The present invention relates generally to a connector for attaching the ends of two cables. More specifically, the present invention relates to a connector having a housing and a slidable clamping body. Still, more specifically, the present invention relates to an electrical connector for a mechanical overhead splice connection for splicing overhead power distribution conductors.
Common splice devices in use today are complex and expensive. Typically, conventional splice devices use four electrical interfaces to conduct power from one conductor to another. The electrical path passes from one conductor into a first set of jaws, from the first set of jaws into the outer shell or housing, from the outer shell to a second set of jaws, and from the second set of jaws into an opposite conductor.
U.S. Pat. No. 3,384,704 to Vockroth discloses a typical high tensile automatic electrical connector for joining stranded conductors. The electrical connector has an outer ferrule with a pair of tapered gripping jaw means. The gripping jaw means are spatially positioned from the ends of the ferrule. Tubular inserts are used for enclosing the gripping jaw means for gripping conductors. A common failure with automatic splicing connectors is mechanical failure due to improper installation, usually when the installer is unable to determine if the conductor is fully inserted. Therefore, premature failure occurs. If the conductor is not fully inserted, the conductor will not properly engage the full length of the jaws inside the connector.
Difficulties also arise when the pilot cup is engaged in the rear of the jaws, thus preventing engagement of the jaws with the conductor. Therefore, full compression of the jaws onto the conductor is prevented. If undetected during the installation process, improper positioning of the pilot cup may result in an incomplete assembly or catastrophic mechanical failure.
Consequently, a continuing need exists to provide a splicing connector in which an installer can determine if full insertion is achieved.
An object of the present invention is to provide a connector having a preassembled housing and clamping body, thus avoiding field assembly.
Another object of the present invention is to provide a connector wherein determining full insertion of the splicing connectors is easily ascertainable by an installer, thereby preventing mechanical failure due to improper installation.
A further object of the present invention is to provide a connector that is relatively simple and inexpensive to manufacture and package.
The foregoing objects are basically obtained by a connector housing having a receiving end, a narrow end, first and second side walls, and a housing nesting section. A closed end recess is longitudinally disposed on the first side wall. First and second guide flanges are connected to the top edges of the first and second side walls, respectively. A clamping body is slidably engaged with the housing. The clamping body includes first and second side members having upper bearing surfaces, a base wall connecting the side members, and a clamping body nesting section. At least one protrusion extends laterally from the first member, and is slidably engaged within the closed end recess. A cable passageway is positioned between the nesting sections. The upper bearing surfaces of the clamping body slidably engage the guide flanges of the housing.
The foregoing objects are also attained by a connector having a housing having a receiving end, a narrow end, first and second side walls, and a housing nesting section. A closed end recess is longitudinally disposed on the second side wall. First and second guide flanges are connected to top edges of the first and second side walls, respectively. A clamping body is slidably engaged within the housing. The clamping body includes first and second side members having upper bearing surfaces, a base wall connecting the side members, and a clamping body nesting section. At least one protrusion extends laterally from the second member, and is slidably engaged within the closed end recess. A cable passageway is positioned between the nesting sections. The upper bearing surfaces of the clamping body slidably engage the guide flanges of the housing.
The foregoing objects are further attained by a method comprising the steps of engaging at least one protrusion of a clamping body within a closed end recess longitudinally disposed on one of a first or second side wall of a housing. Then, a first cable is inserted into a receiving end of the housing proximate a housing nesting section. Next, a second cable is inserted into a narrow end of the housing proximate a clamping body nesting section. Thus, both cables are positioned in a cable passageway formed between the nesting sections, respectively. Consequently, the clamping body is advanced towards the housing narrow end and an engagement surface of the clamping body nesting section cams in a direction toward the engagement surface of the housing cable nesting section.
By forming the connector and by performing the method in this manner, an installer may determine if splicing connectors are in the fully inserted position, thereby improving electrical contact between the connectors and preventing mechanical failure.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
Referring to the drawings which form a part of this disclosure:
Referring to
As illustrated in
As best seen in
The housing nesting section 18 is disposed between the bottom sections 56a–b and along inner surfaces 50a–b. The longitudinal centerline 54 of the housing 12 divides the housing nesting section 18. Housing cable nesting section 18 is contiguous with the base of the U-shaped housing and has a housing engagement surface 60. The housing engagement surface 60 may be provided with frictional enhancement features 62 (
A cable locating tab 64 (
Attached to the top sections 48a–b of each side wall are guide flanges 22a–22b, respectively. Each guide flange 22a–b is substantially U-shaped and forms a respective U-shaped channel 24a–b for receiving the upper bearing surfaces 32, 34 of the clamping body 26. Each guide flange 22a–b has first, second, and third sections, each with inner and outer surfaces. Each first section extends upwardly and coplanar to the respective top sections 48a–b. Each second section extends inwardly in a direction perpendicular to each guide flange's 22a–b respective first section. Each third section extends downwardly, in a direction parallel to the respective first section and perpendicular to the second section. The third sections of the respective guide flanges 22a–b abut one another along their outer walls.
The guide channels 24a–b have inner surfaces which are angularly oriented relative to the longitudinal axis 54 from receiving end 44 of the housing 12 to the narrow end 46. Therefore, the upper bearing surfaces 32, 34 of the clamping body 26 are guided downwardly at a predetermined angle when moved along the guide channels 24a–b.
