiment, the constant voltage material 200 can be or include a coating on a surface of the connector 100. In at least one embodiment, the constant voltage material 200, such as a substrate 210 on which the constant voltage material is disposed, can be disposed adjacent to one or more surfaces of the connector 100. For example, the substrate 200 can be disposed adjacent to the top of the surface connection section 130, such as between the face 310 of the bolt 300 and the connector 100, the substrate 200 can be disposed adjacent to the bottom of the surface connection section 130, such as between the connector 100 and the bus bar 400, the substrate 200 can be disposed adjacent to the bottom of the bus bar 400, such as between the bus bar 400 and the nut 320 that holds the bolt 300 in place, or any combination thereof.

[0047] In at least one embodiment, an electrical connector system 50 may include or include: one or more bus bars 400 that can be coupled to a plurality of other connectors 100, such as wire / cable lugs, the one or more bus bars 400 having one or more holes 410 therethrough for receiving bolts 300 to secure the connectors 100, 400 together; and a constant voltage material 200 applied to the connectors 100, 400. In at least one embodiment, the constant voltage material 200 may include or include carbon nanotubes. In at least one embodiment, the constant voltage material 200 may include or include carbon nanotubes that are vertically aligned relative to one or more surfaces of the connectors 100, 400. In at least one embodiment, the constant voltage material 200 may be applied to one or more sides of the connectors 100, 400, such as the top side, bottom side, and / or one or more other sides of the connectors 100, 400.

[0048] In at least one embodiment, the bus bar 400 may include one or more bolts 300 for coupling one or more other connectors 100 to the bus bar 400. In at least one embodiment, a constant voltage material 200 may be applied between the connector 100 and the bus bar 400. In at least one embodiment, the constant voltage material 200 may be applied to the connector 100 and / or the bus bar 400. In at least one embodiment, the constant voltage material 200 may be applied to a surface of the bus bar 400 opposite the connector 100.

[0049] In at least one embodiment, a constant pressure material may be applied between the connector 100, 400 and the face 310 of the bolt 300. In at least one embodiment, the constant pressure material 200 may be applied to the face 310 of the bolt 300. In at least one embodiment, the constant pressure material 200 may be applied to the threads 330 of the bolt 300. In at least one embodiment, the connector 100, 400 may include a nut 320 that holds the connector 100 between the bolt 300 and the bus bar 400. In at least one embodiment, the constant pressure material 200 may be applied to the nut 320.

[0050] In at least one embodiment, the constant voltage material 200 may be or include a coating disposed on or in contact with a surface of the bus bar 400. In at least one embodiment, the constant voltage material 200 may be or include one or more washers, disks, or other substrate 210 structures disposed adjacent to one or more surfaces of the bus bar and / or adjacent to one or more surfaces of a corresponding coupling structure, such as a washer, bolt head, etc. For example, the constant voltage material 200 may be disposed adjacent to the top of the bus bar 400, such as between the connector 100 and the bus bar 400, and the constant voltage material 200 may be disposed adjacent to the bottom of the bus bar 400, such as between the nut 320 and the bus bar 400.

[0051] In at least one embodiment, the electrical connection system 50 may be or include one or more electrical connection blocks 500. In at least one embodiment, the electrical connection block 500 may include: a conductive body 510; a hole 520 located in the body 510 and configured to receive the conductor 120 therein; a clamping device 530 configured to at least partially secure the conductor 120 within the hole 520; a constant voltage material 200 covering at least a portion of the clamping device 530; or any combination thereof. In at least one embodiment, the clamping device 530 may be or include one or more threaded fasteners, such as one or more bolts 300 or other fasteners. In at least one embodiment, the constant voltage material 200 may be or include carbon nanotubes. In at least one embodiment, the constant voltage material 200 may be or include carbon nanotubes aligned perpendicularly or at another angle relative to one or more surfaces of the clamping device 530 and / or the body 510.

