Horizontal insulating layer piercing connector with parallel connector blades

Abstract

An electrical connector includes a first pad having a first conductor trench and a second conductor trench. A second pad having a third conductor trench and a fourth conductor trench is movably connected to the first pad by a fastener. A first contact is connected to the first pad. The first contact has a first set of teeth extending into the first groove and a second set of teeth extending into the second groove. A first contact washer is connected to the first pad and is positioned over the first contact. A second contact is connected to the second pad. The second contact has a third set of teeth extending into the third groove and a fourth set of teeth extending into the fourth groove. A second contact washer is connected to the second pad and is positioned over the second contact.

Description

[0001] Related applications

[0002] This application is based on and claims priority to U.S. Provisional Application Serial No. 63 / 590,599, filed on October 16, 2023, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] Various exemplary embodiments relate to an electrical connector for electrically connecting a first conductor and a second conductor of various diameters. Background Technology

[0004] Power line clamp connectors are used for permanent or temporary connections to overhead power lines. Parallel cable clamps are configured to electrically connect a main conductor to a tap conductor extending parallel to the main conductor. A parallel cable clamp typically comprises an upper and a lower portion, each having a first groove for receiving the main conductor and a second groove for receiving the tap conductor. The upper and lower portions are typically held together by mechanical fasteners. Summary of the Invention

[0005] In some configurations, the electrical connector includes a first pad having a first conductor trench and a second conductor trench. A second pad having a third conductor trench and a fourth conductor trench is movably connected to the first pad by fasteners. A conductive first contact is connected to the first pad. The first contact has a first set of teeth extending into the first trench and a second set of teeth extending into the second trench. A first contact washer is connected to the first pad and positioned above the first contact. The first contact washer has a first slot aligned with the first set of teeth and a second slot aligned with the second set of teeth. A conductive second contact is connected to the second pad. The second contact has a third set of teeth extending into the third trench and a fourth set of teeth extending into the fourth trench. A second contact washer is connected to the second pad and positioned above the second contact. The second contact washer has a third slot aligned with the third set of teeth and a fourth slot aligned with the fourth set of teeth.

[0006] In some configurations, the electrical connector includes a first pad and a second pad movably connected to the first pad by fasteners. A conductive first contact is connected to the first pad, and the first contact has a first set of teeth and a second set of teeth. A first contact washer is connected to the first pad and positioned above the first contact. The first contact washer includes a first bent portion for receiving a first conductor, a second bent portion for receiving a second conductor, a first slot aligned with the first set of teeth, and a second slot aligned with the second set of teeth. A conductive second contact is connected to the second pad. The second contact includes a third set of teeth and a fourth set of teeth. A second contact washer is connected to the second pad and positioned above the second contact. The second contact washer includes a third slot aligned with the third set of teeth and a fourth slot aligned with the fourth set of teeth. Attached Figure Description

[0007] The aspects and features of these exemplary embodiments will become more apparent from the description of the various exemplary embodiments with reference to the accompanying drawings.

[0008] Figure 1 This is a top-view perspective view of the insulation layer piercing the electrical connector.

[0009] Figure 2 yes Figure 1 Side view of the connector.

[0010] Figure 3 yes Figure 2 A sectional view.

[0011] Figure 4 This is a top perspective view of the first pad, the first contact washer, and the first contact.

[0012] Figure 5 yes Figure 4 A perspective view from below.

[0013] Figure 6 yes Figure 4 The exploded diagram.

[0014] Figure 7 This is a top perspective view of the contact gasket.

[0015] Figure 8 yes Figure 7 A perspective view from below.

[0016] Figure 9 This is a top perspective view of the second pad, the second contact washer, and the second contact.

[0017] Figure 10 yes Figure 9 A top-down perspective view.

[0018] Figure 11 yes Figure 9 The exploded diagram.

[0019] Figure 12 This is a top-down front perspective view of another insulating layer piercing the electrical connector.

[0020] Figure 13 This is a top-down perspective view of another insulating layer piercing the electrical connector.

[0021] Figure 14 yes Figure 12 Top perspective view of the first pad.

[0022] Figure 15 yes Figure 14 A top-down perspective view.

[0023] Figure 16 yes Figure 12 An exploded view of the first pad, the first contact washer, and the first contact.

[0024] Figure 17 yes Figure 16 Top perspective view of the contact gasket.

[0025] Figure 18 yes Figure 17 A perspective view from below.

[0026] Figure 19 yes Figure 12 Top perspective view of the second pad.

[0027] Figure 20 yes Figure 19 A top-down perspective view.

[0028] Figure 21 yes Figure 12 An exploded view of the second pad, the second contact washer, and the second contact.

[0029] Figure 22 This is a cross-sectional view of the insulation layer piercing the electrical connector in a fully closed position.

[0030] Figure 23 yes Figure 22 A magnified partial view of the tooth and cable trench area.

[0031] Figure 24 This is a cross-sectional view showing the insulation layer piercing the electrical connector in the open position.

