Multi-tap mechanical shear bolt insulation piercing connector

Abstract

The connector includes a conductor block having a trunk opening, a trunk insulation piercing member extending into the trunk opening, a tap opening, and a tap insulation piercing member extending into the tap opening. A trunk cap extends above the trunk opening. A trunk bolt extends through the trunk cap into the trunk opening. The trunk bolt includes a first threaded shank and a first shearable head. The first shearable head is configured to disconnect from the first threaded shank when a first torque limit is reached. A tap cap extends above the tap opening. A tap bolt extends through the tap cap into the tap opening. The tap bolt includes a second threaded shank and a second shearable head. The second shearable head is configured to disconnect from the second threaded shank when a second torque limit is reached.

Description

[0001] Related applications

[0002] This application is based on and claims priority to U.S. Provisional Application Serial No. 63 / 561,944, filed March 6, 2024, and U.S. Provisional Application Serial No. 63 / 730,704, filed December 11, 2024, the disclosures of which are incorporated herein by reference in their entirety. Technical Field

[0003] This disclosure relates to an electrical connector for connecting a main conductor or trunk conductor to one or more tap conductors. Background Technology

[0004] Electrical connectors come in various forms, including terminals, connectors, trunk lines, and taps. Tap connectors are used to establish an electrical connection between a continuous trunk power conductor or main power conductor and a tap or branch conductor. Existing compression connectors are generally suitable for receiving branch or tap conductors to engage with the continuous trunk conductor and are compressed using a crimping tool to achieve the desired connection.

[0005] Compression connectors may include insulating piercing teeth that pierce the non-conductive outer insulation layer of the conductor to contact the inner core. The core may be a solid wire or stranded wire made of a conductive material. Using insulating piercing teeth reduces or eliminates the need to strip the conductor before making the connection and eliminates the need to use bonding materials such as solder to secure the connection. Summary of the Invention

[0006] Some configurations involve an electrical connector for connecting multiple conductors. The connector includes a conductor block having a body having a trunk opening, a trunk insulation piercing member extending into the trunk opening, a tap opening, and a tap insulation piercing member extending into the tap opening. A trunk cap extends above the trunk opening. A trunk bolt extends through the trunk cap into the trunk opening. The trunk bolt includes a first threaded shank and a first shearable head. The first shearable head is configured to disconnect from the first threaded shank upon reaching a first torque limit. A tap cap extends above the tap opening. A tap bolt extends through the tap cap into the tap opening. The tap bolt includes a second threaded shank and a second shearable head. The second shearable head is configured to disconnect from the second threaded shank upon reaching a second torque limit.

[0007] Some configurations involve an electrical connector for connecting multiple conductors. The connector includes a conductor block having a body having a trunk opening, a trunk insulation piercing member extending into the trunk opening, a trunk guide groove extending from the trunk opening, a tap opening, a tap insulation piercing member extending into the tap opening, and a tap guide groove extending from the tap opening. A trunk cap is connected to the conductor block via the trunk guide groove. A trunk bolt extends through the trunk cap into the trunk opening. The trunk bolt includes a first threaded shank and a first shearable head. The first shearable head is configured to disconnect from the first threaded shank when a first torque limit is reached. A tap cap is connected to the conductor block via a tap guide groove. A tap bolt extends through the tap cap into the tap opening. The tap bolt includes a second threaded shank and a second shearable head. The second shearable head is configured to disconnect from the second threaded shank when a second torque limit is reached.

[0008] Some implementations involve a method of connecting multiple electrical conductors. A tap conductor is inserted into a tap opening of a conductor block. A tap bolt is rotated to engage the tap conductor. The tap conductor is driven into a tap insulation piercing member extending into the tap opening. The tap bolt is rotated until a first torque limit is reached and the head of the tap bolt is sheared off. A main conductor is inserted into a main opening of the conductor block. A main bolt is rotated to engage the main conductor. The main conductor is driven into a main insulation piercing member extending into the main opening. The main bolt is rotated until a second torque limit is reached and the head of the main bolt is sheared off.

[0009] Some configurations involve electrical connectors for connecting multiple conductors. The conductor block includes a body having a trunk opening, a trunk insulation piercing member extending into the trunk opening, a tap opening, and a tap insulation piercing member extending into the tap opening. A trunk cap extends above the trunk opening. A trunk bolt extends through the trunk cap into the trunk opening. The trunk bolt includes a first threaded shank and a first shearable head. The first shearable head is configured to disengage from the first threaded shank upon reaching a first torque limit. A tap bolt extends through the conductor block into the tap opening. Attached Figure Description

[0010] 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.

[0011] Figure 1 This is a perspective view of an exemplary configuration of a multi-tap electrical connector.

[0012] Figure 2 yes Figure 1 Front view of the connector.

[0013] Figure 3 yes Figure 1 Top view of the connector.

[0014] Figure 4 yes Figure 1 An exploded view of the connector.

[0015] Figure 5 This is a perspective view of another exemplary configuration of a multi-tap electrical connector.

[0016] Figure 6 yes Figure 5 An exploded view of the connector.

[0017] Figure 7 This is a perspective view of another exemplary configuration of a multi-tap electrical connector.

[0018] Figure 8 yes Figure 7 Bottom perspective view of the connector.

[0019] Figure 9 yes Figure 7 An exploded view of the connector.

[0020] Figure 10 This is a front view of another exemplary configuration of a multi-tap electrical connector.

[0021] Figure 11 This is a front view of another exemplary configuration of a multi-tap electrical connector.

[0022] Figure 12 This is a front view of another exemplary configuration of a multi-tap electrical connector.

[0023] Figure 13 This is a perspective view of another exemplary configuration of a multi-tap electrical connector.

[0024] Figure 14 yes Figure 13 Front view.

[0025] Figure 15 yes Figure 14 The exploded diagram.

[0026] Figure 16 This is a perspective view of another exemplary configuration of a multi-tap electrical connector.

[0027] Figure 17 yes Figure 16 The front view.

[0028] Figure 18 yes Figure 17 The exploded diagram.

[0029] Figure 19 This is a perspective view of another exemplary configuration of a multi-tap electrical connector.

[0030] Figure 20 yes Figure 19 The front view.

[0031] Figure 21 yes Figure 20 The exploded diagram. Detailed Implementation

[0032] Tap connectors are used in various power distribution applications. Tap connectors are used to transfer power between one or more conductors. For example, a primary, main, or trunk conductor and one or more secondary, branch, or tap conductors are physically and electrically connected, such as a distribution block, terminal block, connector, or other connector. Power is transferred between the primary conductor and the tap conductor.

[0033] For example, tap conductors can be used in solar power plants to help distribute power from individual solar panels to the trunk line. Each panel or array of panels can generate power and feed it to a junction box. Wires exit from the junction box and can connect to a combiner box. The combiner box combines the electrical outputs of multiple strings of panels into a single output. The trunk line, also known as a busbar, is a heavy-duty cable or set of cables that runs along a row of solar panels. It collects the combined electrical outputs of all parallel strings in the array. The trunk line typically delivers DC power to a central location, such as an inverter station or substation, for further processing or distribution. Inverters convert the DC power from the solar panels into AC power suitable for grid connection or use in a local network.

[0034] As demand for solar energy grows, solar power facilities are trending towards larger footprints and production capacities. However, expanding solar farm capacity also increases complexity. Costs associated with installation, operation, and maintenance are constantly rising. Site topography and other factors can pose challenges to the layout of photovoltaic modules, requiring flexible connections between these installations. Therefore, the ability to generate flexible, repeatable, and reliable connections within power distribution systems, such as solar farms, offers numerous advantages.

