Single pole connectors, single pole connector systems and methods thereof

Abstract

Single pole connectors, systems for bundling single pole connectors and methods of use are provided. A single pole electrical connector includes a housing having a first end and a second end, the first end configured to receive a conductive contact that receives a conductor and the second end configured to mate with a second housing of a complementary contact, the first end further configured with a threaded surface; a grommet disposed over the conductor; and a fastener disposed over the conductor and grommet, the fastener configured to mate with the threaded surface of the housing and to compress the grommet between the fastener and first end of the housing when tightened. Keying features may be employed on the housings to insure male and female devices can only mate with the appropriate like conductor. Systems and methods are provided for organizing and bundling multiple single pole connectors.

Description

SINGLE POLE CONNECTORS, SINGLE POLE CONNECTOR SYSTEMS AND METHODS THEREOFPRIORITY

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 654,526 filed May 31 , 2024, the contents of which are hereby incorporated by reference in its entirety.

[0002] This application also claims priority to U.S. Provisional Patent Application Serial No. 63 / 744,558 filed January 13, 2025, the contents of which are hereby incorporated by reference in its entirety.FIELD

[0003] The present disclosure relates to electrical connectors. More particularly, the present disclosure relates to single pole connectors, systems for bundling single pole connectors and methods of use.BACKGROUND

[0004] Electrical connectivity devices, such as electrical connectors, are prevalent anywhere power from a source must be carried through wires for power delivery to equipment and devices. Commonly encountered electrical connectors include so-called single pole electrical connectors. As will be appreciated by one of ordinary skill in the art, single pole electrical connectors are typically used for supplying electrical power and are configured to connect and disconnect quickly and easily. The single pole electrical connectors include a male plug having a pin and a female contact having a sleeve. The male plug and female contact are generally rated for 600 volts max and up to 400 amps max. The contact of the male plug and the sleeve of the female contact are high conductivity brass contacts that are disposed within non-conductive housings. Non-conductive retaining screws are used to secure the contact and sleeve within their respective housings.

[0005] In today’s environment, demand for higher amperage connectivity solutions is increasing. For example, data centers have a growing need for high amperage connectors. Artificial Intelligence (Al) and other technologies are driving servers and associated supporting equipment to consume more power. The conventional connectors available today to support these applications must be much larger than standard connectors and thus can be difficult for a user to manage.

[0006] When data centers need wiring devices at currents far exceeding 100 Amp (e.g. 200 Amp), the conductors will be very large. It will be very difficult to handle such large conductors if they are bundled together - e.g., in a jacketed cord or within a flexible conduit.

[0007] Therefore, a need exists for techniques for bundling large conductors to meet the needs of devices requiring large amperage currents. Additionally, there is a need for techniques for configuring high ampere single pole connectors, e.g., 200 Amp connectors, in form factors conventionally used for lower amperage rated single pole connectors.SUMMARY

[0008] Various examples of the present disclosure can overcome various of the aforementioned and other disadvantages associated with known connectors. For example, the present inventors recognized a need for organizing and controlling a sequencing of connecting various connectivity devices. The present inventors also recognized a need for connected devices that run cooler than their predecessors. Cooler running connection solutions would aid in the cooling load that must be managed and mitigated with higher amperage operations.

[0009] Various embodiments of the present disclosure provide connectivity solutions that reduce insertion forces and / or extraction forces of male into female electrical connectors, thus minimizing the ergonomic burdens. The various embodiments provide other advantages and benefits. For example, another benefit of various embodiments is toproduce male and female contacts with greater conductivity to minimize thermal energy generated from electrical contacts under load.

[0010] According to one aspect of various embodiments of the present disclosure there is provided various connectivity devices that make use of novel form factors, novel male and female contact configurations, and novel mechanical connection mechanisms that aid the ability to mate and unmate the devices with manageable effort. In some forms, the novel form factors, novel male and female contact configurations, novel contact materials and thermal management techniques enable single pole connectors to be configured with a high amperage rating, e.g., at least 200 amps, while having a reduced size (or form factor) compared to conventional single pole connectors.

[0011] In some forms, a silver plating or other plating is provided on parts or areas that contact each other to aid the electrical conductivity of the connector once engaged. In other embodiments, single pole connectors are provided with improved water ingress prevention, improved strain relief and novel keying features.

[0012] Single pole connectors, systems for bundling single pole connectors and methods of use are provided. A single pole electrical connector includes a housing having a first end and a second end, the first end configured to receive a conductive contact and the second end configured to mate with a second housing of a complementary contact, the first end further configured with a threaded surface; a grommet disposed over a conductor; and a fastener disposed over the conductor and grommet, the fastener configured to mate with the threaded surface of the housing and to compress the grommet between the fastener and first end of the housing when tightened. Keying features may be employed on the housings to insure only male and female devices can only mate with the appropriate like conductor. Systems and methods are provided for organizing and bundling multiple single pole connectors.

[0013] According to one aspect of the present disclosure, single pole electrical connector is provided including a housing having a first end and a second end, the first end configured to receive a conductive contact and the second end configured to mate with a second housing of a complementary contact, the first end further configured with a threaded surface; the conductive contact disposed in the first end of the housing, the conductive contact including a termination portion for receiving a conductor; a grommetdisposed over the conductor; and a fastener disposed over the conductor and grommet, the fastener configured to mate with the threaded surface of the first end of the housing and to compress the grommet between the fastener and the first end of the housing when tightened.

[0014] In one aspect, the fastener is a gland nut.

[0015] In another aspect, the second end of the housing includes at least two keying elements.

[0016] In a further aspect, the at least two keying elements are disposed on an outer surface of the second end of the housing.

[0017] In another aspect, the at least two keying elements are disposed on an inner surface of the second end of the housing.

[0018] In one aspect, positions of each of the at least two keying elements on the housing indicate a function of the single pole electrical connector.

[0019] In a yet another aspect, the conductive contact includes a male portion and the complementary contact includes a female portion, further including silver plating on at least interfacing surfaces between the male and female portions.

[0020] In one aspect, the conductive contact and the complementary contact include a copper alloy.

[0021] In another aspect, the copper alloy includes at least one of tellurium copper, chromium copper and zirconium copper.

[0022] In a further aspect, the termination portion of the conductive contact includes a cavity that receives the conductor and at least two apertures arranged circumferentially to the cavity, each aperture configured to receive a screw to secure the conductor in the cavity.

[0023] In In another aspect, the high strength copper alloy includes at least one of beryllium copper and copper titanium.

[0024] In yet another aspect, the termination portion of the conductive contact includes a cavity that receives the conductor and an inner surface of the cavity is configured with asperity points to create predictable points of contact between the inner surface of the cavity and the conductor.

[0025] In one aspect, the housing is configured from a flexible thermoplastic elastomer (TPE) material.

[0026] In another aspect, the second end of the housing has a first diameter and the second housing has a second diameter, the first diameter being greater than the second diameter to receive the second end of the first housing.

[0027] In a further aspect, an inner diameter of the second end of the housing tapers inward at a first predetermined angle and an outer diameter of the second housing tapers outward at a second predetermined angle, the second predetermined angle being greater than the first predetermined angle.

[0028] In one aspect, a seal is disposed on the second housing at an interface of the second end of the housing and the second housing.

[0029] In another aspect, the seal is an O-ring disposed on the second housing.

[0030] In still another aspect, at least one of the housing or second housing includes a flange configured for mounting to a structure.

[0031] In another aspect, a bracket for supporting the single pole electrical connector and at least one second single pole electrical connector is provided.

[0032] According to another aspect of the present disclosure, a bracket for organizing at least two single pole electrical connectors includes at least two housing receivers, each housing receiver including first and second arms configured to flex in respect to each other to allow a portion of a housing of a single pole connector to be placed in the housing receiver and retained therein, wherein adjacent housing receivers are coupled together by an extension member.