[0032] Figure 25 It is a cross-sectional view of the insulation layer clamping the primary and secondary conductors piercing the electrical connector. Detailed Implementation

[0033] In various implementations, parallel trench insulation-piercing connector clamps can be used for tapping, splicing, and dead-end connections in a variety of utility line operations. The clamp may include a pair of pads, each with a connector body having a first groove for primary connection and a second groove for tapping. Fasteners may extend through the pads to engage them and allow the clamp to be tightened onto one or more electrical conductors. Teeth may be provided so that the clamp pierces the conductor insulation, allowing line workers to make electrical connections without stripping the cable.

[0034] Figures 1 to 3 An exemplary configuration of a connector 100 having a first pad 102, a second pad 202, a spring member 106, and a fastener 108 is shown. The fastener 108 secures the spring member 106 against the second pad 202 such that the first pad 102 and the second pad 202 are biased toward each other. The spring member 106 also provides a clamping force to secure the first conductor and the second conductor between the first pad 102 and the second pad 202.

[0035] Fastener 108 may include bolt 110, washer 112, and shear nut 114. Shear nut 114 may include an upper engagement portion, a breakable section, and a lower engagement portion. A tool can be used to tighten the shear nut 114 through the upper engagement portion until a certain torque limit is reached, and the breakable section is sheared to remove the upper engagement portion. This helps prevent the fastener from being overtightened, thereby avoiding potential damage to the connector or conductor.

[0036] One or more conductor seals 116 may also be used with connector 100. The conductor seal 116 may be placed over an exposed portion of the conductor. For example, the free end of a tap conductor may have an exposed end without insulation. The conductor seal 116 may be used to cover this free end to prevent water or debris from entering the tap line, which could lead to corrosion.

[0037] Figures 4 to 6An exemplary configuration of a first pad 102 having an outer surface 120, a first end 122, a second end 122, a first side 124, and a second side 126 is shown. The first pad 102 may be a single-piece component or may be made of multiple connected parts. The first pad 102 may be made of a conductive material (e.g., metal) or a non-conductive material (such as a polymer or composite material). The first pad 102 includes a first conductor trench 128 and a second conductor trench 130. The first conductor trench 128 and the second conductor trench 130 are substantially parallel to each other and configured to receive a first conductor and a second conductor, respectively. The first conductor trench 128 and the second conductor trench 130 are arcuate or partially cylindrical trenches extending between the first side 124 and the second side 126. In various configurations, the size, shape, length, and orientation of the first conductor trench and the second conductor trench may vary, for example, depending on the type of conductor to be connected and the direction in which the conductors are to extend.

[0038] Each side of the first pad 102 may include an upwardly extending protrusion 132. The protrusion 132 may extend between the first conductor trench 128 and the second conductor trench 130. The protrusion 132 may have a generally triangular configuration with dots. The protrusion 132 engages in a corresponding trench 232 on the side of the second pad 202, such as... Figure 1 and Figure 2 As shown. The protrusion 132 and the groove 232 help to limit the pivoting movement of the first pad 102 and the second pad 202 relative to each other.

[0039] A first end 120 of the first pad 102 may include a raised lip 136 extending from a first conductor trench 128. A second end 122 of the first pad 102 may include one or more legs 138 extending from a lower surface at an angle. The angle of the legs 138 allows a user to grip the outer surface and apply pressure to pivot the first pad 102 and the second pad 202 relative to each other.

[0040] like Figure 5 As shown in the best embodiment, the first pad 102 includes a fastener opening 140 extending through the outer surface 118 to receive a bolt 110. A pair of protrusions 142 extend from the outer surface 118 near the opening 140. The protrusions 142 help retain the head of the bolt 110 to prevent rotation when tightening the shear nut 114 without the need for a separate tool. A sleeve 144 extends from the inner portion of the first pad 102 opposite the opening 140 (e.g., ...). Figure 4 and Figure 6 (As shown) The sleeve 144 extends. The sleeve 144 has a hollow cylindrical body that receives the fastener bolt 110. The size and shape of the sleeve 144 can vary depending on the type of fastener 108 used to connect the first pad 102 and the second pad 202. In some configurations, the sleeve 144 is integrally formed with the first pad 102.

[0041] At least one insulating layer shift contact can be connected to the first pad 102. For example... Figure 4 and Figure 6 As shown, the first contact 146A extends on a first side of the first pad 102 between the first conductor trench 128 and the second conductor trench 130. The second contact 146B extends on a second side of the first pad 102 between the first conductor trench 128 and the second conductor trench 130. Each contact 146A, 146B includes a first set of teeth 150A, 150B, a second set of teeth 152A, 152B, and central portions 154A, 154B bridging the first teeth 150A, 150B and the second teeth 152A, 152B. The first insulation layer shifting contact 146A and the second insulation layer shifting contact 146B are depicted as single-piece contacts or integral contacts that form an electrical connection between the first conductor trench 128 and the second conductor trench 130, but multi-piece contacts may also be used.