[0035] Some implementations involve connectors configured to connect trunk lines to multiple taps. Certain configurations may utilize insulating piercing teeth in one or both of the trunk lines and taps, thereby reducing or eliminating the need to strip conductors prior to installation. Compression connectors with insulating piercing teeth are described in U.S. Application No. 18 / 211,102, Publication No. US 2023 / 0411871, the disclosure of which is incorporated herein by reference in its entirety.

[0036] Main conductors are typically larger than tap conductors. Both main and tap conductors can be solid conductors or stranded conductors. Typically, both main and tap conductors are stranded. Different sizes and types of conductors can be used. Furthermore, while the terms "main / trunk conductor" and "secondary / tap / branch conductor" may be used, the described connector is suitable for mechanically and electrically connecting any one conductor to any one or more other conductors, regardless of the type of conductor or the implementation of the power system.

[0037] The connection can be secured using either a conventional bolt connector or a shear bolt connector. A shear bolt may include a head that connects to a threaded shaft via a shearable portion. This shearable portion can be a weakened area, designed to break or otherwise separate once a certain torque limit is reached. As the fastener rotates, the shaft or associated pressure bar engages the conductor. As the fastener is tightened, the engagement with the conductor increases the amount of torque required to further rotate the fastener. Once the torque limit is reached, the head shears off, separating from the fastener. This ensures a certain level of engagement with the conductor while preventing over-tightening that could damage the conductor.

[0038] The use of shear bolt connectors can be accomplished with standard tools, such as electric impact actuators. This eliminates the need for more complex tools, such as electric crimping tools, which can be heavier and more expensive.

[0039] Using these types of connectors offers numerous advantages. In any power distribution system, they increase the flexibility of system design and reduce the need for complex tools and installation procedures. They also improve the repeatability and reliability of connections. In solar panel installations, they can eliminate the need for combiner boxes, allowing the panels to be connected more directly to the mains.

[0040] Figures 1 to 4 An exemplary configuration of a multi-tap connector 100 is shown, which includes a conductor block 102, a trunk cap 104, a trunk bolt 106, multiple tap caps 108, and multiple tap bolts 110. The illustrated configuration shows a single trunk cap 104 and bolt 106, and four tap caps 108, each with two tap bolts 110. Other configurations can use more or fewer trunks and taps as needed.

[0041] Conductor block 102 includes a body 112 having a generally U-shaped configuration. Body 112 has a bottom portion 114, a first side portion 116, and a second side portion 118. A trunk opening 120 is formed in body 112 between the first side portion 116 and the second side portion 118. Trunk opening 120 is configured to receive a trunk conductor. The size of trunk opening 120 can vary depending on one or more sizes of conductors to be received.

[0042] The trunk opening 120 is defined on a first side by a first sidewall 122 and on a second side by a second sidewall 124. A set of trunk insulation piercing members 126 extend into the trunk opening 120. The insulation piercing members 126 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor. In some configurations, the insulation piercing members 126 include a pair of outer teeth 128 and a central tooth 130. The outer teeth 128 may extend higher than the central teeth 130 and may be angled toward the central teeth 130.

[0043] Each of the teeth 128, 130 may include an insulating piercing tip configured and designed to pierce or cut through the insulating sheath of the trunk conductor to create an electrical path between the trunk conductor and the conductor block 102. One or more insulating piercing members 126 may be integrally or integrally formed into the bottom portion 114 of the conductor block 102 such that one or more insulating piercing members 126 extend into the trunk opening 120.

[0044] In other configurations, one or more insulating piercing members 126 may be attached to the body 112 of the conductor block 102. For example, the insulating piercing member 126 may be formed as part of a removable assembly that can be mounted or secured to the body 112 of the conductor block 102. Furthermore, the insulating piercing member 126 may be made of a different material than the body 112.

[0045] In some embodiments, the performance of the insulating piercing member 126 can be improved by using a relatively hard material. One or more insulating piercing members 126 may be made of different materials (e.g., copper, tempered aluminum, stainless steel, etc.) and fixed to or attached to the conductor block 102 such that one or more insulating piercing members 126 extend into the trunk opening 120.

[0046] The insulating piercing member 126 is shown as having a substantially triangular configuration. However, the insulating piercing member 126 may include different shapes and sizes, configured and designed to pierce or cut through the insulating sheath of the wire surrounding the main conductor, such as one or more tapered members and / or one or more members with sharp tips. Furthermore, one or more insulating piercing members in the insulating piercing member 126 may include serrations on one or both sides of the insulating piercing member 126.

[0047] In some configurations, a pair of trunk guide slots 132 extend from the trunk opening 120. The trunk guide slots 132 are configured to slidably receive the trunk cap 104. In the illustrated configuration, the guide slots 132 include an inner wall 134, an outer wall 136, and a side wall 138. The inner wall 134 extends further into the trunk opening 120 than the outer wall 136. The outer wall 136 has angled portions forming dovetail grooves for receiving the trunk cap 104 in the correct orientation.

[0048] Other configurations can utilize different sizes and shapes of guide slots, including square and round configurations. Some configurations can also utilize a one-piece body, in which the trunk cap 104 is integrally formed with the conductor block.

[0049] The trunking cap 104 may include a body 140 configured to mate with the trunking guide groove 132 and be fitted into the conductor block 102. In the illustrated configuration, the trunking cap 104 includes an outer portion 142 and an inner portion 144. The inner portion 144 is wider than the outer portion 142 to form a first shoulder 146 and a second shoulder 148. The outer edges of the shoulders 146, 148 are angled to correspond to the angled outer wall 136 of the trunking guide groove 132.

[0050] The trunk cap 104 slidably engages the conductor block 102 above the trunk opening 120. A trunk bolt opening 150 is provided in the trunk cap 104 to receive a trunk bolt 106. The opening 150 may be threaded and sized to accommodate a bolt suitable for the trunk conductor.

[0051] In some configurations, the trunk bolt 106 is a shearing bolt having a shearable head 152, a shank 154, and a pressure bar 156. The shank may include threads and be threadedly connected to the trunk cap. The pressure bar 156 may be rotatably connected to the shank 154 and is configured to engage the trunk conductor. In other configurations, the trunk bolt 106 is a non-shearing bolt.

[0052] The head 152 can be connected to the shank 154 via a shearable connector. The shearable portion can be a weakened area, designed to break or otherwise separate once a certain torque limit is reached. The shearable portion can be formed from a fragile connector, such as a hole or groove placed in the material, or it can be formed from one or more portions with reduced thickness. As the fastener rotates, the shank 154 or the associated pressure bar 156 engages the conductor. As the fastener is tightened, the engagement with the conductor increases the amount of torque required to further turn the fastener. Once the torque limit is reached, the head 152 shears off, separating from the shank 154. This ensures a certain degree of engagement with the conductor while preventing over-tightening that could damage the conductor. Different shear limits can be used depending on the conductor.