[0052] In at least one embodiment, the clamping device 530 can be or include a bolt 300 or other threaded fastener threaded into a portion of the block 500, such as the body 510. In at least one embodiment, the constant voltage material 200 can cover at least a portion of the clamping device 530, such as the portion 540 that engages the conductor 120 and / or the body 510. In at least one embodiment, the constant voltage material 200 can cover at least a portion of the threads 330 of the clamping devices 530, 300. In at least one embodiment, the constant voltage material 200 can cover at least a portion of the hole 520.

[0053] In at least one embodiment, an electrical connector system may include two or more conductors such as bus bars and a conductive constant torque material coupled together in electrical communication with each other. In at least one embodiment, the two or more conductors may include or be made of one or more conductive materials, and the one or more conductive materials may be the same material or different materials from one conductor to another. In at least one embodiment, a fastener may be arranged to couple the two or more conductors together, and the constant torque material may be arranged to electrically communicate with the conductors. In at least one embodiment, the constant torque material may be or include a conductive material and may be arranged to support electrical communication between or between two or more conductors, fasteners, and / or other components.

[0054] In at least one embodiment, the constant torque material may be disposed on a substrate, which may include the constant torque material being formed on the substrate, being formed elsewhere and transferred to the substrate, or any combination of the foregoing. In at least one embodiment, the constant torque material may be or include carbon nanotubes. In at least one embodiment, a plurality of carbon nanotubes may be aligned at least substantially perpendicular to the face or other surface of one or more conductors. In at least one embodiment, the substrate may be coupled to at least a portion of a first conductor, such as to one or more faces or other surfaces of the first conductor. In at least one embodiment, the substrate may be coupled to at least a portion of a second conductor, such as to one or more faces or other surfaces of the second conductor. In at least one embodiment, two or more substrates comprising constant torque material may be coupled to any one or more of a plurality of conductors and / or to each other.

[0055] In at least one embodiment, a constant torque material can resist movement of two or more conductors relative to each other and / or relative to one or more other system components, such as a fastener or its components. In at least one embodiment, the fastener can include: a bolt having a head portion and a shaft portion; a nut configured to couple to the shaft portion of the bolt; and at least one washer configured to be positioned along the shaft portion. In at least one embodiment, the one or more washers can be or include Belleville washers and / or can be positioned between a portion of the fastener and the conductor. In at least one embodiment, the constant torque material can be coupled to a portion of the fastener.

[0056] In at least one embodiment, one or more conductors can be or include copper. In at least one embodiment, the system can include two or more bus bars and a constant torque material disposed on a substrate, the constant torque material configured to be compressed between the bus bars. In at least one embodiment, the substrate can include one or more openings configured to receive at least a portion of one or more fasteners therein and / or to receive at least a portion of one or more fasteners therethrough. In at least one embodiment, the constant torque material can be disposed in direct physical contact with the two or more conductors.

[0057] In at least one embodiment, the electrical connector system may be or include an electrical connector, such as a wire or cable lug. In at least one embodiment, the electrical connector may include: a conductor connection section that can be connected to a conductor; and a surface connection section that can be connected to another connector, such as a busbar, the surface connection section having a constant torque (or torque compensation) material applied thereto. In at least one embodiment, the constant pressure material may be or include carbon nanotubes. In at least one embodiment, the constant pressure material may be or include carbon nanotubes that are vertically aligned relative to the surface of the connector. In at least one embodiment, the constant pressure material may be applied to the top side and / or bottom side of the connector. In at least one embodiment, the constant pressure material may be applied to the conductor connection section and / or the surface connection section, and the conductor connection section and / or the surface connection section may be designed to be connected to a busbar, for example, by a bolted connection. In at least one embodiment, the constant pressure material may be applied between the conductor connection section and the conductor.

[0058] In at least one embodiment, the connector system may include a bus bar and / or bolts connecting the surface connection section to the bus bar. In at least one embodiment, a constant pressure material may be applied between the surface connection section and the bus bar. In at least one embodiment, the constant pressure material may be applied to the bus bar. In at least one embodiment, the constant pressure material may be applied to the surface of the bus bar opposite the connector.