[0042] In some configurations, the first pad 102 may include a first slot 156 for receiving a first contact 146A and a second slot 158 ​​for receiving a second contact 146B, such as Figure 6 As best shown. The first slot 156 and the second slot 158 ​​extend into the first pad 102 and extend from the first conductor trench 128 to the second conductor trench 130 on either side of the sleeve 144. The first slot 156 and the second slot 158 ​​may be blind slots that extend in a stepped manner into the inner surface of the first pad 102.

[0043] Insulation layer shifting contacts 146A and 146B facilitate engagement of insulated conductors and displacement of the insulation layer. In some applications, the teeth are designed to pierce the insulation layer of the corresponding conductor. The electrical connector can also be used with conductors that do not have an insulation layer, and the insulation layer shifting contacts can be used to clamp or retain the conductor.

[0044] In some configurations, the first contact washer 160 is connected to the first pad 102. For example... Figure 7 and Figure 8As best shown, the contact washer 160 includes a front portion 162, a central region 164, and a rear portion 166. The front portion 162 can be positioned within the lip 136 of the first pad 102 and can engage with the lip 136 to help hold the washer 160 in place. The front portion 162 includes a curved section 168 corresponding to the second conductor trench 130. A pair of slots 170 are formed in opposite sides of the washer 160 to receive second conductor trench teeth 152A, 152B of contacts 146A, 146B. The first washer 160 can be configured such that, in a stress-free position, the teeth 152A, 152B do not extend beyond the slots 170 but are positioned below the outer edge of the slots 170. In other configurations, the teeth 152A, 152B may extend partially beyond the slots 170, with a majority of the teeth 152A, 152B below the outer edge.

[0045] A central region 164 extends between a front portion 162 and a rear portion 166. The central region 164 includes a raised surface extending above sections of the front and rear portions 166. An opening 172 extends through the central region 164 and into the front portion 164 to receive a sleeve 144. The opening 172 has an elliptical or oblong configuration to allow movement of the sleeve 144 within the opening.

[0046] The rear portion 166 of the first contact washer 160 may include a rear edge 174. A portion of the rear edge 174 may be received in a first side recess 176 and a second side recess 178 formed in the first pad 102 (e.g., Figure 6 (As best shown), to help hold the washer 160 in place. The rear portion 166 includes a curved section 180 corresponding to the first conductor groove 128. A pair of slots 182 are formed in opposite sides of the washer 160 to receive the first conductor groove teeth 150A, 150B of the contact. The first washer 160 may be configured such that, in a stress-free position, the teeth 150A, 150B do not extend beyond the slots 182, but are positioned below the outer edge of the slots 182. In other configurations, the teeth 150A, 150B may extend partially beyond the slots 182, with most of the teeth 150A, 150B below the outer edge.

[0047] like Figure 8 As shown, the lower portion of the first contact washer 160 includes a pair of tongues 184 configured to be received in contact slots 156, 158 of the first pad 102. The tongues 184 have a generally rectangular configuration and extend away from the upper surface of the first contact washer 160. The tongues 184 may have hollow sections and communicate with slots 170, 182 on corresponding sides of the first contact washer 160.

[0048] like Figures 9 to 11 As best shown, the second pad 202 includes an outer surface 218, a first end 220, a second end 222, a first side 224, and a second side 226. The second pad 202 can be a single-piece component. The second pad 202 can be made of a conductive material (e.g., metal) or a non-conductive material (such as a polymer or composite material). The second pad 202 includes a first conductor trench 228 and a second conductor trench 230. The first conductor trench 228 and the second conductor trench 230 are substantially parallel to each other and are configured to receive a first conductor and a second conductor, respectively. The first conductor trench 228 and the second conductor trench 230 are arcuate or partially cylindrical trenches extending between the first side 224 and the second side 226. In various configurations, the size, shape, length, and orientation of the first conductor trench and the second conductor trench 228, 230 can vary, for example, depending on the type of conductor to be connected and the direction in which the conductor is to extend.

[0049] The front portion 220 of the second pad 202 may include a raised lip 236 extending from the first conductor trench 228. The rear portion 222 of the second pad 202 may include legs 238 extending from the upper surface at an angle. The angle of the legs 238 allows a user to grip the outer surface and apply pressure to pivot the first pad 102 and the second pad 202 relative to each other.

[0050] like Figure 10 As shown, the second pad 202 includes a fastener opening 240 extending through the outer surface to receive the bolt 110. A recess 242 is formed around the opening 240. The recess 242 has an elongated oval shape and is configured to receive a washer and shear nut for the fastener.