[0053] Similar to a trunk connection, conductor block 102 may include a plurality of tap openings for allowing connection to tap conductors. In some configurations, a first side portion 116 and a second side portion 118 of conductor block 102 each include two sets of tap openings 158. The tap openings 158 are defined on the first side by a first sidewall 160 and on the second side by a second sidewall 162. A set of tap insulation piercing members 164 extends into each tap opening 158. The insulation piercing members 164 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor. In some configurations, the insulation piercing members 164 include a pair of outer teeth 166 and a center tooth 168. The outer teeth 166 may extend further than the center teeth 168 and may be angled toward the center teeth 168. Tap insulation piercing member 164 may have any of the same properties as trunk insulation piercing member 126 described herein, including being made of different materials, having different configurations, and being a separate component formed as releasable connection to conductor block 102.

[0054] A pair of tap guide slots 170 extend from each tap opening in the tap opening 158. The tap guide slots 170 may have a configuration similar to the trunk guide slot 132. The tap guide slot 170 includes an inner wall 172, an outer wall 174, and a side wall 176. The inner wall 172 extends further into the tap opening 158 than the outer wall 174. The outer wall 174 has angled portions forming dovetail grooves for receiving the tap cap 108 in the correct orientation.

[0055] Other configurations can utilize different sizes and shapes of the tap guide slots 170, including square and circular configurations. Fewer or more tap guide slots 170 can also be incorporated into the conductor block 102. Some configurations can also utilize a one-piece body in which the tap cap 108 is integrally formed with the conductor block 102.

[0056] Tap cap 108 may include a body 178 configured to mate with tap guide groove 170 and fit into conductor block 102. In the illustrated configuration, tap cap 108 includes an outer portion 180 and an inner portion 182. The inner portion 182 is wider than the outer portion 180 to form a first shoulder 184 and a second shoulder 186. The outer edges of the shoulders 184, 186 are angled to correspond to the angled outer wall 174 of the tap guide groove 170. Tap cap 108 slidably engages conductor block 102 above tap opening 158.

[0057] In the illustrated configuration, two bolt openings 188 are provided in each tap cap 108 to receive a pair of tap bolts 110. The openings 188 may be threaded and sized to accommodate bolts suitable for tap conductors. Fewer or more tap bolt openings 188 may be used as needed. Using two tap bolt openings 188 allows each tap opening 158 to receive two taps, one on each side. Some configurations may utilize internal dividers as part of the conductor block 102 or tap cap 108 to divide each tap opening 158 into a first chamber and a second chamber, as needed. This helps the user ensure the correct placement of the tap conductors.

[0058] Each tap bolt 110 may include a head 190, a shank 192, and a pressure rod 194. The shank 192 may be threaded and threadedly connected to the tap cap 108. The pressure rod 194 may be rotatably connected to the shank 192 and configured to engage a trunk conductor. The head 190 may be connected to the shank 192 via a shearable connector as discussed with respect to the trunk shear bolt 106. In other configurations, the head is a non-shear bolt.

[0059] During installation, the tap conductor can be placed into the tap opening 158. The associated tap bolt 110 is then tightened by rotating the head 190, causing the tap pressure bar 194 to engage the tap conductor. The tap bolt 110 is then further tightened, driving the tap conductor into the tap insulation piercing member 164. The insulation piercing member 164 pierces the outer insulation of the tap conductor to form an electrical and mechanical connection with the tap conductor and conductor block 102. At a certain point, the shear limit of the head 190 is reached, causing the head 190 to separate from the handle 192 and preventing overtightening. Additional tap conductors can be connected in this manner as needed. Similarly, the main conductor can be placed into the main conductor opening 120. The main conductor bolt 106 is then tightened by rotating the head 152, causing the tap pressure bar 156 to engage the main conductor. The main conductor bolt 106 is then further tightened, driving the main conductor into the main conductor insulation piercing member 126. The insulating piercing member 126 will pierce the outer insulation of the tap conductor to form an electrical and mechanical connection with the tap conductor and conductor block 102. At a certain point, the shear limit of the head 152 will be reached, causing the head 152 to separate from the handle 154 and preventing over-tightening. The main conductor and tap conductor can be connected to the conductor block 102 in this manner in any order.

[0060] The use of shear bolts 106, 110 and insulating piercing members 126, 164 simplifies the installation procedure and can result in faster, more repeatable connections. For example, the need to strip the conductor before connecting to conductor block 102 can be eliminated, and lighter tools such as impact drivers can be used instead of heavier crimping tools. However, the advantages of easier and more reliable connections can also be achieved without using shear bolts.

[0061] In some configurations, conductor block 102 and body 112 can be modified to connect to other conductor blocks or block extensions to increase the number of taps that can be connected to block 102. For example, body 112 may include mating features, such as male and female mating features, which can allow additional blocks or extensions to be added in the field as needed. These can be connected to the bottom of the block to add additional tap openings 158 to access the existing trunk opening 120.

[0062] Figure 5 and Figure 6 An exemplary configuration of a multi-tap connector 200 is shown, which includes a conductor block 202, a trunk cap 204, a trunk bolt 206, multiple tap caps 208, and multiple tap bolts 210. The illustrated configuration shows a single trunk cap 204 and bolt 206, and two tap caps 208, each with two tap bolts 210. Other configurations can use more or fewer trunks and taps as needed.

[0063] Conductor block 202 includes a body 212 having a generally L-shaped configuration. Body 212 has a trunk-side portion 216 and a tap-side portion 218. A trunk opening 220 is formed in the trunk-side portion 216. The trunk opening 220 is configured to receive a trunk conductor. The size of the trunk opening 220 can vary depending on one or more sizes of the conductor to be received.

[0064] The trunk opening 220 is defined on a first side by a first sidewall 222 and on a second side by a second sidewall 224. A set of trunk insulation piercing members 226 extend into the trunk opening 220. The insulation piercing members 226 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor. In some configurations, the insulation piercing members 226 include a pair of outer teeth 228 and a center tooth 230. The outer teeth 228 may extend higher than the center teeth 230 and may be angled toward the center teeth 230.

[0065] Each of the teeth 228, 230 may include an insulating piercing tip configured and designed to pierce or cut through the insulating sheath of the main conductor to create an electrical path between the main conductor and the conductor block 202. One or more insulating piercing members 226 may be integrally or integrally formed into the bottom portion 214 of the conductor block 202 such that the one or more insulating piercing members 226 extend into the main conductor opening 220. In other configurations, one or more insulating piercing members 226 may be attached to the body 212 of the conductor block 202.

[0066] For example, the insulating piercing member 226 can be formed as part of a removable assembly that can be mounted or secured to the body 212 of the conductor block 202. Furthermore, the insulating piercing member 226 can be made of a different material than the body 212.

[0067] In some configurations, a pair of trunk guide slots 232 extend from the trunk opening 220. The trunk guide slots 232 are configured to slidably receive the trunk cap 204. In the illustrated configuration, the guide slots 232 include an inner wall 234, an outer wall 236, and a side wall 238. The inner wall 234 extends further into the trunk opening 220 than the outer wall 236. The outer wall 236 has angled portions forming dovetail grooves for receiving the trunk cap 204 in the correct orientation.

[0068] Other configurations can utilize different sizes and shapes of guide slots, including square and round configurations. Some configurations can also utilize a one-piece body, in which the trunk cap 204 is integrally formed with the conductor block.

[0069] The trunking cap 204 may include a body 240 configured to mate with the trunking guide slot 232 and be fitted into the conductor block 202. In the illustrated configuration, the trunking cap 204 includes an outer portion 242 and an inner portion 244. The inner portion 244 is wider than the outer portion 242 to form a first shoulder 246 and a second shoulder 248. The outer edges of the shoulders 246, 248 are angled to correspond to the angled outer wall 236 of the trunking guide slot 232.