[0033] In one aspect, a length of each extension member controls the spacing between each single pole connector.

[0034] In another aspect, the length of each extension member is configured such that the single pole connectors disposed in the housing receivers align with an intended connection structure.

[0035] In a further aspect, each housing receiver is color-coded to indicate a sequencing of the at least two single pole connector.

[0036] In yet another aspect, each housing receiver includes indicia to identify a particular single pole connector to be disposed therein.

[0037] In still another aspect, the indicia is a color of a corresponding single pole connector.

[0038] According to one aspect of the present disclosure, a system for organizing at least two single pole electrical connectors includes a panel having a front face and a rear face including at least two apertures accessible from the front face, each aperture configured for receiving a male portion of a first single pole electrical connector; at least one female receiving housing coupled to the rear face of the panel at each aperture; at least one shutter disposed over at least one of the apertures configured to prevent insertion of a male portion when closed, wherein the shutters are selectively actuated to open upon insertion of an appropriate male portion of the single pole electrical connector.

[0039] In another aspect, each aperture is configured with a unique keying feature.

[0040] In one aspect, the male portion of the single pole electrical connector includes a complementary keying feature to ensure proper mating to a respective aperture.

[0041] In a further aspect, each female receiving housing includes a channel that corresponds to the keying feature of the corresponding aperture.

[0042] In yet another aspect, the channel includes a plunger, and upon insertion of the male portion of the single pole electrical connector into an appropriate aperture, the plunger actuates the at least one shutter of at least one adjacent aperture.

[0043] In one aspect, the at least one shutter is associated to at least three apertures.

[0044] In still another aspect, the complementary keying feature of the male portion actuates the plunger.

[0045] According to another aspect of the present disclosure, a method for sequencing a plurality of single pole electrical connectors includes providing a panel having a front face and a rear face including at least two apertures accessible from the front face, each aperture configured for receiving a male portion of a single pole electrical connector, and at least one shutter disposed over at least one of the apertures configured to prevent insertion of a male portion when closed; inserting a first single pole connector into a first aperture; actuating the at least one shutter associated to an adjacent aperture.

[0046] In one aspect, each aperture is configured with a unique keying feature.

[0047] In another aspect, the male portion of the single pole electrical connector includes a complementary keying feature to ensure proper mating to a respective aperture.

[0048] In a further aspect, the panel is configured for a three-phase electrical system including five apertures, wherein the first aperture is for a ground connector, a second aperture is for a neutral connector and remaining apertures are for line connectors.

[0049] In one aspect of the method, upon insertion of a male portion into first aperture, the second aperture opens.

[0050] In another aspect, the method further includes inserting a neutral connector into the second aperture and actuating the at least one shutter for the remaining apertures.

[0051] According to one aspect of the present disclosure, a single pole electrical connector includes a housing having a first end and a second end, the first end configured to receive a conductive contact and the second end configured to mate with a second housing of a complementary contact; the conductive contact disposed in the first end of the housing, the conductive contact including a termination portion for receiving a conductor; the first end of the housing includes a conductor receiving portion configured to receive the conductor for coupling to conductive contact; and a clamp coupled to the conductor receiving portion to secure the conductor to the housing.

[0052] In another aspect, the conductor receiving potion and the clamp include semicircular recesses configured to conform to an outer surface of the conductor.

[0053] In a further aspect, the semi-circular recess of the clamp has a predetermined diameter, wherein the predetermined diameter is selected based on a diameter of the conductor.

[0054] In yet another aspect, the clamp includes a top surface and a bottom surface, the bottom surface mates with conductor receiving portion, the bottom surface includes at least two clamping members that engage an outer surface of the conductor.

[0055] In still another aspect, the bottom surface of the clamp includes at least two recesses configured to receive at least two raised receivers on the conductor receiving portion.

[0056] In one aspect, the first housing includes a first portion and a second portion, the first portion being generally cylindrical and configured to mate with the second housing, a first recess runs along a length of the first portion and at the juncture of the first portion and second portion, the first recess transitions into a channel circumferentially disposed about the first portion of the housing.

[0057] In another aspect, the second housing includes a first detent configured to translate in the first recess and channel of the first portion of the first housing.

[0058] In a further aspect, the channel of the first portion includes a second detent and a second recess and upon fully inserting the second housing into the first housing, the first detent of the second housing is translated over the second detent into the second recess to prevent unmating.

[0059] In one aspect, the first recess and first detent act as keying elements to prevent improper mating of the first and second housing.

[0060] In another aspect, the first and second housing includes at least one additional keying element.

[0061] In a further aspect, positions of each of the at least two keying elements on the housing indicate a function of the single pole electrical connector.

[0062] In one aspect, the single pole electrical connector configured to carry a high current of at least 200 Amps.BRIEF DESCRIPTION OF THE DRAWINGS

[0063] Various aspects and advantageous features of the present disclosure will become more apparent to those of ordinary skill when described in the detailed description of preferred embodiments and reference to the accompanying drawings, wherein:

[0064] FIG. 1 is a perspective view of a male single pole connector and female single pole connector in accordance with various embodiments disclosed herein.

[0065] FIG. 2 is a side view of the connectors shown in FIG. 1 in accordance with various embodiments disclosed herein.

[0066] FIG. 3A is a cross-sectional view of the connectors shown in FIG. 1 in accordance with various embodiments disclosed herein.

[0067] FIG. 3B is a cross-sectional view of an end of a male single pole connector in accordance with various embodiments disclosed herein.

[0068] FIG. 3C is a cross-sectional view of an end of a female single pole connector in accordance with various embodiments disclosed herein.

[0069] FIG. 3D is a cross-sectional view of a mated single pole connector in accordance with various embodiments disclosed herein.

[0070] FIG. 4A is an exploded view of a male single pole connector in accordance with various embodiments disclosed herein.

[0071] FIG. 4B is an exploded view of a female single pole connector in accordance with various embodiments disclosed herein.

[0072] FIG. 5A is an exploded view of another male single pole connector in accordance with various embodiments disclosed herein.

[0073] FIG. 5B is an exploded view of another female single pole connector in accordance with various embodiments disclosed herein.

[0074] FIG. 6A is a front perspective view of a female single pole connector and FIG. 6B is a front perspective view of male single pole connector in accordance with various embodiments disclosed herein.

[0075] FIGS. 7A and 7B is a front view of the connectors shown in FIG. 6A and 6B in accordance with various embodiments disclosed herein.

[0076] FIG. 8A a front cross-sectional view of a mated single pole connector in accordance with various embodiments disclosed herein.

[0077] FIG. 8B is a cross-sectional view of a mated single pole connector illustrating tapered surfaces of a male connector in accordance with various embodiments disclosed herein.

[0078] FIG. 8C is a side view of unmated single pole connectors in accordance with various embodiments.

[0079] FIG. 8D is a cross-sectional view of a mated single pole connector in accordance with various embodiments disclosed herein.

[0080] FIG. 9 illustrates mating of a corded single pole connector with a panel mounted single pole connector in accordance with various embodiments disclosed herein.

[0081] FIG. 10A illustrates a system for organizing multiple single pole connectors in accordance with various embodiments disclosed herein.

[0082] FIG. 10B illustrates a perspective view of a bracket of a system for organizing multiple single pole connectors in accordance with various embodiments disclosed herein.

[0083] FIG. 10C illustrates a side view of a bracket of a system for organizing multiple single pole connectors in accordance with various embodiments disclosed herein.

[0084] FIG. 1 1 illustrates a system for sequencing of single pole male plugs into a panel containing female receptacles in accordance with various embodiments disclosed herein.