[0051] At least one insulating layer shift contact can be connected to the second pad 202. For example... Figure 11 As shown, a first contact 246A extends on a first side of a second pad 202 between a first conductor trench 228 and a second conductor trench 230. A second contact 246B extends on a second side of a second pad 202 between a first conductor trench 228 and a second conductor trench 230. Each contact 246A, 246B includes a first set of teeth 250A, 250B, a second set of teeth 252A, 252B, and a central portion 254 bridging the first teeth 250A, 250B and the second teeth 252A, 252B. The first insulation layer shifting contact 246A and the second insulation layer shifting contact 246B are depicted as single-piece or integral contacts forming an electrical connection between the first conductor trench 228 and the second conductor trench 230, but multi-piece contacts may also be used.

[0052] In some configurations, the second pad 202 may include a first slot 256 for receiving the first contact 246A and a second slot 258 for receiving the second contact 246B, such as Figure 11 As best shown. The first slot 256 and the second slot 258 extend into the second pad 202 and extend from the first conductor trench 228 to the second conductor trench 238 on either side of the fastener opening 240. The first slot 256 and the second slot 258 may be blind slots that extend in a stepped manner into the inner surface of the first pad 202.

[0053] In some configurations, the second contact washer 260 is connected to the second pad 202. The second contact washer 260 may have a... Figures 6 to 8 The first contact washer 160 shown has a similar or identical construction. In some constructions, the first contact washer 160 and / or the second contact washer 260 may differ from those shown, depending on the application and the conductors to be connected.

[0054] In operation, first pad 102 and second pad 202 are assembled together to form a spring-loaded connector 100. First conductor trenches 128, 228 are aligned to form receiving areas for the first conductor. The trenches of second conductors 130, 230 are aligned to form receiving areas for the second conductor. Spring 106 applies pressure to second pad 202, thereby forcing or biasing first pad 102 and second pad 202 together. First pad 102 and second pad 202 can be separated by overcoming the pressure applied by spring member 106 to allow conductors to be mounted between the conductor trenches of first pad 102 and second pad 202. When first pad 102 and second pad 202 are forced against each other by spring member 106, pressure is generated on the conductors, causing insulating layer displacement contacts 146A, 146B, 246A, 246B to engage the conductors to secure the conductors in conductor trenches 128, 130, 228, 230.

[0055] The force of the spring member 106 is also sufficient to cause the teeth 150A, 150B, 152A, 152B, 250A, 250B, 252A, and 252B to pierce the insulation layer of the conductor. During this operation, the contact washers 160 and 260 can be compressed, causing the teeth 150A, 150B, 152A, 152B, 250A, 250B, 252A, and 252B to extend from the corresponding slots 170 and 182 and engage the conductor, thereby piercing the insulation layer. The contact washers 160 and 260 can form a seal around the opening formed by the teeth 150A, 150B, 152A, 152B, 250A, 250B, 252A, and 252B to prevent water ingress during use.

[0056] In some operations, the second conductor or tap conductor may be inserted into connector 100 first, and then connector 100 may be positioned near the first conductor or main conductor using a live operating lever (not shown) or other suitable utility lineman's lever. The ends of the tap conductor may be sealed with conductor seals 116 to help prevent corrosion of the tap.

[0057] The primary conductor can be inserted into the connector 100 by pushing the first conductor against the inner surfaces of the legs 138, 238. The force exerted by the first conductor on the inner surface overcomes the force of the spring member 106 and pivots the second pad 202 away from the first pad 106. The first conductor can then slide between the first conductor grooves 128, 228. Once the first conductor is positioned in the first conductor grooves 128, 228, the force exerted by the spring member 106 then pivots the second pad 202 back toward the first pad 102, thereby clamping and closing the connection so that the insulating layer pierces the contacts 146A, 146B, 246A, 246B to engage the first conductor and secure it in the first conductor grooves 128, 228. The spring member 106 can apply sufficient force to the teeth 150A, 150B, 250A, 250B to pierce the insulation layer of the first conductor, particularly when the nut 114 is tightened onto the bolt 110, or when the connector can be compressed by the user to pierce the insulation layer. Similarly, the contact washers 160, 260 can be compressed to expose the teeth 150A, 150B, 152A, 152B, 250A, 250B, 252A, 252B, and the washers 160, 260 can form a seal around the openings formed by the teeth 150A, 150B, 152A, 152B, 250A, 250B, 252A, 252B to prevent water ingress during use.

[0058] The insulating piercing contacts 146A, 146B, 246A, and 246B provide an electrical path through connector 100 between the received first and second conductors. While typically the second conductor is inserted first, and then the clamp is attached to the first conductor, in some implementations, the user may insert the first conductor and subsequently the second conductor. The clamp can accommodate conductors of various sizes and types as needed.

[0059] The installation described above can be achieved by attaching a utility lineman's live operating lever to the end of a fastener and / or a nut extending from a second pad; such as by screwing it onto the end of a bolt. Various types of mechanical fasteners can be used in any of the embodiments described above, including those with hooks or eyelets.