[0070] The trunk cap 204 slidably engages the conductor block 202 above the trunk opening 220. A trunk bolt opening 250 is provided in the trunk cap 204 to receive a trunk bolt 206. The opening 250 may be threaded and sized to accommodate a bolt suitable for the trunk conductor.

[0071] In some configurations, the trunk bolt 206 is a shearing bolt having a shearable head 252, a shank 254, and a pressure bar 256. The shank may include threads and be threadedly connected to the trunk cap 204. The pressure bar 256 may be rotatably connected to the shank 254 and is configured to engage the trunk conductor. In other configurations, the trunk bolt 206 is a non-shearing bolt.

[0072] The head 252 can be connected to the shank 254 via a shearable connector with a torque limit. As the fastener rotates, the shank 254 or the associated pressure bar 256 engages the conductor. As the fastener is tightened, the engagement with the conductor increases the amount of torque required to further turn the fastener. Once the torque limit is reached, the head 252 shears off, separating from the shank 254. This ensures a certain level of engagement with the conductor while preventing over-tightening that could damage the conductor. Different shear limits can be applied depending on the conductor.

[0073] Similar to a trunk connection, conductor block 202 may include a plurality of tap openings for allowing connection to tap conductors. In some configurations, tap-side portion 228 of conductor block 202 includes two sets of tap openings 258. Tap openings 258 are defined on a first side by a first sidewall 260 and on a second side by a second sidewall 262. A set of tap insulation piercing members 264 extends into each tap opening 258. Insulation piercing members 264 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor. In some configurations, insulation piercing members 264 include a pair of outer teeth 266 and a center tooth 268. Outer teeth 266 may extend further than center teeth 268 and may be angled toward center teeth 268. Tap insulation piercing members 264 may have any of the same properties as trunk insulation piercing members 226 described herein, including being made of different materials, having different configurations, and being formed as separate components releasably connected to conductor block 202.

[0074] A pair of tap guide slots 270 extend from each tap opening in tap opening 258. The tap guide slots 270 may have a similar configuration to the trunk guide slot 232. The tap guide slots 270 include an inner wall 272, an outer wall 274, and a side wall 276. The inner wall 272 extends further into the tap opening 258 than the outer wall 274. The outer wall 274 has angled portions forming dovetail grooves for receiving the tap cap 208 in the correct orientation.

[0075] Other configurations can utilize different sizes and shapes of the tap guide slots 270, including square and circular configurations. Fewer or more tap guide slots 270 can also be incorporated into the conductor block 202. Some configurations can also utilize a one-piece body in which the tap cap 208 is integrally formed with the conductor block 202.

[0076] Tap cap 208 may include a body 278 configured to mate with tap guide groove 270 and fit into conductor block 202. In the illustrated configuration, tap cap 208 includes an outer portion 280 and an inner portion 282. The inner portion 282 is wider than the outer portion 280 to form a first shoulder 284 and a second shoulder 286. The outer edges of the shoulders 284, 286 are angled to correspond to the angled outer wall 274 of the tap guide groove 270. Tap cap 208 slidably engages conductor block 202 above tap opening 258.

[0077] In the illustrated configuration, two bolt openings 288 are provided in each tap cap 208 to receive a pair of tap bolts 210. The openings 288 may be threaded and sized to accommodate bolts suitable for tap conductors. Fewer or more tap bolt openings 288 may be used as needed. Using two tap bolt openings 288 allows each tap opening 258 to receive two taps, one on each side. Some configurations may utilize internal dividers as part of the conductor block 202 or tap cap 208 to divide each tap opening 258 into a first chamber and a second chamber, as needed. This helps the user ensure the correct placement of the tap conductors.

[0078] Each tap bolt 210 may include a head 290, a shank 292, and a pressure bar 294. The shank 292 may be threaded and threadedly connected to the tap cap 208. The pressure bar 294 may be rotatably connected to the shank 292 and configured to engage the trunk conductor. The head 290 may be connected to the shank 292 via a shearable connector as discussed with respect to the trunk shear bolt 206. In other configurations, the head 290 is a non-shear bolt.

[0079] In some configurations, the main body 212 of conductor block 202 can be modified to connect to other conductor blocks or block extensions to increase the number of taps that can be connected to block 202. For example, the main body 212 may include mating features, such as male and female mating features, which can allow additional blocks or extensions to be added in the field as needed. These can be connected to the tap-side portion 218 of the block to add additional tap openings 258 to access the existing trunk opening 220. The tap-side portion 218 may also be configured to include additional tap openings 258 as needed.

[0080] Figures 7 to 9An exemplary configuration of a multi-tap connector 300 is shown, which includes a conductor block 302, a trunk cap 304, a trunk bolt 306, multiple tap caps 308, and multiple tap bolts 310. The illustrated configuration shows a single trunk cap 304 and bolt 306, and two tap caps 308, each with two tap bolts 310. Other configurations can use more or fewer trunks and taps as needed.

[0081] Conductor block 302 includes a body 312 having a trunk side portion 316 and a tap side portion 318. A trunk opening 320 is formed in the trunk side portion 316. The trunk opening 320 is configured to receive a trunk conductor. The size of the trunk opening 320 can vary depending on one or more sizes of the conductor to be received.

[0082] The trunk opening 320 is defined on a first side by a first sidewall 322 and on a second side by a second sidewall 324. A set of trunk insulation piercing members 326 extend into the trunk opening 320. The insulation piercing members 326 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor. In some configurations, the insulation piercing members 326 include a pair of outer teeth 328 and a center tooth 330. The outer teeth 328 may extend higher than the center teeth 330 and may be angled toward the center teeth 330.

[0083] Each of the teeth 328, 330 may include an insulating piercing tip configured and designed to pierce or cut through the insulating sheath of the main conductor to create an electrical path between the main conductor and the conductor block 302. One or more insulating piercing members 326 may be integrally or integrally formed into the conductor block 302 such that one or more insulating piercing members 326 extend into the main conductor opening 320. In other configurations, one or more insulating piercing members 326 may be attached to the body 312 of the conductor block 302.

[0084] For example, the insulating piercing member 326 can be formed as part of a removable assembly that can be mounted or secured to the body 312 of the conductor block 302. Furthermore, the insulating piercing member 326 can be made of a different material than the body 312.

[0085] In some configurations, a pair of trunk guide slots 332 extend from the trunk opening 320. The trunk guide slots 332 are configured to slidably receive the trunk cap 304. In the illustrated configuration, the guide slots 332 include an inner wall 334, an outer wall 336, and a side wall 338. The inner wall 334 extends further into the trunk opening 220 than the outer wall 336. The outer wall 336 has angled portions forming dovetail grooves for receiving the trunk cap 304 in the correct orientation.

[0086] Other configurations can utilize different sizes and shapes of guide slots, including square and round configurations. Some configurations can also utilize a one-piece body, in which the trunk cap 304 is integrally formed with the conductor block.

[0087] The trunking cap 304 may include a body 340 configured to mate with the trunking guide groove 332 and be fitted into the conductor block 302. In the illustrated configuration, the trunking cap 304 includes an outer portion 342 and an inner portion 344. The inner portion 344 is wider than the outer portion 342 to form a first shoulder 346 and a second shoulder 348. The outer edges of the shoulders 346, 348 are angled to correspond to the angled outer wall 336 of the trunking guide groove 332.