[0059] In at least one embodiment, a constant pressure material may be applied between the surface connection section and the face of the bolt. In at least one embodiment, the constant pressure material may be applied to the face of the bolt. In at least one embodiment, the constant pressure material may be applied to the threads of the bolt. In at least one embodiment, the connector may include a nut that holds the connector between the bolt and the busbar. In at least one embodiment, the constant pressure material may be applied to the nut.

[0060] In at least one embodiment, the constant voltage material can be or include a coating located on or applied to a surface of the connector. In at least one embodiment, the constant voltage material can be or include one or more substrates disposed adjacent to one or more surfaces of the connector. For example, a first substrate can be disposed adjacent to the top of a surface connection section, such as between the face of a bolt and the connector, and a second substrate can be disposed adjacent to the bottom of the surface connection section, such as between the connector and a busbar.

[0061] In at least one embodiment, an electrical connector system may be or include: a busbar for coupling with a plurality of connectors, such as wire / cable lugs, and having a plurality of holes extending through the busbar, wherein each hole is configured to receive a bolt to secure one of the lugs to the busbar; and a constant voltage material applied to the busbar. In at least one embodiment, the constant voltage material may be or include carbon nanotubes. In at least one embodiment, the constant voltage material may be or include carbon nanotubes aligned vertically relative to the surface of the busbar. In at least one embodiment, the constant voltage material may be applied to both the top and bottom sides of the busbar.

[0062] In at least one embodiment, the connector system may include bolts coupling the connector to the busbar. In at least one embodiment, a constant pressure material may be applied between the connector and the busbar. In at least one embodiment, the constant pressure material may be applied to the connector. In at least one embodiment, the constant pressure material may be applied to a surface of the busbar opposite the connector.

[0063] In at least one embodiment, a constant pressure material may be applied between the connector and the face of the bolt. In at least one embodiment, the constant pressure material may be applied to the face of the bolt. In at least one embodiment, the constant pressure material may be applied to the threads of the bolt. In at least one embodiment, the connector may include a nut that holds the connector between the bolt and the busbar. In at least one embodiment, the constant pressure material may be applied to the nut.

[0064] In at least one embodiment, the constant voltage material may be or include a substrate disposed in contact with a surface of a busbar. In at least one embodiment, the substrate may be or include one or more washers disposed adjacent to one or more surfaces of the busbar and / or a separate substrate disposed between a surface of the busbar and one or more other structures, such as washers or bolt heads. For example, a first substrate may be disposed adjacent to the top of the busbar, such as between a connector and the busbar, and a second substrate may be disposed adjacent to the bottom of the busbar, such as between a nut and the busbar.

[0065] In at least one embodiment, the electrical connection block may include: a conductive body; a hole located in the body, the hole configured to receive a conductor therein; a clamping device configured to at least partially secure the conductor within the hole; a constant voltage material covering at least a portion of the clamping device; or any combination thereof. In at least one embodiment, the constant voltage material may be or include carbon nanotubes. In at least one embodiment, the constant voltage material may be or include carbon nanotubes that are vertically aligned relative to a surface and / or the body of the clamping device.

[0066] In at least one embodiment, the clamping device can be or include a threaded fastener threaded into the block. In at least one embodiment, the constant pressure material can cover at least a portion of the clamping device, such as a portion that engages the conductor and / or the body. In at least one embodiment, the constant pressure material can cover at least a portion of the threads of the clamping device. In at least one embodiment, the constant pressure material can cover at least a portion of the hole. In at least one embodiment, the constant pressure material can cover at least a portion of a surface, such as an end of the threaded fastener configured to engage the conductor.