[0060] Figure 12Figure 133 illustrates another exemplary configuration of a connector 300 having a first pad 302, a second pad 402, a spring member 306, and a fastener 308. The fastener 308 secures the spring member 306 against the second pad 402 such that the first pad 302 and the second pad 402 are biased toward each other. The spring member 306 also provides a clamping force to secure the first conductor and the second conductor between the first pad 302 and the second pad 402.

[0061] Fastener 308 may include bolt 310, washer 312, and shear nut 314. Shear nut 314 may include an upper engagement portion, a breakable section, and a lower engagement portion. A tool can be used to tighten the shear nut 314 through the upper engagement portion until a certain torque limit is reached, and the breakable section is sheared to remove the upper engagement portion. This helps prevent the fastener from being overtightened, thereby avoiding potential damage to the connector or conductor.

[0062] One or more conductor seals may also be used with connector 300. The conductor seal may be placed over the exposed portion of the conductor. For example, the free end of the tap conductor may have an exposed end without insulation. The conductor seal may be used to cover this free end to prevent water or debris from entering the tap line, which could lead to corrosion.

[0063] Figures 14 to 16 An exemplary configuration of a first pad 302 having an outer surface 320, a first end 322, a second end 322, a first side 324, and a second side 326 is shown. The first pad 302 can be a single-piece component or can be made of multiple connected parts. The first pad 302 can be made of a conductive material (e.g., metal) or a non-conductive material (such as a polymer or composite material). The first pad 302 includes a first conductor trench 328 and a second conductor trench 330. The first conductor trench 328 and the second conductor trench 330 are substantially parallel to each other and configured to receive a first conductor and a second conductor, respectively. The first conductor trench 328 and the second conductor trench 330 are arcuate or partially cylindrical trenches extending between the first side 324 and the second side 326. In various configurations, the size, shape, length, and orientation of the first conductor trench and the second conductor trench can vary, for example, depending on the type of conductor to be connected and the direction in which the conductors are to extend.

[0064] A first end 320 of the first pad 302 may include a raised lip 336 extending from a first conductor trench 328. A second end 322 of the first pad 302 may include one or more legs 338 extending from a lower surface at an angle. The angle of the legs 338 allows a user to grip the outer surface and apply pressure to pivot the first pad 302 and the second pad 402 relative to each other.

[0065] The first pad 302 includes a fastener opening 340 extending through the outer surface 318 to receive the bolt 310. An outer protrusion 342 extends from the outer surface 318 near the opening 340. The protrusion 342 may have a hexagonal configuration that helps retain the head of the bolt 310 to prevent rotation when tightening the shear nut 314 without the need for a separate tool.

[0066] Sleeve 344 extends from the inner portion of the first pad 302 (e.g.) Figure 15 and Figure 16 (As shown) Extension. The sleeve 344 may have a rectangular or trapezoidal construction with a rounded upper corner and a cylindrical inner opening for receiving the fastener bolt 310. The size and shape of the sleeve 344 may vary depending on the type of fastener 308 used to connect the first pad 302 and the second pad 402. In some configurations, the sleeve 344 is integrally formed with the first pad 302.

[0067] At least one insulating layer shift contact may be connected to the first pad 302. For example... Figure 16 As shown, the first contact 346A extends on a first side of the first pad 302 between the first conductor trench 328 and the second conductor trench 330. The second contact 346B extends on a second side of the first pad 302 between the first conductor trench 328 and the second conductor trench 330. Each contact 346A, 346B includes a first set of teeth 350A, 350B, a second set of teeth 352A, 352B, and a central portion 354A, 354B bridging the first teeth 350A, 350B and the second teeth 352A, 152B. The first insulation layer shifting contact 346A and the second insulation layer shifting contact 346B are depicted as single-piece contacts or integral contacts that form an electrical connection between the first conductor trench 328 and the second conductor trench 330, but multi-piece contacts may also be used.

[0068] In some configurations, the first pad 302 may include a first slot 356 for receiving a first contact 346A and a second slot 358 for receiving a second contact 346B, such as Figure 15 As best shown. The first slot 356 and the second slot 358 extend into the first pad 302 and extend from the first conductor trench 328 to the second conductor trench 330 on either side of the sleeve 344. The first slot 356 and the second slot 358 may be blind slots that extend in a stepped manner into the inner surface of the first pad 302, wherein the central portion is recessed from the outer end.

[0069] Insulation layer shifting contacts 346A and 346B facilitate engagement of insulated conductors and displacement of the insulation layer. In some applications, the teeth are designed to pierce the insulation layer of the corresponding conductor. The electrical connector can also be used with conductors that do not have an insulation layer, and the insulation layer shifting contacts can be used to clamp or retain the conductor.