[0088] The trunk cap 304 slidably engages the conductor block 302 above the trunk opening 320. A trunk bolt opening 350 is provided in the trunk cap 304 to receive a trunk bolt 306. The opening 350 may be threaded and sized to accommodate a bolt suitable for the trunk conductor.

[0089] In some configurations, the trunk bolt 306 is a shearing bolt having a shearable head 352, a shank 354, and a pressure bar 356. The shank may include threads and be threadedly connected to the trunk cap 304. The pressure bar 356 may be rotatably connected to the shank 354 and is configured to engage the trunk conductor. In other configurations, the trunk bolt 306 is a non-shearing bolt.

[0090] The head 352 can be connected to the shank 354 via a shearable connector with a torque limit. When the fastener rotates, the shank 354 or the associated pressure bar 356 engages the conductor. As the fastener is tightened, the engagement with the conductor increases the amount of torque required to further turn the fastener. Once the torque limit is reached, the head 352 shears off, separating from the shank 354. This ensures a certain level of engagement with the conductor while preventing over-tightening that could damage the conductor. Different shear limits can be used depending on the conductor.

[0091] Similar to a trunk connection, conductor block 302 may include a plurality of tap openings for allowing connection to tap conductors. In some configurations, tap-side portions 328 of conductor block 302 each include two sets of tap openings 358. Tap openings 358 are defined on a first side by a first sidewall 360 and on a second side by a second sidewall 362. A set of tap insulation piercing members 364 extends into each tap opening 358. Insulation piercing members 364 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor. In some configurations, insulation piercing members 364 include a pair of outer teeth 366 and a center tooth 368. The outer teeth 366 may extend further than the center teeth 368 and may be angled toward the center teeth 368. Tap insulation piercing members 364 may have any of the same properties as trunk insulation piercing members 326 described herein, including being made of different materials, having different configurations, and being formed as separate components releasably connected to conductor block 302.

[0092] A pair of tap guide slots 370 extend from each tap opening in the tap opening 358. The tap guide slots 370 may have a similar configuration to the trunk guide slot 332. The tap guide slot 370 includes an inner wall 372, an outer wall 374, and a side wall 376. The inner wall 372 extends further into the tap opening 358 than the outer wall 374. The outer wall 374 has angled portions forming dovetail grooves for receiving the tap cap 308 in the correct orientation.

[0093] Other configurations can utilize different sizes and shapes of the tap guide slots 370, including square and circular configurations. Fewer or more tap guide slots 370 can also be incorporated into the conductor block 302. Some configurations can also utilize a one-piece body in which the tap cap 308 is integrally formed with the conductor block 302.

[0094] Tap cap 308 may include a body 378 configured to mate with tap guide groove 370 and fit into conductor block 302. In the illustrated configuration, tap cap 308 includes an outer portion 380 and an inner portion 382. The inner portion 382 is wider than the outer portion 380 to form a first shoulder 384 and a second shoulder 386. The outer edges of the shoulders 384 and 386 are angled to correspond to the angled outer wall 374 of the tap guide groove 370. Tap cap 308 slidably engages conductor block 302 above tap opening 358.

[0095] In the illustrated configuration, two bolt openings 388 are provided in each tap cap 308 to receive a pair of tap bolts 310. The openings 388 may be threaded and sized to accommodate bolts suitable for tap conductors. Fewer or more tap bolt openings 388 may be used as needed. Using two tap bolt openings 388 allows each tap opening 358 to receive two taps, one on each side. Some configurations may utilize internal dividers as part of the conductor block 302 or tap cap 308 to divide each tap opening 358 into a first chamber and a second chamber, as needed. This helps the user ensure the correct placement of the tap conductors.

[0096] Each tap bolt 310 may include a head 390, a shank 392, and a pressure bar 394. The shank 392 may be threaded and threadedly connected to the tap cap 308. The pressure bar 394 may be rotatably connected to the shank 392 and configured to engage the trunk conductor. The head 390 may be connected to the shank 392 via a shearable connector as discussed with respect to the trunk shear bolt 306. In other configurations, the head 390 is a non-shear bolt.

[0097] In some configurations, the body 312 of conductor block 302 can be modified to connect to other conductor blocks or block extensions to increase the number of taps that can be connected to block 302. For example, body 312 may include mating features, such as male and female mating features, which can allow additional blocks or extensions to be added in the field as needed. These can be connected to the tap side of block 302 to add additional tap openings 358 to connect from existing trunk openings 320.

[0098] Figures 10 to 12 Alternative embodiments of conductor blocks 102, 202, 302 with main bolts and tap bolts without pressure bars are shown. Figure 10 A connector 400 is shown, having a conductor block 402, a main bolt 404, and a set of tap bolts 410. The main bolt 404 has a protruding end 412 for engaging the main conductor, and the tap bolts 410 have a protruding end 414 for engaging the tap conductor. Figure 11 A connector 500 is shown, comprising a conductor block 502, a main bolt 504, and a set of tap bolts 510. The main bolt 504 has a protruding end 512 for engaging the main conductor, and the tap bolts 510 have a protruding end 514 for engaging the tap conductor. Figure 12 A connector 600 is shown, having a conductor block 602, a main bolt 604, and a set of tap bolts 610. The main bolt 604 has a protruding end 612 for engaging the main conductor, and the tap bolts 610 have a protruding end 614 for engaging the tap conductor.

[0099] Although the described exemplary configuration utilizes a shear bolt with a single head, different types of shear bolts can be used. For example, shear bolts with more than one head can be used to set different shear limits or to provide non-shear heads to allow for easier removal of the fastener after the initial head has been sheared. Different pressure bar, pressure plate, and pressure bar-less configurations can also be used. Instead of an insulating piercing member associated with the conductor block, or in addition to an insulating piercing member associated with the conductor block, other configurations can implement the insulating piercing as part of the fastener. Other embodiments can utilize non-shear bolts, where torque limits are eliminated or otherwise set on the fastener or as part of an installation tool.

[0100] Figures 13 to 15 An exemplary configuration of a multi-tap connector 700 is shown, which includes a conductor block 702, a trunk cap 704, a trunk bolt 706, multiple trunk openings 708 extending into the conductor block 702, and multiple tap bolts 710. The illustrated configuration shows a single trunk cap 704 and bolt 706, and four tap openings 708, each with two tap bolts 710. Other configurations can use more or fewer trunks and taps as needed.

[0101] Conductor block 702 includes a body 712 having a substantially U-shaped configuration. The body 712 has a bottom portion 714, a first side portion 716, and a second side portion 718. A trunk opening 720 is formed in the body 712 between the first side portion 716 and the second side portion 718. The trunk opening 720 is configured to receive a trunk conductor. The size of the trunk opening 720 can vary depending on one or more sizes of the conductor to be received.

[0102] The trunk opening 720 is defined on a first side by a first sidewall and on a second side by a second sidewall. A set of trunk insulation piercing members 726 extends into the trunk opening 720. The insulation piercing members 726 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor. In some configurations, the insulation piercing members 726 include a plurality of teeth extending in an arcuate pattern.

[0103] Each tooth in the tooth may include an insulating piercing tip configured and designed to pierce or cut through the insulating sheath of the trunk conductor to create an electrical path between the trunk conductor and the conductor block 702. One or more insulating piercing members 726 may be integrally or integrally formed into the bottom portion 714 of the conductor block 702 such that the one or more insulating piercing members 726 extend into the trunk opening 720.