[0067] In at least one embodiment, the electrical connector system 50 or the electrical connector 100 may include or include a first bus bar 400A, a second bus bar 400B, a bolt 300, and a nut 320. In at least one embodiment, the first bus bar 400A includes a first top surface 420, a first bottom surface 425, and a first hole 430 extending from the first top surface 420 to the first bottom surface 425. In at least one embodiment, the constant torque material 200 may be applied to the base plate 210. In at least one embodiment, the base plate 210 including the constant torque material 200 may be positioned between the first bus bar 400A and the second bus bar 400B. In at least one embodiment, the base plate 210 including the constant torque material 200 may be coupled to at least a portion of the first top surface 420. In at least one embodiment, the base plate 210 including the constant torque material 200 may be coupled to at least a portion of the first bottom surface 425. In at least one embodiment, a substrate 210 including a constant torque material 200 may be coupled to at least a portion of the first top surface 420, and another substrate 210 including a constant torque material 200 may be coupled to the first bottom surface 425. In at least one embodiment, the second bus bar 400B includes a second top surface 435, a first bottom surface 440, and a second hole 445 extending from the second top surface 435 to the second bottom surface 440. In at least one embodiment, a substrate 210 including a constant torque material 200 may be coupled to at least a portion of the second top surface 435. In at least one embodiment, a substrate 210 including a constant torque material 200 may be coupled to at least a portion of the second bottom surface 440. In at least one embodiment, a substrate 210 including a constant torque material 200 may be coupled to at least a portion of the second top surface 435, and another substrate 210 including a constant torque material 200 may be coupled to the second bottom surface 440.

[0068] In at least one embodiment, at least a portion of the bolt 300 can be received in the first hole 430 of the first bus bar 400A and the second hole 445 of the second bus bar 400B. In at least one embodiment, the bolt 300 includes a face 310 and a plurality of threads 330. In at least one embodiment, the constant torque material 200 can be applied to at least a portion of the face 310 and at least a portion of the threads 330. In at least one embodiment, the constant torque material 200 can be applied to at least a portion of the face 310 or at least a portion of the threads 330. In at least one embodiment, the nut 320 can be torqued onto the threads 330 of the bolt 300 to a predetermined torque specification. When the nut 320 is torqued onto the threads 330, the first and second bus bars 400A, 400B are pressed together, and the constant torque material 200 positioned between the first and second bus bars 400A, 400B is compressed. In at least one embodiment, the constant torque material 200 can be applied to one or more sides of the nut 320.

[0069] In at least one embodiment, the constant torque material 200 may be or include carbon nanotubes. In at least one embodiment, the constant torque material 200 may be or include carbon nanotubes aligned perpendicularly or at another angle relative to the first top surface 420, the first bottom surface 425, the second top surface 435, and the second bottom surface 440. In at least one embodiment, the carbon nanotubes of the constant torque material 200 may be grown on the substrate 210. In at least one embodiment, the constant torque material 200 may be or include a conductive material having substantially similar conductivity to, or higher conductivity than, the materials of the first and second bus bars 400A, 400B. In at least one embodiment, the constant torque material 200 may dissipate heat, thereby minimizing any temperature changes and resulting physical movement between the first and second bus bars 400A, 400B. In at least one embodiment, the constant torque material 200 can flex and / or otherwise compensate for physical movement between the first bus bar 400A and the second bus bar 400B, thereby maintaining the torque of the bolt 300 within specifications during or despite any such movement. In at least one embodiment, the constant torque material 200 can be in electrical contact with the first bus bar 400A and the second bus bar 400B. In at least one embodiment, the constant torque material 200 can transfer current from the first bus bar 400A to the second bus bar 400B, or transfer current from the second bus bar 400B to the first bus bar 400A.