[0070] In some configurations, the first contact washer 360 is connected to the first pad 302. For example... Figure 17 and Figure 18 As best shown, the contact washer 360 includes a front portion 362, a central region 364, and a rear portion 366. The front portion 362 can be positioned within the lip 336 of the first pad 302 and can engage with the lip 336 to help hold the washer 360 in place. The front portion 362 includes a pair of curved sections 368 corresponding to the second conductor trench 330. A pair of slots 370 are formed in opposite sides of the washer 360 to receive the first conductor trench teeth 352A, 352B of the contacts 346A, 346B. The first washer 360 can be configured such that, in a stress-free position, the teeth 352A, 352B do not extend beyond the slots 370, but are positioned below the outer edge of the slots 370. In other configurations, a small portion of the teeth 352A, 352B may extend beyond the slots 370. For example, less than half of the teeth 352A, 352B may extend beyond the slots 370. In another example, less than a quarter of the teeth 352A, 352B may extend beyond slot 370.

[0071] A central region 364 extends between a front portion 362 and a rear portion 366. The central region 364 includes an upper surface aligned with the upper edges of the front portion 362 and the rear portion 366. An opening 372 extends through the central region 364 to receive a sleeve 344.

[0072] The rear portion 366 of the first contact washer 360 may include a rear edge 374. The rear portion 366 includes a pair of curved sections 380 corresponding to the first conductor groove 328. A pair of slots 182 are formed in opposite sides of the washer 360 to receive the first conductor groove teeth 350A, 350B of the contact. The first washer 360 may be configured such that, in a stress-free position, the teeth 350A, 350B do not extend beyond the slots 382, ​​but are positioned below the outer edge of the slots 382, ​​or only partially extend beyond the slots 382, ​​as described with respect to the front slot 370.

[0073] like Figure 18As shown, the lower portion of the first contact washer 360 includes a pair of tongues 384 configured to be received in contact slots 356, 358 of the first pad 302. The tongues 384 have a stepped configuration and extend away from the upper surface of the first contact washer 360. The tongues 384 may have hollow sections and communicate with slots 370, 382 on corresponding sides of the first contact washer 360.

[0074] like Figures 19 to 20 As best shown, the second pad 402 includes an outer surface 418, a first end 420, a second end 422, a first side 424, and a second side 426. The second pad 402 can be a single-piece component. The second pad 402 can be made of a conductive material (e.g., metal) or a non-conductive material (such as a polymer or composite material). The second pad 402 includes a first conductor trench 428 and a second conductor trench 430. The first conductor trench 428 and the second conductor trench 430 are substantially parallel to each other and are configured to receive a first conductor and a second conductor, respectively. The first conductor trench 428 and the second conductor trench 430 are arcuate or partially cylindrical trenches extending between the first side 424 and the second side 426. In various configurations, the size, shape, length, and orientation of the first conductor trench and the second conductor trench 428, 430 can vary, for example, depending on the type of conductor to be connected and the direction in which the conductor is to extend.

[0075] The front portion 420 of the second pad 402 may include a raised lip 436 extending from the first conductor trench 428. The rear portion 422 of the second pad 402 may include legs 438 extending from the upper surface at an angle. The angle of the legs 438 allows a user to grip the outer surface and apply pressure to pivot the first pad 302 and the second pad 402 relative to each other.

[0076] The second pad 402 includes a fastener opening 440 extending through the outer surface to receive a bolt 310. A recess 442 is formed around the opening 440. The recess 442 has an elongated oval shape and is configured to receive a washer and shear nut for the fastener. A pair of protrusions 444 extend from the interior of the second pad 402 around the fastener opening 440. The protrusions 444 may have an angled configuration such that they extend toward each other. The protrusions may be designed to engage a sleeve 344.

[0077] At least one insulating layer shift contact can be connected to the second pad 402. For example... Figure 21As shown, a first contact 446A extends on a first side of a second pad 402 between a first conductor trench 428 and a second conductor trench 430. A second contact 446B extends on a second side of a second pad 402 between a first conductor trench 428 and a second conductor trench 430. Each contact 446A, 446B includes a first set of teeth 450A, 450B, a second set of teeth 452A, 452B, and a central portion 454 bridging the first teeth 450A, 450B and the second teeth 452A, 452B. The first insulation layer shifting contact 446A and the second insulation layer shifting contact 446B are depicted as single-piece or integral contacts forming an electrical connection between the first conductor trench 428 and the second conductor trench 430, but multi-piece contacts may also be used.

[0078] In some configurations, the second pad 402 may include a first slot 456 for receiving a first contact 446A and a second slot 458 for receiving a second contact 446B. The first slot 456 and the second slot 458 extend into the second pad 202 and extend from the first conductor trench 428 to the second conductor trench 438 on either side of the fastener opening 440. The first slot 456 and the second slot 458 may be blind slots extending in a stepped manner into the inner surface of the first pad 202, with a central portion recessed from the outer end.

[0079] In some configurations, the second contact washer 460 is connected to the second pad 402. The second contact washer 460 may have the same characteristics as... Figures 16 to 18 The first contact washer 160 shown has a similar or identical construction. In some constructions, the first contact washer 360 and / or the second contact washer 460 may differ from those shown, depending on the application and the conductors to be connected.