[0104] In other configurations, one or more insulating piercing members 726 may be attached to the body 712 of the conductor block 702. For example, the insulating piercing member 726 may be formed as part of a removable assembly that can be mounted or secured to the body 712 of the conductor block 702. Furthermore, the insulating piercing member 726 may be made of a different material than the body 712.

[0105] In some embodiments, the performance of the insulating piercing member 726 can be improved by using a relatively hard material. One or more insulating piercing members 726 may be made of different materials (e.g., copper, tempered aluminum, stainless steel, etc.) and fixed to or attached to the conductor block 702 such that one or more insulating piercing members 726 extend into the trunk opening 720.

[0106] The insulating piercing member 726 is shown as having a substantially triangular configuration. However, the insulating piercing member 726 may include different shapes and sizes, configured and designed to pierce or cut through the insulating sheath of the wire surrounding the main conductor, such as one or more tapered members and / or one or more members with sharp tips. Furthermore, one or more insulating piercing members in the insulating piercing member 726 may include serrations on one or both sides of the insulating piercing member 726.

[0107] In some configurations, a pair of trunk line guide slots 732 extend from the trunk line opening 720. The trunk line guide slots 732 are configured to slidably receive the trunk line cap 704. In the illustrated configuration, the guide slots 732 include an inner wall 734, an outer wall 736, and a side wall 738. The inner wall 734 extends further into the trunk line opening 720 than the outer wall 736.

[0108] Other configurations can utilize different sizes and shapes of guide slots, including square and round configurations. Some configurations can also utilize a one-piece body, in which the trunk cap 704 is integrally formed with the conductor block.

[0109] The trunking cap 704 may include a body 740 configured to mate with a trunking guide slot 732 and be fitted into a conductor block 702. In the illustrated configuration, the trunking cap 704 includes an outer portion 742 and an inner portion 744. The inner portion 744 is wider than the outer portion 742 to form a first shoulder 746 and a second shoulder 748. Shoulders 746 and 748 correspond to the trunking guide slot 732.

[0110] The trunk cap 704 slidably engages the conductor block 702 above the trunk opening 720. A trunk bolt opening 750 is provided in the trunk cap 704 to receive a trunk bolt 706. The opening 750 may be threaded and sized to accommodate a bolt suitable for the trunk conductor.

[0111] In some configurations, the trunk bolt 706 is a shearing bolt having a shearable head 752, a shank 754, and a pressure bar 756. The shank may include threads and be threadedly connected to the trunk cap. The pressure bar 756 may be rotatably connected to the shank 754 and is configured to engage the trunk conductor. In other configurations, the trunk bolt 706 is a non-shearing bolt.

[0112] In some configurations, the pressure bar 756 may include a set of insulating piercing members 758 extending from the pressure bar 756 toward the mains opening 720. In the illustrated configuration, the pressure bar insulating piercing members 758 include a plurality of teeth extending in an arcuate pattern. Other configurations may also be used.

[0113] Conductor block 702 may include a plurality of tap openings 708 for allowing connection to tap conductors. In some configurations, a first side portion 716 and a second side portion 718 of conductor block 702 each include two sets of tap openings 708. A set of tap insulation piercing members 764 extends into each tap opening 708. The insulation piercing member 764 may be a tooth, a spike, or other feature configured to pierce the insulating sheath of the conductor.

[0114] In the configuration shown, two bolt openings 788 are configured to communicate with each tap opening in the tap opening 708 to receive a pair of tap bolts 710. The bolt openings 788 may be threaded and sized to accommodate bolts suitable for tap conductors. Fewer or more tap bolt openings 788 may be used as needed. Using two tap bolt openings 788 allows each tap opening 708 to receive two taps, one on each side. Some configurations may utilize an internal separator as part of the conductor block 702 to divide each tap opening 708 into a first chamber and a second chamber as needed. This helps the user ensure the correct placement of the tap conductors.

[0115] Each tap bolt 710 may include a head 790 and a shank 792. The shank 792 may be threaded and threadedly connected to a bolt opening 788. The head 790 may be connected to the shank 792 by a shearable connector as discussed with respect to the trunk line shear bolt 706. In other configurations, the head 790 is a non-shear bolt.

[0116] In some configurations, the body 712 of conductor block 702 can be modified to connect to other conductor blocks or block extensions to increase the number of taps that can be connected to block 702. For example, body 712 may include mating features, such as male and female mating features, which can allow additional blocks or extensions to be added in the field as needed. These can be connected to the bottom of the block to add additional tap openings 708 to access the existing trunk opening 720.

[0117] Figures 16 to 18 An exemplary configuration of a multi-tap connector 800 is shown, which includes a conductor block 802, a trunk cap 804, a trunk bolt 806, multiple tap openings 808, and multiple tap bolts 810. The illustrated configuration shows a single trunk cap 804 and bolt 806, and two tap openings 808, each with a single tap bolt 810. Other configurations can use more or fewer trunks and taps as needed.

[0118] The conductor block 802 includes a body 812 having a trunk side portion 816 and a tap side portion 818. A trunk opening 820 is formed in the trunk side portion 816. The trunk opening 820 is configured to receive a trunk conductor. The size of the trunk opening 820 can vary depending on one or more sizes of the conductor to be received.

[0119] The trunk opening 820 is defined on a first side by a first sidewall and on a second side by a second sidewall. A set of trunk insulation piercing members 826 extends into the trunk opening 820. The insulation piercing members 826 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor. In some configurations, the insulation piercing members 826 include a plurality of teeth extending in an arcuate pattern.

[0120] The teeth may include insulating piercing tips configured and designed to pierce or cut through the insulating sheath of the main conductor to create an electrical path between the main conductor and the conductor block 802. One or more insulating piercing members 826 may be integrally or integrally formed into the conductor block 802 such that the one or more insulating piercing members 826 extend into the main conductor opening 820. In other configurations, one or more insulating piercing members 826 may be attached to the body 812 of the conductor block 802.

[0121] For example, the insulating piercing member 826 can be formed as part of a removable assembly that can be mounted or secured to the body 812 of the conductor block 802. Furthermore, the insulating piercing member 826 can be made of a different material than the body 812.

[0122] In some configurations, a pair of trunk guide slots 832 extend from the trunk opening 820. The trunk guide slots 832 are configured to slidably receive the trunk cap 804. The trunk guide slots have a rectangular configuration, with their inner walls extending further than their outer walls. Other configurations may utilize different sizes and shapes of the guide slots, including square and circular configurations. Some configurations may also utilize a one-piece body, in which the trunk cap 804 is integrally formed with the conductor block.

[0123] The trunk cap 804 may include a body 840 configured to mate with a trunk guide groove 832 and fit into a conductor block 802. In the illustrated configuration, the trunk cap 804 includes an outer portion 842 and an inner portion 844. The inner portion 844 is wider than the outer portion 842 to form a first shoulder 846 and a second shoulder 848. The trunk cap 804 slidably engages the conductor block 802 above a trunk opening 820. A trunk bolt opening 850 is provided in the trunk cap 804 to receive a trunk bolt 806. The opening 850 may be threaded and sized to accommodate a bolt suitable for a trunk conductor.

[0124] In some configurations, the trunk bolt 806 is a shearing bolt having a shearable head 852, a shank 854, and a pressure bar 856. The shank may include threads and be threadedly connected to the trunk cap 804. The pressure bar 856 may be rotatably connected to the shank 854 and is configured to engage the trunk conductor. In other configurations, the trunk bolt 806 is a non-shearing bolt.