[0085] FIG. 12 is a front view of a panel of the system shown in FIG. 1 1 in accordance with various embodiments disclosed herein.

[0086] FIG. 13 is a rear view of a panel of the system shown in FIG. 1 1 in accordance with various embodiments disclosed herein.

[0087] FIG. 14 is a bottom view of a panel of the system shown in FIG. 11 in accordance with various embodiments disclosed herein.

[0088] FIG. 15 is perspective bottom view of a panel of the system shown in FIG. 11 in accordance with various embodiments disclosed herein.

[0089] FIG. 16 is a rear perspective view of a panel of the system shown in FIG. 1 1 with shutters and plungers removed in accordance with various embodiments disclosed herein.

[0090] FIG. 17A is a close-up view of a receptacle housing in accordance with various embodiments disclosed herein.

[0091] FIG. 17B is an exploded view of the receptacle housing shown in FIG. 17A in accordance with various embodiments disclosed herein.

[0092] FIG. 18 illustrates a male plug being inserted into a panel of the system shown in FIG. 1 1 in accordance with various embodiments disclosed herein.

[0093] FIGS. 19A-19C illustrate a method of sequencing connections of a single pole system in accordance with various embodiments disclosed herein.

[0094] FIG. 20 is another perspective front view of a panel of the system shown in FIG. 1 1 in accordance with various embodiments disclosed herein.

[0095] FIG. 21 is a close-up transparent view of a panel of the system shown in FIG. 11 in accordance with various embodiments disclosed herein.

[0096] FIG. 22 is another rear perspective view of a panel of the system shown in FIG. 1 1 in accordance with various embodiments disclosed herein.

[0097] FIG. 23 is an exploded rear view of the receptacle housing shown in FIG. 23 in accordance with various embodiments disclosed herein.

[0098] FIG. 24 is a rear view of receptacle housings before insertion of a male plug in accordance with various embodiments disclosed herein.

[0099] FIG. 25 illustrates actuation of a shutter as shown in FIG. 24 in accordance with various embodiments disclosed herein.

[0100] FIG. 26 illustrates complete actuation of a shutter as shown in FIGS. 24 and 25 in accordance with various embodiments disclosed herein.

[0101] FIG. 27 is a perspective view of another male single pole connector and another female single pole connector in accordance with various embodiments disclosed herein.

[0102] FIG. 28 is a side view of the connectors shown in FIG. 27 in accordance with various embodiments disclosed herein.

[0103] FIG. 29 is a cross-sectional view of the connectors shown in FIG. 27 in accordance with various embodiments disclosed herein.

[0104] FIG. 30 is an exploded view of the male connector shown in FIG. 27 in accordance with various embodiments disclosed herein.

[0105] FIGS. 31A-31 E illustrate various views of a housing of the male single pole connector shown in FIG. 27 in accordance with various embodiments disclosed herein.

[0106] FIGS. 32A-32F illustrate various views of a clamp of the male single pole connector shown in FIG. 27 in accordance with various embodiments disclosed herein.

[0107]

[0108] FIG. 33 illustrates various clamps to be employed with a male single pole connector in accordance with various embodiments disclosed herein.

[0109] FIGS. 34A-34D illustrate various views of a housing of the male single pole connector shown in FIG. 27 in accordance with various embodiments disclosed herein.

[0110] FIG. 35 is a front perspective view of a housing of the female single pole connector shown in FIG. 27 in accordance with various embodiments disclosed herein.

[0111] FIG. 36A is a cross-sectional view of a male and female single pole connector being mated in accordance with various embodiments disclosed herein.

[0112] FIG. 36B is a cross-sectional view of the male and female single pole connectors in a fully locked position in accordance with various embodiments disclosed herein.

[0113] FIGS. 37A-37F illustrate front views of single pole connectors having various keying features in accordance with various embodiments disclosed herein.

[0114] It should be understood that the drawings are for purposes of illustrating the concepts of the disclosure and are not necessarily the only possible configuration for illustrating the disclosure. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiment.DETAILED DESCRIPTION

[0115] The various exemplary embodiments disclosed herein provide connectivity devices with improved water ingress prevention, improved strain relief and features to facilitate managing and sequencing of a plurality of single poled devices. Some of the various embodiments provide connectivity devices with greater conductivity characteristics.

[0116] As used in this application, terms such as “front,” “rear,” “side,” “top,” “bottom,” “above,” “below,” “upwardly” and “downwardly” are intended to facilitate the description of the electrical connector according to the present disclosure and are not to be construed as limiting the structure of the electrical connector to any particular position or orientation.

[0117] Referring to FIGS. 1 to 4B, a single pole electrical connector assembly 100 is provided. The single pole electrical connector assembly 100 includes a male plug 102 and a female connector 104. Electrical cables 106 and 108 are connected to the male plug 102 and female connector 104, respectively. Connecting the male plug 102 and female connector 104 enables the transmission of electrical power therethrough.

[0118] The male plug 102 includes a male contact 110 having a first end 112 and a second end 114. A cable 106 is connected to the first end 1 12 of the male contact 110. The second end 1 14 is adapted to engage a corresponding female contact 116. The male contact 1 10 has a rear portion 1 18 and a front portion 120 connected thereto. A cavity 122 is formed in the rear portion 118 to receive the electrical cable 106. A first opening 124 is formed circumferentially in the rear portion 118 to receive a housingretaining fastener 126 that secures the male contact 110 to a housing 128. Second and third openings 132 and 134 are formed circumferentially in the rear portion 118 and extend into the cavity 122. Fasteners 136 are received by the openings 132 and 134 to secure the cable 106 within the cavity 122.

[0119] The front portion 120 is generally cylindrical. A slot 138 extends from the second end 114 of the male contact 110 rearwardly toward the rear portion 1 18 of the contact. The slot 138 forms first and second slotted portions 140 and 142 of the front portion 120 of the contact 110, thereby providing the slotted portions 140 and 142 with spring-like or resilient properties to facilitate connecting the male plug 102 with the female connector 104.

[0120] The female connector 104 includes a female contact 116 having a first end 150 and a second end 152. A cable 108 is connected to the first end 150 of the female contact 116. The second end 152 is adapted to engage a corresponding male contact 1 10. The female contact 1 16 has a rear portion 154 and a front portion 156 connected thereto. A cavity 158 is formed in the rear portion 154 to receive the electrical cable 108. A first opening 160 is formed circumferentially in the rear portion 154 to receive a housing retaining fastener 162 that secures the female contact 1 16 to a housing 164. Second and third openings 166 and 168 are formed circumferentially in the rear portion 154 and extend into the cavity 158. Fasteners (not shown) are received by the openings 166 and 168 to secure the cable 108 within the cavity 158. The front portion 156 is generally cylindrical and includes a second cavity 170 adapted to receive the front portion 120 of male contact 1 10. In certain embodiments, a rivet 157 is provided on the inner surface of cavity 170.

[0121] Termination of legacy single pole products to cables or conductors is cumbersome and time consuming. It requires wrapping a wire around a foil jacket.

[0122] The single pole connectors of the present disclosure provide for improved cable termination resulting in quicker installation and more robust strain relief. Referring to FIG. 4A, the male plug 102 further includes a sleeve 172, grommet 174 and a fastener 176. The sleeve 172 is generally cylindrical and includes a first end 178 and a second end 180. The first end 178 is threaded on an outer surface of the sleeve 172 and configured to receive the fastener 176, e.g., a gland nut. The second end 180 is configured to be slidover the first end 112 of the male contact 110. An aperture 182 is provided adjacent the second end 180 and is configured to receive the housing retaining fastener 126 that secures the male contact 1 10 to the housing 128, when apertures 124 and 182 align. It is to be appreciated that the housing 128, sleeve 172 and fastener 176 are to be constructed from the same material, e.g., a thermoplastic resin.