[0080] In operation, the first pad 302 and the second pad 402 are assembled together to form a spring-loaded connector 300. First conductor trenches 328 and 428 are aligned to form a receiving area for the first conductor. The trenches of the second conductors 330 and 430 are aligned to form a receiving area for the second conductor.

[0081] In some constructions, such as Figure 22 and Figure 23 As shown, the inner edges of pads 302, 402 and washers 360, 460 can be substantially aligned to allow pads 302, 402 to be securely abutted against each other. This helps reduce storage costs and allows for safer transport of connector 300 prior to installation.

[0082] In some configurations, teeth 350A, 350B, 352A, 352B, 450A, 450B, 452A, 452B may be offset from the bends 368, 380, 468, 480 of conductor trenches 328, 330, 428, 430 and / or washers 360, 460. For example, teeth 350A, 350B, 352A, 352B, 450A, 450B may each include multiple teeth, and the center tooth may be offset from the center of cable trenches 328, 330, 428, 430 toward the center of pads 302, 304. In the illustrated embodiments, as Figure 23 As shown in the optimal configuration, teeth 350A, 350B, 352A, 352B, 450A, 450B, 452A, and 452B each comprise three teeth, with the center tooth spaced apart from the center point of the curved sections 368, 380, 468, and 480 of washers 360 and 460. Although most of the teeth are below washers 360 and 460, the offset spacing allows the outer teeth to extend slightly more into the opening than the inner teeth. This offset spacing helps to pull the conductor inward toward the center of connector 300 during clamping. This not only enhances retention force and cable hold but also results in a better conductive connection.

[0083] During installation, spring 306 applies pressure to the second pad 402, thereby forcing or biasing the first pad 302 and the second pad 402 together. The first pad 302 and the second pad 402 can be separated by overcoming the pressure applied by spring member 306 to allow conductors to be mounted between the conductor trenches of the first pad 302 and the second pad 402. When the first pad 302 and the second pad 402 are forced against each other by spring member 306, pressure is generated on the conductors, causing insulation displacement contacts 346A, 346B, 446A, 446B to engage the conductors to secure them in the conductor trenches 328, 330, 428, 430.

[0084] The force of the spring member 306 is also sufficient to cause the teeth 350A, 350B, 352A, 352B, 450A, 450B, 452A, and 452B to pierce the insulation layer of the conductor. During this operation, the contact washers 360 and 460 can be compressed, causing the teeth 350A, 350B, 352A, 352B, 450A, 450B, 452A, and 452B to extend from or further out of the corresponding slots 370 and 382 and engage the conductor, thereby piercing the insulation layer. The contact washers 360 and 460 can form a seal around the openings formed by the teeth 350A, 350B, 352A, 352B, 450A, 450B, 452A, and 452B to prevent water ingress during use.

[0085] Figure 25The installation of tap conductor 502 and primary conductor 504 is shown. In some operations, the second conductor or tap conductor 502 may be inserted into connector 300 first, and then connector 300 may be positioned near the first conductor or primary conductor 504 using a live operating lever (not shown) or other suitable utility lineman's lever. The ends of the tap conductor may be sealed with conductor seals 116 to help prevent corrosion of the tap line.

[0086] The primary conductor can be inserted into the connector 300 by pushing the first conductor against the inner surfaces of the legs 338, 438. The force exerted by the first conductor on the inner surface overcomes the force of the spring member 306 and pivots the second pad 402 away from the first pad 306. In some configurations, the sleeve 344 of the first pad 302 can pivot on the protrusion 444 of the second pad 402. The first conductor can then slide between the first conductor grooves 328, 428.

[0087] Once the first conductor is positioned in the first conductor grooves 328, 428, the force applied by the spring member 306 then causes the second pad 402 to pivot back toward the first pad 302, thereby clamping and closing, causing the insulation layer to pierce the contacts 346A, 346B, 446A, 446B to engage the first conductor and secure it in the first conductor grooves 328, 428. The spring member 306 can apply sufficient force to the teeth 450A, 450B to pierce the insulation layer of the first conductor, particularly when the nut 314 is tightened onto the bolt 310, or when the connector can be compressed by the user to pierce the insulation layer. Similarly, contact gaskets 360 and 460 can be compressed to expose teeth 350A, 350B, 352A, 352B, 450A, 450B, 452A, and 452B, and gaskets 360 and 460 can form a seal around the opening formed by teeth 350A, 350B, 352A, 352B, 450A, 450B, 452A, and 452B to prevent water ingress during use.

[0088] The insulating piercing contacts 346A, 346B, 446A, and 446B provide an electrical path through connector 100 between the received first and second conductors. While typically the second conductor is inserted first, and then the clamp is attached to the first conductor, in some implementations, the user may insert the first conductor and subsequently the second conductor. The clamp can accommodate conductors of various sizes and types as needed.