[0125] In some configurations, the pressure bar 856 may include a set of insulating piercing members 858 extending from the pressure bar 856 toward the main branch opening 820. In the illustrated configuration, the pressure bar insulating piercing members 858 include a plurality of teeth extending in an arcuate pattern. Other configurations may also be used.

[0126] The head 852 can be connected to the shank 854 via a shearable connector with a torque limit. As the fastener rotates, the shank 854 or the associated pressure bar 856 engages the conductor. As the fastener is tightened, engagement with the conductor increases the amount of torque required to further turn the fastener. Once the torque limit is reached, the head 852 shears off, separating from the shank 854. This ensures a certain level of engagement with the conductor while preventing over-tightening that could damage it. Different shear limits may be used depending on the conductor. In other configurations, the head 850 is a non-shearing bolt.

[0127] Similar to a trunk connection, conductor block 802 may include a plurality of tap openings 808 for allowing connection to tap conductors. In some configurations, tap-side portion 828 of conductor block 802 includes two tap openings 808. The tap openings 808 may be open to the outside of conductor block 802, as shown, or closed. A set of tap insulation piercing members 864 extends into each tap opening 808. The insulation piercing members 864 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor.

[0128] In the illustrated configuration, bolt openings 888 are provided in each tap opening of tap opening 808 to receive a pair of tap bolts 810. Openings 888 may be threaded and sized to accommodate bolts suitable for tap conductors. Fewer or more tap bolt openings 888 may be used as needed.

[0129] Each tap bolt 810 may include a head 890 and a shank 892. The shank 892 may include threads and be threadedly connected to the tap cap 808. The head 890 may be connected to the shank 892 by a shearable connector as discussed with respect to the trunk line shear bolt 806. In other configurations, the head 890 is a non-shear bolt.

[0130] In some configurations, the body 812 of conductor block 802 can be modified to connect to other conductor blocks or block extensions to increase the number of taps that can be connected to block 802. For example, body 812 may include mating features, such as male and female mating features, which can allow additional blocks or extensions to be added in the field as needed. These can be connected to the tap side of block 802 to add additional tap openings 808 to connect from existing trunk openings 820.

[0131] Figures 19 to 21 An exemplary configuration of a multi-tap connector 900 is shown, which includes a conductor block 902, a trunk cap 904, a trunk bolt 906, multiple trunk openings 908 extending into the conductor block 902, and multiple tap bolts 910. The illustrated configuration shows a single trunk cap 904 and bolt 906, and four tap openings 908, each with two tap bolts 910. Other configurations can use more or fewer trunks and taps as needed.

[0132] Conductor block 902 includes a body 912 having a generally circular U-shaped configuration with curved sides. The body 912 has a bottom portion 914, a first side portion 916, and a second side portion 918. A trunk opening 920 is formed in the body 912 between the first side portion 916 and the second side portion 918. The trunk opening 920 is configured to receive a trunk conductor. The size of the trunk opening 920 can vary depending on one or more sizes of conductors to be received.

[0133] The trunk opening 920 is defined on a first side by a first sidewall and on a second side by a second sidewall. A set of trunk insulation piercing members 926 extend into the trunk opening 920. The insulation piercing members 926 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor. In some configurations, the insulation piercing members 926 include a plurality of teeth extending in an arcuate pattern.

[0134] Each tooth in the tooth may include an insulating piercing tip configured and designed to pierce or cut through the insulating sheath of the trunk conductor to create an electrical path between the trunk conductor and the conductor block 902. One or more insulating piercing members 926 may be integrally or integrally formed into the bottom portion 914 of the conductor block 902 such that one or more insulating piercing members 926 extend into the trunk opening 920.

[0135] In other configurations, one or more insulating piercing members 926 may be attached to the body 912 of the conductor block 902. For example, the insulating piercing member 926 may be formed as part of a removable assembly that can be mounted or secured to the body 912 of the conductor block 902. Furthermore, the insulating piercing member 926 may be made of a different material than the body 912.

[0136] In some embodiments, the performance of the insulating piercing member 926 can be improved by using a relatively hard material. One or more insulating piercing members 926 may be made of different materials (e.g., copper, tempered aluminum, stainless steel, etc.) and fixed to or attached to the conductor block 902 such that one or more insulating piercing members 926 extend into the trunk opening 920.

[0137] The insulating piercing member 926 is shown as having a substantially triangular configuration. However, the insulating piercing member 926 may include different shapes and sizes, configured and designed to pierce or cut through the insulating sheath of the wire surrounding the main conductor, such as one or more tapered members and / or one or more members with sharp tips. Furthermore, one or more insulating piercing members in the insulating piercing member 926 may include serrations on one or both sides of the insulating piercing member 926.

[0138] In some configurations, a pair of trunk guide slots 932 extend from the trunk opening 920. The trunk guide slots 932 are configured to slidably receive the trunk cap 904. In the illustrated configuration, the guide slots 932 include an inner wall, an outer wall, and a side wall. The inner wall extends further into the trunk opening 920 than the outer wall.

[0139] Other configurations can utilize different sizes and shapes of guide slots, including square and round configurations. Some configurations can also utilize a one-piece body, in which the trunk cap 904 is integrally formed with the conductor block.

[0140] The trunking cap 904 may include a body 940 configured to mate with a trunking guide slot 932 and fit into a conductor block 902. In the illustrated configuration, the trunking cap 904 includes an outer portion 942 and an inner portion 944. The outer portion 942 may have a curved upper edge corresponding to a curved side of the conductor block body 912. The inner portion 944 is wider than the outer portion 942 to form a first shoulder 946 and a second shoulder 948. Shoulders 946 and 948 correspond to the trunking guide slot 932.

[0141] The trunk cap 904 slidably engages the conductor block 902 above the trunk opening 920. A trunk bolt opening 950 is provided in the trunk cap 904 to receive a trunk bolt 906. The opening 950 may be threaded and sized to accommodate a bolt suitable for the trunk conductor.

[0142] In some configurations, the trunk bolt 906 is a shearing bolt having a shearable head 952, a shank 954, and a pressure bar 956. The shank may include threads and be threadedly connected to the trunk cap. The pressure bar 956 may be rotatably connected to the shank 954 and is configured to engage the trunk conductor. In other configurations, the trunk bolt 906 is a non-shearing bolt.

[0143] In some configurations, the pressure bar 956 may include a set of insulating piercing members 958 extending from the pressure bar 956 toward the mains opening 920. In the illustrated configuration, the pressure bar insulating piercing members 958 include a plurality of teeth extending in an arcuate pattern. Other configurations may also be used.

[0144] Conductor block 902 may include a plurality of tap openings 908 for allowing connection to tap conductors. In some configurations, a first side portion 916 and a second side portion 918 of conductor block 902 each include two sets of tap openings 908. A set of tap insulation piercing members 964 extends into each tap opening 908. The insulation piercing member 964 may be teeth, spikes, or other features configured to pierce the insulating sheath of the conductor.

[0145] In the configuration shown, two bolt openings 988 are configured to communicate with each tap opening in the tap opening 908 to receive a pair of tap bolts 910. The bolt openings 988 may be threaded and sized to accommodate bolts suitable for tap conductors. Fewer or more tap bolt openings 988 may be used as needed. Using two tap bolt openings 988 allows each tap opening 908 to receive two taps, one on each side. Some configurations may utilize an internal separator as part of the conductor block 902 to divide each tap opening 908 into a first chamber and a second chamber as needed. This helps the user ensure the correct placement of the tap conductors.