[0123] Once the cable 106 is terminated to the male contact 1 10, the thread is exposed on the first end 178 of the sleeve 172. An appropriately sized grommet 174 is then slid over the cable 106. The gland nut 176 engages the exposed male thread on the sleeve 172 and is tightened to compress the grommet 174 between the fastener 176 and the first end 178 of the sleeve 172. It is to be appreciated that the grommet 174 may be flexible and / or compressible and configured from various materials to achieve such functionality such as, but not limited to, rubber, neoprene, etc. It is further to be appreciated that wrench flats may be appropriate to tighten the gland nut.

[0124] Similarly, the female connector 104 includes the cable termination described above. Referring to FIG. 4B, the female connector 104 further includes a sleeve 192, grommet 194 and fastener 196. The sleeve 192 is generally cylindrical and includes a first end 198 and a second end 199. The first end 198 is threaded on an outer surface of the sleeve 192 and configured to receive fastener 196, e.g., a gland nut. The second end 200 is configured to be slid over the first end 150 of the female contact 116. An aperture 202 is provided adjacent the second end 200 and is configured to receive the housing retaining fastener 162 that secures the female contact 116 to the housing 164, when apertures 160 and 202 align. It is to be appreciated that the housing 164, sleeve 192 and fastener 196 are to be constructed from the same material, e.g., a thermoplastic resin.

[0125] Once the cable 108 is terminated to the female contact 116, the thread is exposed on the first end 198 of the sleeve 192. An appropriately sized grommet 194 is then slid over the cable 108. The gland nut 196 engages the exposed male thread on the sleeve 192 and is tightened to compress the grommet 194 between the fastener 196 and the first end 198 of the sleeve 192. It is to be appreciated that the grommet 194 may be flexible and / or compressible and configured from various materials to achieve such functionality such as, but not limited to, rubber, neoprene, etc.

[0126] In certain embodiments, sleeves 172, 192 may be eliminated. In these embodiments, the housing may include a threaded end to mate with a fastener in a similar fashion as shown in FIGS. 4A and 4B.

[0127] Referring to FIGS. 5A and 5B, a male plug 102-2 and a female connector 104-2 are illustrated, respectively. In this embodiment, housing 228 of male connector 102-2 includes a second end 210-2 that is threaded on an outer surface of the housing 228 and configured to receive fastener 176, as shown in FIG. 5A. Similar to the embodiment shown in FIG. 4A, once the cable 106 is terminated to the male contact 110, an appropriately sized grommet 174 is slid over the cable 106 and the gland nut 176 engages the male threads on the housing 228 and is tightened to compress the grommet 174 between the fastener 176 and the second end 210-2 of the housing 222.

[0128] Referring to FIG. 5B, housing 264 of female connector 104-2 includes a second end 205-2 that is threaded on an outer surface of the housing 264 and configured to receive fastener 196. Similar to the embodiment shown in FIG. 4B, once the cable 108 is terminated to the female contact 116, an appropriately sized grommet 194 is slid over the cable 108 and the gland nut 196 engages the male threads on the housing 264 and is tightened to compress the grommet 194 between the fastener 196 and the second end 205-2 of the housing 264.

[0129] It is to be appreciated that although the housings 228, 264 are different in the embodiments shown in FIGS. 5A and 5B relative to the housings 128, 164 shown in FIGS. 4A and 4B, the contacts 1 10, 1 16, the grommets 174, 194 and fasteners 176, 196 are of similar construction. It is further to be appreciated that the cable terminations of FIGS. 4A,4B and 5A,5B provide for quicker installation and more robust strain relief.

[0130] The single pole connectors of the present disclosure will be able to handle higher amperage current than legacy products. Therefore, the new improved design of the present disclosure will include mechanisms for preventing mating to a legacy connector. In one embodiment, unique keying features are provided on both the male and female single pole housings. Referring to FIGS. 6A and 6B, front perspective views of the female connector 104 and male plug 102 are illustrated, respectively. FIGS. 7A and 7B are front views of the connectors shown in FIG. 6A and 6B, respectively. The housing 164 of the female connector 104 includes a first end 201 and a second end 205. The first end 201includes a detent 204 and notch 206 formed on an outer surface 203 of the housing 164. The detent 204 is located at the 12:00 o’clock position and the notch 206 is located at the 6:00 o’clock position. The housing 128 of the male connector 102 includes a first end 208 and a second end 210. The first end 208 includes a notch 212 and detent 214 formed on an inner surface 209 of the housing 128. The notch 212 is located at the 12:00 o’clock position and the detent 214 is located at the 6:00 o’clock position. It is to be appreciated that the notch 212 and detent 214 of the male plug 102 are configured to be complementary to the detent 204 and notch 206 of the female connector 104 as to allow only the proper connector to be mated, e.g., prevent matching of connectors having different ratings.

[0131] Although a detent and notch have been shown and described it is to be appreciated that other shapes and sizes for the keying mechanism are contemplated to be within the scope of the present disclosure. Additionally, the detent and notch may be located at other positions besides the 12:00 o’clock and 6:00 o’clock positions as long as the detents and notches are configured to be complementary on the housings 128, 164 of the male and female connectors 102, 104 respectively. It is further to be appreciated that in certain embodiments more than two keying features may be employed on complementary housings.

[0132] In other embodiments, unique keying may be employed for each single pole connector within a three-phase electrical circuit, e.g., ground GND, Neutral and Lines, to insure only male and female devices can only mate with the appropriate like conductor. In certain embodiments, the positions of the keys on a particular housing will indicate a function of the particular single pole connector.

[0133] The conductivity of the male and female contacts can be increased by plating the surfaces with a high conductivity material such as silver. The use of selective plating, utilizing silver on all interfacing surfaces, is added to the electrical contacts as shown in FIG. 3B-3D. These areas include the surfaces where the front portion 120 of male contact 1 10 contacts the front portion 156 of the female connector 1 16 when fully mated. For example, as shown in FIG. 3B, the front portion 120 of male contact 110 may be plated, while the rivet 157 and inner surface of bore 170 may be plated on the female contact 1 16 shown in FIG. 3C. When the male contact 110 is initially inserted, the rivet 157 onthe female contact 116 contacts the flat portion 131 on the male contact 1 10. After insertion, as the male plug 102 rotates, the contact surface moves from the flat portion 131 to the full radius as shown in FIG. 3D. The thickness of silver is optimized to maximize electrical efficiency, thereby minimizing resistance that generates unwanted heat that has to be managed and removed, increasing operating cost.

[0134] In some implementations the plating is only be applied to critical areas where contact is made in order to save on material costs. In other implementations, entire parts are plated to streamline the manufacturing process.

[0135] In further implementations, the male and / or female contact may be made of highly conductive contact materials. Contacts heat up while carrying a high current. Existing male and female connectors use brass for the contacts. Typically, brass has an electrical conductivity ranging from 23% to 44% IACS, depending on the specific type of brass. For reference, the conductivity of copper is 100% IACS. In one embodiment, the male and female contacts are constructed from Tellurium Copper (C14500) with electrical conductivity of about 90% IACS. Other material may include but are not limited to Copper Chromium (C18200; -80% IACS) and Copper Zirconium (C15000; -80% IACS). By employing such materials for male and female connectors, lower temperature rise and improved resistance to arcing can be achieved.