[0070] Without departing from the spirit of the applicant's disclosure, it is conceivable that other and further embodiments utilizing one or more aspects of the present disclosure may be devised. For example, devices, systems, and methods may be implemented for many different types and sizes in many different industries. In addition, various methods and embodiments of devices, systems, and methods may be included in a manner combined with each other to produce variations of the disclosed methods and embodiments. Discussions of singular elements may include plural elements, and discussions of plural elements may include singular elements. Unless otherwise specifically limited, the order of steps may occur in various orders. The various steps described herein may be combined with other steps, interspersed with the stated steps, and / or split into multiple steps. Similarly, elements have been functionally described and may be implemented as separate components or may be combined into components with multiple functions.

[0071] The present invention has been described in the context of preferred and other embodiments, but not every embodiment of the invention has been described. Obvious modifications and variations of the described embodiments will be readily apparent to those skilled in the art having the benefit of this disclosure. The disclosed and undisclosed embodiments are not intended to limit or restrict the scope or applicability of the invention conceived by the applicant, but rather, the applicant intends to fully protect, as per patent law, all such modifications and improvements that come within the scope or range of equivalents of the appended claims.

Claims

1. An electrical connector system, comprising: a first conductor comprising a first conductive material, the first conductor having a first top surface and a first bottom surface; a second conductor comprising a first conductive material, the second conductor having a second top surface and a second bottom surface; a fastener configured to couple the first conductor to the second conductor; as well as a constant torque material comprising a second conductive material; Wherein, the constant torque material is configured to be arranged in electrical communication with the first conductor and the second conductor.

2. The electrical connector system according to claim 1, wherein: The constant torque material is arranged on a substrate.

3. The electrical connector system according to claim 1, wherein: The second conductive material includes a plurality of carbon nanotubes.

4. The electrical connector according to claim 3, wherein: The plurality of carbon nanotubes of the second conductive material are configured to be aligned substantially perpendicular to the first top surface of the first conductor, the first bottom surface of the first conductor, the second top surface of the second conductor, and the second bottom surface of the second conductor.

5. The electrical connector system according to claim 2, wherein: The substrate is configured to be coupled to at least a portion of the first conductor.

6. The electrical connector system according to claim 2, wherein: The substrate is configured to be coupled to at least a portion of the second conductor.

7. The electrical connector system according to claim 2, wherein: The substrate is configured to be coupled to at least a portion of the first conductor and further includes a second substrate having an additional amount of the constant torque material disposed thereon, wherein the second substrate is configured to be coupled to at least a portion of the second conductor.

8. The electrical connector system according to claim 2, wherein: The substrate is configured to be coupled to a portion of the first top surface of the first conductor.

9. The electrical connector system according to claim 2, wherein: The substrate is configured to be coupled to a portion of the first bottom surface of the first conductor.

10. The electrical connector system according to claim 2, wherein: The substrate is configured to be coupled to a portion of the second top surface of the second conductor.

11. The electrical connector system according to claim 2, wherein: The substrate is configured to be coupled to a portion of the second bottom surface of the second conductor.

12. The electrical connector system according to claim 1, wherein: The constant torque material is configured to resist relative movement of the first conductor and the second conductor.

13. The electrical connector system according to claim 1, wherein: The fastener comprises: a bolt comprising a head portion and a shaft portion; a nut configured to be coupled to the shaft portion of the bolt; and At least one washer is configured to be positioned along the shaft portion.

14. The electrical connector system according to claim 13, wherein: The at least one washer is a Belleville washer configured to be positioned between the nut and the second conductor.

15. The electrical connector system according to claim 1, wherein: The constant torque material is coupled to a portion of the fastener.

16. The electrical connector system according to claim 1, wherein: The first conductive material is copper.

17. The electrical connector system according to claim 1, wherein: The first conductor and the second conductor are bus bars.

18. The electrical connector system according to claim 17, wherein: The constant torque material is disposed on a substrate and is configured to be compressed between the bus bars.

19. The electrical connector system according to claim 18, wherein: The base plate includes an opening configured to receive at least a portion of the fastener therethrough.

20. The electrical connector system of claim 1, wherein: At least a portion of the constant torque material is configured to be placed in direct physical contact with the first conductor and the second conductor.

Images