[0146] Each tap bolt 910 may include a head 990 and a shank 992. The shank 992 may be threaded and threadedly connected to a bolt opening 988. The head 990 may be connected to the shank 992 by a shearable connector as discussed with respect to the trunk line shear bolt 906. In other configurations, the head 990 is a non-shear bolt.

[0147] In some configurations, the body 912 of conductor block 902 can be modified to connect to other conductor blocks or block extensions to increase the number of taps that can be connected to block 902. For example, body 912 may include mating features, such as male and female mating features, which can allow additional blocks or extensions to be added in the field as needed. These can be connected to the bottom of the block to add additional tap openings 908 to connect from existing trunk openings 920.

[0148] The foregoing detailed description of certain exemplary configurations and embodiments has been provided for the purpose of explaining general principles and practical applications, thereby enabling others skilled in the art to understand the disclosure of various 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 the disclosed exemplary embodiments. Any of the embodiments and / or elements disclosed herein may be combined with each other to form various additional embodiments not specifically disclosed. Accordingly, additional embodiments are possible and are intended to be covered within the scope of this specification and the appended claims. The specification describes specific examples to accomplish a more general objective that may be accomplished in another manner.

[0149] As used herein, the terms “front,” “rear,” “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 degree terms 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 “mounted,” “connected,” “supported,” and “joined,” and variations thereof, are used extensively and cover both direct and indirect mounting, connection, support, and joining.

[0150] Functions described herein as being performed by a single component can be performed by multiple components in a distributed manner. Similarly, functions performed by multiple components can be combined and performed by a single component. Likewise, components described as performing specific functions can also perform additional functions not described herein. For example, a device or structure that is "configured" in a certain way is configured at least in this way, but may also be configured in ways not explicitly listed.

Claims

1. An electrical connector for connecting a plurality of conductors, the electrical connector comprising: A conductor block having a body having a trunk opening, a trunk insulation piercing member extending into the trunk opening, a tap opening, and a tap insulation piercing member extending into the tap opening; A trunk line cap, the trunk line cap extending above the trunk line opening; A trunk bolt extending through the trunk cap into the trunk opening, wherein the trunk bolt includes a first threaded shank and a first shearable head, wherein the first shearable head is configured to disconnect from the first threaded shank when a first torque limit is reached; Tap cap, the tap cap extending above the tap opening; as well as Tap bolts extending through the tap cap into the tap opening, wherein the tap bolts include a second threaded shank and a second shearable head, wherein the second shearable head is configured to disconnect from the second threaded shank upon reaching a second torque limit.

2. The electrical connector according to claim 1, wherein the trunk insulation piercing member is integrally formed with the conductor block.

3. The electrical connector of claim 1, wherein the trunk cap is removably connected to the conductor block.

4. The electrical connector of claim 1, wherein the trunk cap is slidably connected to the conductor block.

5. The electrical connector of claim 1, wherein the tap cap is removably connected to the conductor block.

6. The electrical connector of claim 1, wherein the trunk insulation piercing member comprises a set of teeth.

7. The electrical connector of claim 1, wherein the trunk bolt includes a pressure rod connected to the first shank.

8. The electrical connector of claim 1, wherein the tap opening is a first tap opening, the conductor block further includes a second tap opening, and the trunk opening is positioned between the first tap opening and the second tap opening.

9. The electrical connector of claim 1, wherein the conductor block has a substantially L-shaped configuration, wherein the body has a trunk portion and a tap portion extending from the trunk portion.

10. The electrical connector of claim 1, wherein the tap cap includes a first tap bolt opening for receiving the tap bolt and a second tap bolt opening for receiving the second tap bolt.

11. An electrical connector for connecting a plurality of conductors, the electrical connector comprising: A conductor block having a body having a trunk opening, a trunk insulation piercing member extending into the trunk opening, a trunk guide groove extending from the trunk opening, a tap opening, a tap insulation piercing member extending into the tap opening, and a tap guide groove extending from the tap opening. A trunk cap, which is slidably connected to the conductor block via the trunk guide groove; A trunk bolt extending through the trunk cap into the trunk opening, wherein the trunk bolt includes a first threaded shank and a first shearable head, wherein the first shearable head is configured to disconnect from the first threaded shank when a first torque limit is reached; Tap cap, the tap cap being slidably connected to the conductor block via the tap guide groove; as well as Tap bolts extending through the tap cap into the tap opening, wherein the tap bolts include a second threaded shank and a second shearable head, wherein the second shearable head is configured to disconnect from the second threaded shank upon reaching a second torque limit.

12. The electrical connector of claim 11, wherein the tap opening is a first tap opening, the conductor block further includes a second tap opening, and the trunk opening is positioned between the first tap opening and the second tap opening.

13. The electrical connector of claim 11, wherein the conductor block has a substantially L-shaped configuration, wherein the body has a trunk portion and a tap portion extending from the trunk portion.

14. The electrical connector of claim 11, wherein the tap opening is a first tap opening, the conductor block further includes a second tap opening, and the trunk opening is positioned above the first tap opening and the second tap opening.

15. The electrical connector of claim 11, wherein the trunk guide groove has a first angled wall, and the trunk cap includes a second angled wall complementary to the first angled wall to form a dovetail connection between the trunk guide groove and the trunk cap.

16. The electrical connector of claim 11, wherein the trunk bolt includes a pressure rod connected to the first shank.

17. A method for electrically connecting a plurality of conductors, the method comprising: Insert the tap conductor into the tap opening of the conductor block; Rotate the tap bolt to engage the tap conductor; Drive the tap conductor into the tap insulation piercing member that extends into the tap opening; Rotate the tap bolt until the first torque limit is reached and the head of the tap bolt is sheared off; Insert the main conductor into the main conductor opening of the conductor block; Rotate the trunk bolt to engage the trunk conductor; Drive the trunk conductor into the trunk insulation piercing member that extends into the trunk opening; Rotate the main bolt until the second torque limit is reached and the head of the main bolt is sheared off.

18. An electrical connector for connecting a plurality of conductors, the electrical connector comprising: A conductor block having a body having a trunk opening, a trunk insulation piercing member extending into the trunk opening, a tap opening, and a tap insulation piercing member extending into the tap opening; A trunk line cap, the trunk line cap extending above the trunk line opening; A trunk line bolt extending through the trunk line cap into the trunk line opening, wherein the trunk line bolt includes a first threaded shank and a first shearable head, wherein the first shearable head is configured to disengage from the first threaded shank upon reaching a first torque limit; and Tap bolts extend through the conductor block into the tap opening.

19. The electrical connector of claim 18, wherein the trunk insulation piercing member is integrally formed with the conductor block.

20. The electrical connector of claim 18, wherein the trunk cap is removably connected to the conductor block.

21. The electrical connector of claim 18, wherein the trunk cap is slidably connected to the conductor block.

22. The electrical connector of claim 18, wherein the trunk insulation piercing member comprises a set of teeth.

23. The electrical connector of claim 18, wherein the trunk bolt includes a pressure bar connected to the first shank.

24. The electrical connector of claim 23, wherein the pressure rod includes a second insulating piercing member.

25. The electrical connector of claim 18, wherein the tap opening is a first tap opening, the conductor block further includes a second tap opening, and the trunk opening is positioned between the first tap opening and the second tap opening.

26. The electrical connector of claim 18, wherein the conductor block has a substantially circular configuration.

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