[0136] Terminal screws are typically used to connect a wire or conductor to a male or female connector. By providing multiple termination screws, the possibility of stress relaxation can be reduced while increasing the high-pressure connection area between the wire and terminal to reduce contact resistance and temperature rise. Conductivity improves by additional terminal screws, e.g., screws 136 as shown in FIG. 5, attached to the contact via threaded holes 132, 134 for each screw. This improves surface area of engagement between a conductor or cable and the cavity 122, 158 of the contact terminal. Although two screws 136 are shown in FIG. 5, it is to be appreciated that more than two screws 136 (and corresponding apertures 132, 134) may be provided.

[0137] Further to the goal of reducing unwanted heat rise, the present disclosure provides alternative ways to terminate conductors. Terminal screws, e.g., screws 136, are employed to engage terminal conductors, e.g., conductors 106, 108. Conductivity relies on the screws pressing the conductor against the opposite wall in the terminal bore, i.e.,an inner surface of cavity 122, 158. Approximately half of the conductor surface area makes contact with the highly conductive sleeve material. Terminal screws are typically made from stainless steel and less conductive, with a typical conductivity of 2-3% IACS. To further reduce contact resistance at the wire or conductor terminal, the terminal screws may be made from significantly more conductive materials that are sufficiently strong. For example, beryllium copper with 15-30% IACS may be used in terminal screws. By doing so, the electrical path from the conductor through the screw to the contact terminal is enhanced. In addition to beryllium copper, other high strength copper alloys, such as Copper-Titanium (CuTi), may be employed in the screws.

[0138] In addition, the terminal bores are typically smooth. Adding points of asperity 159 inside the terminal cavities or bores 122, 158, for example, using threads or ribs, creates predictable points of contact to the conductor to improve heat transfer, as shown in FIG. 3D.

[0139] In certain embodiments, the housings 128, 164 of the male plug 102 and female connector 104 include features to prevent water ingress. For example, in one embodiment, the male and female housings 128, 164 are made of flexible TPE (thermoplastic elastomer) material where minimal interferences between male and female housings creates a seal on the radial walls, as shown in FIGS. 8A and 8B. In one embodiment as shown in FIG. 8B, a tapered LD (inner diameter) 129 of male housing 128 interferes with a larger taper on the O.D. (outer diameter) 165 of the female housing 164. It is to be appreciated that the inner diameter 129 tapers inward at a first predetermined angle, i.e., the diameter gets smaller in the direction from end 208 toward end 201 , and the outer diameter 165 tapers outward in a second predetermined angle, i.e., the diameter gets larger in the direction from end 201 toward end 208. Since the second predetermined angle is larger than the first predetermined angle, as the male contact is inserted further, additional axial engagement results. In one embodiment, the first predetermined angle is approximately 0.6 degrees and the second diameter is approximately 1 .0 degree; however, other angles are complicated to be within the scope of the present disclosure.

[0140] In another embodiment, a soft durometer face seal 220 for the housings can also be added, as shown in FIG. 8C. In this embodiment, seal 220, e.g., a o-ring seal, isdisposed over the end 204 of the female housing 164 and, when the housings 1 8, 164 are mated, the end 208 of the male housing 128 comes into contact with the seal 220 to prevent water ingress.

[0141] In a further embodiment, the housings 128, 164 may be made of more rigid materials, e.g., valox, nylon, etc., that have minimal radial clearances and elongated axial engagement of male and female housings to create an elongated leak path labyrinth, as shown in FIG. 8D.

[0142] It is to be appreciated that the features of the above-described embodiments may be employed in corded and / or panel mount versions of the male plug and female connector. For example, as shown in FIG. 9, a corded male plug 102 and panel female connector 304 are illustrated. In this embodiment, the female connector 304 includes housing 364 as described above. Additionally, the housing 364 includes a flange 365 for mounting the housing 364 on a panel or an appropriate structure. The flange 365 includes at least one aperture 367 configured for receiving a fastener to securely fasten the flange 365 to a panel or other structure, for example, a rack.

[0143] In certain embodiments, the present disclosure provides for techniques for organizing and bundling multiple single pole connectors. Referring to FIGS. 10A-10C, a bracket 400 for nesting or ganging individual single pole connectors is illustrated. The bracket 400 includes at least two flexible housing receivers 402 where adjacent housing receivers 402 are coupled together by an extension member 404. Each receiver 402 includes first and second arms 406, 408 respectively which flex in respect to each other to allow a portion of a housing, e.g., housing 128 or housing 164, to be placed in the receiver and retained therein. It is to be appreciated that the spacing of the first and second arms 406, 408 may be configured for specific sizes of the housings. In certain embodiments, a portion of the arms 406, 408 flare outward from each other to facilitate the insertion of a single pole connector housing.

[0144] Additionally, the length of the extension members 404 controls the spacing between each single pole connector 410, 412, 414, 416, 418, and therefore, the length of the extensions members 404 may be configured such that the single pole connectors disposed in the bracket 400 align with an intended connection receiver, e.g., a matching number of panel or rack mounted single pole connectors.

[0145] FIG. 10A illustrates a bracket 400 for a three-phase system, i.e., the bracket 400 includes at least five housing receivers 402 that receive the following single pole devices: a ground 410, neutral 412, line L1 414, line L2416 and line L3418. It is to be appreciated that the number of receivers 402 and the lengths of the extension members 404 may be modified to accommodate other systems.

[0146] In other embodiments, the housings of the connectors may be color coded to facilitate identifying the single pole device and to control the sequence of mating of the single pole connectors. For example, the ground single pole device 410 may be green, the neutral single pole connector 412 may be white, the line L1 single pole connector 414 may be black, the line L2 single pole connector 416 may be red and the line L3 single pole connector 418 may be blue. In one embodiment, the bracket 400 will bear indicia to identify the proper placement of each single pole connector. For example, each receiver 402 may be labeled with the corresponding color of the proper single pole connector. In another example, each receiver 402 may be color coded to indicate the proper placement of each single pole connector. In a further example, indicia 405 on each housing receiver 402 may include a label, e.g., engraved text, raised lettering, etc., to indicate the proper single pole connector to be placed therein.

[0147] In certain embodiments, the present disclosure provides for techniques for sequencing the mating of multiple single pole connectors. Referring to FIGS. 1 1 and 20, a system 500 for sequencing of single pole male plugs into a panel containing female receptacles is illustrated. The system 500 includes a panel 502 and a plurality of female receptacle housings 504, 506, 508, 510, 512. The panel 502 includes a front face 514 and a rear face 516, as shown in FIGS. 12 and 13. The front face 514 of panel 502 includes apertures 518, 520, 522, 524, 526 that correspond to female receptacle housings 504, 506, 508, 510, 512. As will be described below, each female receptacle housing 504, 506, 508, 510, 512 is configured to receive a female receptacle 541 , 543, as illustrated in FIGS. 11 and 22.

[0148] In one embodiment, aperture 518 corresponds to ground receptacle housing 504, aperture 520 corresponds to neutral receptacle housing 506, aperture 522 corresponds to line L1 receptacle housing 508, aperture 524 corresponds to line L2 receptacle housing 510 and aperture 526 corresponds to line L3 receptacle housing 512. It is to beappreciated that each aperture 518, 520, 522, 524, 526 includes a keying feature 530, 532, 534, 536, 538, respectively, to ensure a proper male plug is inserted into the proper aperture and corresponding female receptacle, e.g., male plugs 540, 542 are inserted into aperture 518, 520 respectively, to mate with female receptacles 541 , 543.

[0149] Referring to FIG. 14, a bottom view of the panel 502 is illustrated while FIG. 15 is a perspective bottom view of the panel 502. The panel includes a plurality of shutters 550, 552, 554, 556 that are configured to selectively block apertures 520, 522, 524, 526 respectively. At least two plungers 558, 560 are configured to selectively actuate the shutters 550, 552, 554, 556. FIG. 21 illustrates panel 502 transparently to show shutter 550 blocking aperture 520.