As best seen in
At least one closed end recess 20 is longitudinally disposed on an inner surface 50a–b of one of the first or second side walls 14, 16. Alternatively, a closed end recess 20 may be placed on both the first and second side walls 14, 16. The closed end recess 20 extends through the predetermined thickness and is visible from the outer surfaces 52a–b by an outward projection. The closed end recess 20 is preferably substantially oblong in shape; however, any suitable polygonal shape may be used. The closed end recess 20 substantially angles with respect to the longitudinal centerline 54 of the housing 12. The closed end recess 20 is disposed proximate the top portion 48 of a respective side wall 14, 16 and preferably closer to the receiving end 44 than to the narrow end 46.
As seen in
Strengthening ribs 76 may be formed in between each gripping ear 74 and the respective side walls 14, 16 to enhance the rigidity of the device, while providing increased structural support.
The housing 12 may be manufactured by any suitable conventional means such as casting, swaging, molding, forging, or extrusion. Preferably, the housing is made of aluminum; however, any suitable metal or plastic material can be used.
As best seen in FIGS. 1 and 3–4, a clamping body 26 is substantially U-shaped with a first end 78 and a second end 80.
As seen in
The first and second members 28, 30 have an inner surface 84 and an outer surface 86. Each member 28, 30 extends upwardly orthogonal to the longitudinal axis 96 of the clamping body 26. The upper edges of each member form upper bearing surfaces 32, 34. The upper bearing surfaces 32, 34 of each member 28, 30 extend downwardly from the clamping body 26 first end 78 to the second end 80 at a predetermined angle to slidably engage the guide flanges 22a–b. The angel is preferably about 6–7 degrees; however, other suitable arrangement and angles maybe used.
The upper bearing surfaces 32, 34 have the ratcheting serrations 70, 72 proximate the second end 80. Each ratcheting serration 70, 72 is substantially triangular in shape. Preferably, each ratcheting serration 70, 72 has a shape similar to a right triangle. The uppermost point of each ratcheting serration 70, 72 has a planar section 71, 73, as shown in
As stated earlier, clamping body nesting section 38 includes the bottom surface 88 on the bottom of the base wall 36. The bottom surface 88 may be provided with frictional enhancement features 90 (
A protrusion or plurality of protrusions 40 may extend laterally from one or both of the outer surfaces of the first and second members 28, 30. Each protrusion 40 is preferably integrally molded; however other suitable conventional means maybe used for connection to each member 28, 30. The one or more protrusions 40 preferably slidably engage a respective closed end recess 20 of the housing 12. As best seen in
A cable positioning tab 98 (
As best seen in
Strengthening ribs 94 are formed between a respective gripping ear 92 and the outer surface 86 of side members 30, 32 to enhance the rigidity of the device and provide increased structural support. The strengthening ribs 94 are placed in between the gripping ear 92 and the first and/or second members 30, 32 at a predetermined angle.
The clamping body 26 may be manufactured by any suitable conventional means such as casting, swaging, molding, forging, or extrusion. Preferably, the clamping body 26 is made of aluminum; however, any suitable metal or plastic material can be used.
Preferably, the connector 10 is preassembled prior to packaging. Assembly is accomplished by first inserting the clamping body 26 into the receiving end 44 of the housing 12. At least one of side walls 14 or 16 deflects, and the protrusion 40 of the clamping body 26 is compressed inwardly. Upon insertion of the clamping body 26 beyond the side walls 14, 16 and adjacent closed end recess 20, the protrusion 40 moves into, and is slidably positioned within the closed end recess 20. It should be understood, that alternatively, closed end recesses 20 and protrusions 40 may be placed on each side wall 14, 16 and on both the first and second members 30, 32, respectively, or can be reversed.
Following assembly, the electrical connector 10 is ready to receive the first and second cables A, B. The clamping body 26 may be retracted or advanced slightly to facilitate insertion. As best seen in
Once the cables A, B are fully inserted, the clamping body 26 is urged forward. The clamping body 26 slides parallel to the longitudinal axes 54, 96 and along angled guide channels 24a–b. The clamping body 26 upper bearing surfaces 32, 34 may also be angled such that, when the clamping body 26 is urged forward along the guide channels 24a–b, the distance between surfaces 60, 88 or the height of the cable passageway 42 decreases. Thus, a clamping or gripping action is achieved. The clamping or gripping action is enhanced by frictional enhancement features 62, 90 formed on the respective surfaces 60, 88 of the housing 12 and clamping body 26.
Turning to
In one embodiment, cables A, B are electrical cables having an oxide layer. Additionally, as the two cables A, B are clamped towards one another, an oxide layer on the surface of each cable A, B is abraded. Thus, cables A, B are forced into intimate electrical contact with one another due to the compressive force of the clamping body 26. Thus, the connector 10 provides an excellent, high integrity electrical interface.
While a particular embodiment has been chosen to illustrate the invention, it would be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.
Number | Name | Date | Kind |
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492811 | Kisinger | Mar 1893 | A |
772798 | Giltner | Oct 1904 | A |
1251103 | Rasck | Dec 1917 | A |
1630880 | Yates | May 1927 | A |
1656226 | Palm et al. | Jan 1928 | A |
1796738 | Wagner | Mar 1931 | A |
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2849772 | Buzowski | Sep 1958 | A |
2983012 | Madden | May 1961 | A |
3384704 | Vockroth | May 1968 | A |
4451104 | Hodgson et al. | May 1984 | A |
4634205 | Gemra | Jan 1987 | A |
5147145 | Facey et al. | Sep 1992 | A |
5151560 | Kreinberg et al. | Sep 1992 | A |
6193565 | Herron | Feb 2001 | B1 |
6773311 | Mello et al. | Aug 2004 | B1 |