[0089] The foregoing detailed description has been provided for the purpose of explaining the general principles and practical applications, thereby enabling others skilled in the art to understand the disclosure of various constructions and embodiments, and various modifications suitable for the particular intended use. This description is not necessarily intended to be exhaustive or to limit the disclosure to what is disclosed. Any of the constructions and / or elements disclosed herein can be combined with each other to form various additional embodiments not specifically disclosed. Accordingly, additional constructions and embodiments are possible and are intended to be covered within the scope of this specification and the appended claims. Specific examples are described to accomplish a more general objective that could be accomplished in another manner.

[0090] As used herein, the terms “front,” “back,” “up,” “down,” “upward,” “downward,” and other orientation descriptors are intended to facilitate the description of exemplary embodiments of this disclosure and are not intended to limit the structure of exemplary embodiments of this disclosure to any particular location or orientation. Those skilled in the art will understand that terms of degree such as “substantially” or “probably” refer to a reasonable range beyond a given value, for example, general tolerances associated with the manufacture, assembly, and use of the described embodiments. Unless otherwise specified or limited, the terms “installation,” “connection,” “support,” and “linkage,” and variations thereof, are used extensively and cover both direct and indirect installation, connection, support, and linking. The terms “component,” “part,” “module,” “mechanism,” “element,” “device,” etc., are not substitutes for the term “device.” Accordingly, no claim element should be construed as a component plus a function unless the element is explicitly stated using the phrase “device for…”.

Claims

1. An electrical connector comprising: A first pad, the first pad having a first conductor trench and a second conductor trench; The second pad has a third conductor trench and a fourth conductor trench, and the second pad is movably connected to the first pad by fasteners; A conductive first contact is connected to the first pad, the first contact having a first set of teeth extending into the first trench and a second set of teeth extending into the second trench; A first contact washer is connected to the first pad and positioned above the first contact, the first contact washer having a first slot aligned with the first set of teeth and a second slot aligned with the second set of teeth. A conductive second contact is connected to the second pad, the second contact having a third set of teeth extending into the third trench and a fourth set of teeth extending into the fourth trench; and The second contact washer is connected to the second pad and positioned above the second contact, and the second contact washer has a third slot aligned with the third set of teeth and a fourth slot aligned with the fourth set of teeth.

2. The electrical connector of claim 1, further comprising a conductor seal configured to be positioned on an end of a conductor received by the first pad and the second pad.

3. The electrical connector of claim 1, wherein the fastener extends through an opening in the first pad and an opening in the second pad.

4. The electrical connector of claim 3, wherein the fastener extends through a sleeve in the first pad.

5. The electrical connector of claim 4, wherein the sleeve has a cylindrical construction.

6. The electrical connector of claim 4, wherein the sleeve has a trapezoidal configuration.

7. The electrical connector of claim 6, wherein a pair of protrusions extend from the second pad opposite to the sleeve.

8. The electrical connector of claim 1, wherein the first contact gasket includes a first bent section aligned with the first conductor trench and a second bent section aligned with the second conductor trench.

9. The electrical connector of claim 1, wherein when the conductor washer is in an uncompressed state, at least a majority of the first tooth is positioned below the outer edge surrounding the first slot.

10. The electrical connector of claim 1, wherein the first set of teeth is offset from the first conductor groove, and the second set of teeth is offset from the second conductor.

11. An electrical connector comprising: First pad; The second pad is movably connected to the first pad by fasteners; A conductive first contact element is connected to the first pad, and the first contact element has a first set of teeth and a second set of teeth. A first contact washer is connected to the first pad and positioned above the first contact. The first contact washer has a first bent section for receiving a first conductor, a second bent section for receiving a second conductor, a first slot aligned with the first set of teeth, and a second slot aligned with the second set of teeth. A conductive second contact element, the conductive second contact element being connected to the second pad, the second contact element having a third set of teeth and a fourth set of teeth; and The second contact washer is connected to the second pad and positioned above the second contact, and the second contact washer has a third slot aligned with the third set of teeth and a fourth slot aligned with the fourth set of teeth.

12. The electrical connector of claim 11, wherein the fastener extends through an opening in the first pad and an opening in the second pad.

13. The electrical connector of claim 12, wherein the fastener extends through a sleeve in the first pad.

14. The electrical connector of claim 13, wherein the sleeve has a cylindrical construction.

15. The electrical connector of claim 13, wherein the sleeve has a trapezoidal configuration.

16. The electrical connector of claim 15, wherein a pair of protrusions extend from the second pad opposite to the sleeve.

17. The electrical connector of claim 11, wherein the first contact gasket includes a first bent section aligned with the first conductor trench and a second bent section aligned with the second conductor trench.

18. The electrical connector of claim 11, wherein when the conductor washer is in an uncompressed state, at least a majority of the first tooth is positioned below the outer edge surrounding the first slot.

19. The electrical connector of claim 11, wherein the first set of teeth is offset from the first conductor groove, and the second set of teeth is offset from the second conductor.

20. The electrical connector of claim 11, wherein the first pad includes an external protrusion configured to resist rotation of a portion of the fastener.

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