[0150] Referring to FIG. 16, a rear perspective view of panel 502 is illustrated with the shutters 550, 552, 554, 556 and plungers 558, 560 removed. Each receptacle housing 504, 506, 508, 510, 512 includes a channel 505, 507, 509, 511 , 513, respectively. The channels 505, 507, 509, 51 1 , 513 are configured to receive a keying feature on an appropriate male plug. The rear face 516 of the panel 502 further includes a first retaining groove 551 , e.g., a L-shaped member, and a plurality of second retaining grooves 553 e.g., a L-shaped member, that are configured to retain the shutters 550, 552, 554, 556 in a parallel relationship with the rear face 516 while allowing the shutters 550, 552, 554, 556 to translate therein. In one embodiment, first retaining grove 551 is a single groove for retaining at least one end of shutters 550, 552, 554, 556 simultaneously. In another embodiment, a first retaining groove 551 is provided for each shutter 550, 552, 554, 556. In this embodiment, each shutter 550, 552, 554, 556 will be retained by a pair of first and second retaining groves 551 , 553. Additionally, the channels 505, 507, 509, 511 , 513 are configured to retain the plungers. FIG. 17A illustrates a close-up view of the housing 504, shutter 550 and plunger 558 associated with the ground GND receptacle 518. FIG. 17B and 23 are exploded views of the housing 504, shutter 550 and plunger 558 shown in FIG. 17A.

[0151] The operation of shutter 550 and plunger 558 will now be described in relation to FIGS. 17A-B, 18 and 24-26. Male plug 540 includes a first housing 570 and a second housing 572 configured to be inserted into aperture 518. The second housing 574 includes a lengthwise detent 574, which acts as a keying feature. It is to be appreciatedthat detent 574 mates with keying feature 530 of aperture 518. FIG. 24 shows an unactuated state of shutter 550. As plug 540 is inserted into aperture 530, detent 574 enters channel 505 and comes into contact with plunger 558, as shown in FIG. 25. As the plug 540 is further inserted, the plunger 558 comes into contact with and actuates shutter 550. When shutter 550 is actuated, the shutter 550 translates within the first and second retaining grooves 551 , 553 in direction A, as indicated in FIG. 18, until aperture 518 is no longer blocked by the shutter 550, as shown in FIG. 26. Male plug 542, e.g., a neutral single pole connector, is now enabled to be inserted into aperture 520. In one embodiment, when plug 542 is inserted into aperture 520, shutter 552 is actuated to open aperture 522, where subsequent insertions of plugs will open an adjacent aperture. In another embodiment, when plug 542 is inserted into aperture 520, the remaining shutters 552, 554, 556 are simultaneously actuated to open apertures 522, 524, 526.

[0152] It is to be appreciated that, in one embodiment, the pluggers and / or shutters may be spring loaded such that when an appropriate plug is removed, a corresponding shutter returns to its unbiased state to prevent access to the corresponding aperture. In other embodiments, the shutters may be manually operated to a closed position preventing access to the apertures.

[0153] Referring to FIGS. 19A-19C, a method of sequencing connections of a single pole system is illustrated. In step 1 , shutters 550, 552, 554, 556 are closed, while aperture or port 518 is open, as shown in FIG. 19A. In step 2, after the ground GND plug 540 is inserted into aperture or port 518, the neutral shutter 550 opens, as shown in FIG. 19B. In step 3, after the neutral plug 542 is inserted into aperture or port 520, the line shutters 552, 554, 556 open, as shown in FIG. 19C.

[0154] Referring to FIGS. 27 to 31 E, another single pole electrical connector assembly 600 is provided. The single pole electrical connector assembly 600 includes a male plug 602 and a female connector 604. Electrical cables 606 and 608 are connected to the male plug 602 and female connector 604, respectively. Connecting the male plug 602 and female connector 604 enables the transmission of electrical power therethrough.

[0155] The male plug 602 includes a male contact 610 having a first end 612 and a second end 614. A cable 606 is connected to the first end 612 of the male contact 610.The second end 614 is adapted to engage a corresponding female contact 616. The male contact 610 has a rear portion 618 and a front portion 620 connected thereto. A cavity is formed in the rear portion 618 to receive the electrical cable 606. A first opening 624 is formed circumferentially in the rear portion 618 to receive a housing retaining fastener 626 that secures the male contact 61 O to a housing 628. Second and third openings 632 and 634 are formed circumferentially in the rear portion 618 and extend into the cavity 622. Fasteners 636 are received by the openings 632 and 634 to secure the cable 606 within the cavity 622.

[0156] It is to be appreciated that the female connector 604 is similar to the female connectors described above except for functionality of the housing and clamp which will now be described below in regard to the male connector 602.

[0157] The single pole connectors 602, 604 of the present disclosure provide for improved cable termination resulting in quicker installation and more robust strain relief. Referring to FIGS. 30 and 31 A-B, the male plug 602 further includes a housing 628 having a first end 621 and a second end 623. The first end 621 of the housing 628 includes a conductor receiving portion 630 configured to receive a conductor for coupling to contact 618. The conductor receiving portion 630 has a semi-circular surface 632 configured to confirm with an outer surface of a conductor, e.g., conductor 606. Each end of the semi-circular surface 632 includes a flat surface 634, 636 respectively, which includes a raised fastener receiver 638, 640.

[0158] To terminate a conductor to the male plug 602, a portion of a conductor jacket 642 is removed to expose a conductor 646. The exposed conductor 646 is disposed in cavity 648 that includes the contact 618. The exposed conductor 646 is translated into the cavity 648 until a leading edge 650 of the conductor jacket 624 comes into contact with surface 652. Once fully inserted, the exposed conductor 646 is secured in the contact 618 via screws or fasteners 636. A clamp 676 is then coupled to the conductor receiving portion 630 to secure the cable 606 to housing 628.

[0159] Referring to FIGS. 32A-32F, various views of the clamp 676 are illustrated, FIG. 32A is a perspective view, FIG. 32B is another perspective view, FIG. 32C is a side view, FIG. 32D is a top view, FIG. 32E is a bottom perspective view and FIG. 32F is a bottom view.

[0160] Clamp 676 includes a top surface 677 and a bottom surface 678. The clamp 676 includes two apertures 679, 680 that receive fasteners 681. The fasteners 681 pass through the aperture 679, 680 to be coupled with the raised fastener receivers 638, 640 of housing 628 to secure the clamp 676 to the housing 628. As best shown in FIG. 32F, recesses 684 are formed on the bottom surface 378 around the apertures 679, 680, where the recesses 684 mate with the raised fastener receivers 638, 640. The bottom surface 678 further includes semi-circular recesses 682 which conform to the shape of the jacket 642 of cable 606. Clamping members 683 are disposed on both ends of the semi-circular recesses 682. It is to be appreciated that the clamping members 683 will engage (or “dig into”) the jacket 642 of cable 606 to provide strain relief.

[0161] It is to be appreciated that the clamp and clamping functions are substantially similar for the male and female connectors 602, 604.

[0162] To address a range of cable sizes, the clamps of the present disclosure may be configured with different cable grasping diameters. Referring to FIG. 33, a male connector 602 is illustrated with at least three clamps 676A, 676B, 676C. Each of the three clamps 676A, 676B, 676C have a different cable grasping diameter d1 , d2, d3 respectively to accommodate different cable sizes. It is to be appreciated that the cable size will differ depending on the amperage rating of the cable. For example, in one embodiment, clamp 676 is configured to accommodate a cable rated for at least 200 amps. It is further to be appreciated that a 200 amp cable is just one example and other cable sizes and ratings are contemplated to be within the scope of the present disclosure.

[0163] In addition to the clamping feature for strain relief described above, an anti-rotation detent feature provides additional resistance to untwist and un-mate a male connector from a female connector. The detent is accomplished by using the protruding keying feature, similar to the keying feature described above in relation FIGS. 6A-7B.

[0164] Referring to FIG. 34A, a front perspective view of housing 628 is provided. Housing 628 includes a first portion 702 and a second portion 704. The first portion 702 is generally cylindrical and configured to mate with housing 750 of female connector 604, as shown in FIG. 35. First portion 702 includes a detent 706 and a recess 708 disposed on an outer surface of end 623. As shown in FIG. 34C, recess 708 runs along a length of the first portion 702. At the juncture of the first portion 702 and second portion 704, the recess708 transitions into channel 710. Channel 710 is circumferentially disposed about the first portion 702 of the housing. At the furthest end of the channel 710, the channel includes a detent 712 and a recess 714.

[0165] Referring to FIG. 35, the housing 750 of the female connector 604 includes a first portion 752 and a second portion 754. The first portion 752 includes a notch 756 and detent 758 formed on an inner surface at end 760. It is to be appreciated that the recess 708 and detent 706 of the male plug 602 are configured to be complementary to the detent 758 and notch 756 of the female connector 604 as to allow only the proper connector to be mated, e.g., prevent matching of connectors having different ratings. In this embodiment, when end 623 of the male housing 628 is inserted into end 760 of the female housing, the detent 758 of the female housing will translate along recess 708 of the male housing 628. Once fully inserted, the female housing 750 is twisted relative to the male housing 628 and detent 758 will travel along channel 710, ride over detent 712 (as shown in FIG. 36A) and will come to rest in recess 714 (as shown in FIG. 36B) preventing rotation of the housings 628, 750 relative to other. It is to be appreciated that the detent 712 has a ramp that guides the protruding keying feature, i.e., detent 758, up and over detent 712. It is further to be appreciated that the width of detent 758 is dimensioned to travel within recess 708 and channel 710, i.e., the width of detent 758 is less than a width of recess 708 and channel 710.

[0166] Referring to FIGS. 37A and 37B, a front view of the male housing 628, as shown in FIG. 37A, and the female housing 750, as shown in 37B, are illustrated. The detent 706 of the male housing 628 is located at the 12:00 o’clock position and the notch 708 is located at the 6:00 o’clock position. As shown in FIG. 37B, the female housing 750 includes a notch 756 and detent 758 formed on an inner surface of the housing 750. The notch 756 is located at the 12:00 o’clock position and the detent 758 is located at the 6:00 o’clock position. It is to be appreciated that the notch 706 and detent 708 of the male plug 602 are configured to be complementary (or a mirror image) to the detent 758 and notch 756 of the female connector 604 as to allow only the proper connector to be mated, e.g., prevent matching of connectors having different ratings or different purposes.

[0167] It is to be appreciated that the detent and notch may be located at other positions besides the 12:00 o’clock and 6:00 o’clock positions as long as the detents and notchesare configured to be complementary on the housings 628, 750 of the male and female connectors 602, 604 respectively. It is further to be appreciated that in certain embodiments more than two keying features may be employed on complementary housings.

[0168] In other embodiments, for example, unique keying may be employed for each single pole connector within a three-phase electrical circuit, e.g., ground GND, Neutral and Lines, to insure only male and female devices can only mate with the appropriate like conductor. In certain embodiments, the positions of the keys on a particular housing will indicate a function of the particular single pole connector. As shown in FIG. 37A and 37B, the male housing 628 of a ground connector 602 and female housing 750 of ground connector 604 include keying features at the 12:00 o’clock and 6:00 o’clock positions. To prevent mating to a neutral connector, the neutral connector will have the keying features in other positions. For example, referring to FIG. 37C, a neutral male plug 802 includes a housing 804 where the detent 806 is at the 3:00 o’clock position and the notch 808 is at the 12:00 o’clock position. Complementary neutral female connector 810 includes a housing 804 where the detent 814 is at the 12:00 o’clock position and the notch 816 is at the 9:00 o’clock position, as shown in FIG. 37D. In such a configuration, the male plug 628 will not be able to mate with female connector 810 due to the positions of the keying features, i.e., the notches and detents. As a further example, referring to FIG. 37E, a line male plug 820 includes a housing 822 where the detent 824 is at the 6:00 o’clock position and the notch 826 is at the 9:00 o’clock position. Complementary line female connector 830includes a housing 832 where the detent 834 is at the 3:00 o’clock position and the notch 836 is at the 6:00 o’clock position, as shown in FIG. 37F. In such a configuration, the male plug 628 will not be able to mate with either female connector 810 or female connector 830 due to the positions of the keying features, i.e., the notches and detents.

[0169] It is to be appreciated that the clock positions shown in FIG. 37A-37F are exemplary and other clock positions for detents and notches are contemplated to be within the scope of the present disclosure as long as the clocking scheme from male plug to female connector is complementary, i.e., a mirror image of each other. The present disclosure also contemplates the use of other clocking schemes to prevent mating among ground / neutral / line using one male and one female key per ground / neutral / line device.

[0170] One of ordinary skill in the art armed with the present specification will readily appreciate that the exemplary single pole connector embodiments described above were provided for explanatory purposes and are not to be interpreted as limiting the present disclosure to any of the specific features, combinations, configurations, form factors, or other limitations described in connection with the embodiments depicted in the figures. It is to be appreciated that the various features shown and described are interchangeable, that is a feature shown in one embodiment may be incorporated into another embodiment.

[0171] For example, in various embodiments, the novel form factors, novel male and female contact configurations, novel contact materials and thermal management techniques enable single pole connectors to be configured with a high amperage rating, e.g., at least 200 amps, while having a reduced size (or form factor) compared to conventional single pole connectors having a comparable amperage rating.

[0172] While not shown in the various exemplary embodiments, the connectors disclosed herein may be provided with other mechanical friction connections or the like to visually or audibly ensure a full connection, and / or prevent inadvertent disconnection, and / or lock connectors in a closed position.

[0173] One of ordinary skill will appreciate that the exact dimensions and materials are not critical to the disclosure and all suitable variations should be deemed to be within the scope of the disclosure if deemed suitable for carrying out the objects of the disclosure.

[0174] One of ordinary skill in the art will also readily appreciate that it is well within the ability of the ordinarily skilled artisan to modify one or more of the constituent parts for carrying out the various embodiments of the disclosure. Once armed with the present specification, routine experimentation is all that is needed to determine adjustments and modifications that will carry out the present disclosure.

[0175] The above embodiments are for illustrative purposes and are not intended to limit the scope of the disclosure or the adaptation of the features described herein to particular electrical connectors. Those skilled in the art will also appreciate that various adaptations and modifications of the above-described preferred embodiments can be configured without departing from the scope and spirit of the disclosure. Therefore, it is to beunderstood that, within the scope of the appended claims, the invention may be practiced other than as specifically described.

Claims

WHAT IS CLAIMED IS:1 . A single pole electrical connector comprising: a housing having a first end and a second end, the first end configured to receive a conductive contact and the second end configured to mate with a second housing of a complementary contact, the first end further configured with a threaded surface; the conductive contact disposed in the first end of the housing, the conductive contact including a termination portion for receiving a conductor; a grommet disposed over the conductor; and a fastener disposed over the conductor and grommet, the fastener configured to mate with the threaded surface of the first end of the housing and to compress the grommet between the fastener and the first end of the housing when tightened.

2. The single pole electrical connector of claim 1 , wherein the fastener is a gland nut.

3. The single pole electrical connector of claim 1 , wherein the second end of the housing includes at least two keying elements.

4. The single pole electrical connector of claim 3, wherein the at least two keying elements are disposed on an outer surface of the second end of the housing.

5. The single pole electrical connector of claim 3, wherein the at least two keying elements are disposed on an inner surface of the second end of the housing.

6. The single pole electrical connector of claim 3, wherein positions of each of the at least two keying elements on the housing indicate a function of the single pole electrical connector.

7. The single pole electrical connector of claim 1 , wherein the conductive contact includes a male portion and the complementary contact includes a female portion, further comprising silver plating on at least interfacing surfaces between the male and female portions.

8. The single pole electrical connector of claim 1 , wherein the conductive contact and the complementary contact include a copper alloy.

9. The single pole electrical connector of claim 8, wherein the copper alloy includes at least one of tellurium copper, chromium copper and zirconium copper.

10. The single pole electrical connector of claim 1 , wherein the termination portion of the conductive contact includes a cavity that receives the conductor and at least two apertures arranged circumferentially to the cavity, each aperture configured to receive a screw to secure the conductor in the cavity.1 1 . The single pole electrical connector of claim 10, wherein the screw includes a high strength copper alloy.

12. The single pole electrical connector of claim 1 1 , wherein the high strength copper alloy includes at least one of beryllium copper and copper titanium.

13. The single pole electrical connector of claim 1 , wherein the termination portion of the conductive contact includes a cavity that receives the conductor and an inner surface of the cavity is configured with asperity points to create predictable points of contact between the inner surface of the cavity and the conductor.

14. The single pole electrical connector of claim 1 , wherein the housing is configured from a flexible thermoplastic elastomer (TPE) material.

15. The single pole electrical connector of claim 14, wherein the second end of the housing has a first diameter and the second housing has a second diameter, the first diameter being greater than the second diameter to receive the second end of the first housing.

16. The single pole electrical connector of claim 15, wherein an inner diameter of the second end of the housing tapers inward at a first predetermined angle and an outer diameter of the second housing tapers outward at a second predetermined angle, the second predetermined angle being greater than the first predetermined angle.

17. The single pole electrical connector of claim 1 , further comprising a seal disposed on the second housing at an interface of the second end of the housing and the second housing.

18. The single pole electrical connector of claim 17, wherein the seal is an O-ring disposed on the second housing.

19. The single pole electrical connector of claim 1 , wherein at least one of the housing or second housing includes a flange configured for mounting to a structure.

20. The single pole electrical connector of claim 1 , further comprising a bracket for supporting the single pole electrical connector and at least one second single pole electrical connector.21 . A bracket for organizing at least two single pole electrical connectors comprising: at least two housing receivers, each housing receiver including first and second arms configured to flex in respect to each other to allow a portion of a housing of a single pole connector to be placed in the housing receiver and retained therein, wherein adjacent housing receivers are coupled together by an extension member.

22. The bracket of claim 21 , wherein a length of each extension member controls the spacing between each single pole connector23. The bracket of claim 22, wherein the length of each extension member is configured such that the single pole connectors disposed in the housing receivers align with an intended connection structure.

24. The bracket of claim 21 , wherein each housing receiver is color-coded to indicate a sequencing of the at least two single pole connector.

25. The bracket of claim 21 , wherein each housing receiver includes indicia to identify a particular single pole connector to be disposed therein.

26. The bracket of claim 25, wherein the indicia is a color of a corresponding single pole connector.

27. A system for organizing at least two single pole electrical connectors comprising: a panel having a front face and a rear face including at least two apertures accessible from the front face, each aperture configured for receiving a male portion of a first single pole electrical connector; at least one female receiving housing coupled to the rear face of the panel at each aperture; at least one shutter disposed over at least one of the apertures configured to prevent insertion of a male portion when closed, wherein the shutters are selectively actuated to open upon insertion of an appropriate male portion of the single pole electrical connector.

28. The system of claim 27, wherein each aperture is configured with a unique keying feature.

29. The system of claim 28, wherein the male portion of the single pole electrical connector includes a complementary keying feature to ensure proper mating to a respective aperture.

30. The system of claim 29, wherein each female receiving housing includes a channel that corresponds to the keying feature of the corresponding aperture.31 . The system of claim 30, wherein the channel includes a plunger, and upon insertion of the male portion of the single pole electrical connector into an appropriate aperture, the plunger actuates the at least one shutter of at least one adjacent aperture.

32. The system of claim 31 , wherein the at least one shutter is associated to at least three apertures.

33. The system of claim 31 , wherein the complementary keying feature of the male portion actuates the plunger.

34. A method for sequencing a plurality of single pole electrical connectors comprising: providing a panel having a front face and a rear face including at least two apertures accessible from the front face, each aperture configured for receiving a male portion of a single pole electrical connector, and at least one shutter disposed over at least one of the apertures configured to prevent insertion of a male portion when closed; inserting a first single pole connector into a first aperture; actuating the at least one shutter associated to an adjacent aperture.

35. The method of claim 34, wherein each aperture is configured with a unique keying feature.

36. The method of claim 35, wherein the male portion of the single pole electrical connector includes a complementary keying feature to ensure proper mating to a respective aperture.

37. The method of claim 34, wherein the panel is configured for a three phase electrical system including five apertures, wherein the first aperture is for a ground connector, a second aperture is for a neutral connector and remaining apertures are for line connectors.

38. The method of claim 37, wherein upon insertion of a male portion into first aperture, the second aperture opens.

39. The method of claim 38, further comprising inserting a neutral connector into the second aperture and actuating the at least one shutter for the remaining apertures.

40. A single pole electrical connector comprising: a housing having a first end and a second end, the first end configured to receive a conductive contact and the second end configured to mate with a second housing of a complementary contact; the conductive contact disposed in the first end of the housing, the conductive contact including a termination portion for receiving a conductor; the first end of the housing includes a conductor receiving portion configured to receive the conductor for coupling to the conductive contact; and a clamp coupled to the conductor receiving portion to secure the conductor to the housing.41 . The single pole electrical connector of claim 40, wherein the conductor receiving potion and the clamp include semi-circular recesses configured to conform to an outer surface of the conductor.

42. The single pole electrical connector of claim 41 , wherein the semi-circular recess of the clamp has a predetermined diameter, wherein the predetermined diameter is selected based on a diameter of the conductor.

43. The single pole electrical connector of claim 40, wherein the clamp includes a top surface and a bottom surface, the bottom surface mates with conductor receiving portion, the bottom surface includes at least two clamping members that engage an outer surface of the conductor.

44. The single pole electrical connector of claim 40, wherein the bottom surface of the clamp includes at least two recesses configured to receive at least two raised receivers on the conductor receiving portion.

45. The single pole electrical connector of claim 40, wherein the first housing includes a first portion and a second portion, the first portion being generally cylindrical and configured to mate with the second housing, a first recess runs along a length of the first portion and at the juncture of the first portion and second portion, the first recess transitions into a channel circumferentially disposed about the first portion of the housing.

46. The single pole electrical connector of claim 45, wherein the second housing includes a first detent configured to translate in the first recess and channel of the first portion of the first housing.

47. The single pole electrical connector of claim 46, wherein the channel of the first portion includes a second detent and a second recess and upon fully inserting the second housing into the first housing, the first detent of the second housing is translated over the second detent into the second recess to prevent unmating.

48. The single pole electrical connector of claim 46, wherein the first recess and first detent act as keying elements to prevent improper mating of the first and second housing.

49. The single pole electrical connector of claim 48, wherein the first and second housing includes at least one additional keying element.

50. The single pole electrical connector of claim 49, wherein positions of each of the at least two keying elements on the housing indicate a function of the single pole electrical connector.51 . The single pole electrical connector of claim 40, wherein the conductive contact is configured to carry a high current of at least 200 Amps.

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