Abstract:
Disclosed herein is an electrical connector set-screw. The electrical connector set-screw includes a body part and a head part. The body part includes a threaded section and a channel. The threaded section extends between a first end and an opposite second end of the body part. The channel extends through a portion of the body part. The channel is spaced from the first end and the second end of the body part The head part is connected to the body part. The head part includes a top section and an integral locking section. The top section is configured to be received by a tool. The integral locking section extends through the channel.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority under 35 U.S.C. §119(e) to U.S. provisional patent application No. 60/927,031 filed Apr. 30, 2007 which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to an electrical connector and, more particularly, to a submersible electrical set-screw connector. 
     2. Brief Description of Prior Developments 
     Submersible electrical set-screw connectors for making connections in power distribution networks are known in the art. U.S. Pat. No. 6,764,354 B2, which is hereby incorporated by reference in its entirety, discloses a submersible electrical set-screw connector. A similar insulated water-tight connector assembly including a set screw driver and plug is disclosed in U.S. Patent Publication No. 2006/0155280 A1 which is hereby incorporated by reference in its entirety. These conventional connectors provide set-screw assemblies having various configurations. There is a problem in that the electrical connections within these conventional configurations may become compromised as electrical utility operating environments become more severe and demanding. 
     Accordingly, there is need to for an improved submersible electrical set-screw connector. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the invention, an electrical connector set-screw is disclosed. The electrical connector set-screw includes a body part and a head part. The body part includes a threaded section and a channel. The threaded section extends between a first end and an opposite second end of the body part. The channel extends through a portion of the body part. The channel is spaced from the first end and the second end of the body part. The head part is connected to the body part. The head part includes a top section and an integral locking section. The top section is configured to be received by a tool. The integral locking section extends through the channel. 
     In accordance with another aspect of the invention, a submersible electrical set-screw connector is disclosed. The submersible electrical set-screw connector includes a connector body section and a set-screw assembly. The connector body section includes a first opening and a second opening. The first opening is substantially perpendicular to the second opening. The first opening is configured to receive a portion of an electrical conductor. The set-screw assembly is fastened to the connector body section at the second opening. The set-screw assembly includes a body part and a head part. The body part includes a threaded section and a first channel. The first channel extends in a direction substantially transverse to a central axis of the threaded section. The head part includes a top section and an integral locking section. The top section is configured to be received by a tool. The integral locking section extends through the first channel. 
     In accordance with yet another aspect of the invention, a method of manufacturing an electrical connector set-screw is disclosed. A body part having a threaded section and a channel is provided. The threaded section extends between a first end and an opposite second end of the body part. The channel extends through a portion of the body part. The channel is spaced from the first end and the second end of the body part. A head part is molded over a portion of the body part. The head part includes a top section configured to be received by a tool. A portion of the head part extends through the channel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of a submersible electrical set-screw connector comprising features of the invention; 
         FIG. 2  is a cross section view of the submersible electrical set-screw connector shown in  FIG. 1 ; 
         FIG. 3  is a front view of a set-screw assembly used in the submersible electrical set-screw connector shown in  FIG. 1 ; 
         FIG. 4  is a cross section view of the set-screw assembly shown in  FIG. 3 ; 
         FIG. 5  is another a cross section view of the set-screw assembly shown in  FIG. 3 ; 
         FIG. 6  is a top plan view of the set-screw assembly shown in  FIG. 3 ; 
         FIG. 7  is a front view of a head part of the set-screw assembly shown in  FIG. 3 ; 
         FIG. 8  is a cross section view of the head part shown in  FIG. 7 ; 
         FIG. 9  is a top plan view of the head part shown in  FIG. 7 ; 
         FIG. 10  is a perspective view of the head part shown in  FIG. 7 ; 
         FIG. 11  is a front view of an alternative set-screw assembly used in the submersible electrical set-screw connector shown in  FIG. 1 ; 
         FIG. 12  is a cross section view of the set-screw assembly shown in  FIG. 11 ; 
         FIG. 13  is a front view of another alternative set-screw assembly used in the submersible electrical set-screw connector shown in  FIG. 1 ; and 
         FIG. 14  is a cross section view of the set-screw assembly shown in  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , there is shown a perspective view of a submersible electrical set-screw connector  10  incorporating features of the invention, intended to be used to connect multiple electrical conductors  12  (only one of which is shown) to each other. Although the invention will be described with reference to the exemplary embodiments shown in the drawings, it should be understood that the invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used. 
     Referring also to  FIG. 2 , the connector  10  generally comprises a body  14 , a cover  16 , set screw assemblies  18 , adapters  20 , and sealing members  22 . In an alternate embodiment the adapters  20  might not be provided. The connector might also include sealing plugs (not shown) to cover unused holes in the connector. The body, or connector body section,  14  is comprised of electrically conductive material, such as aluminum for example. The body  14  has holes (or openings)  24  for receiving the conductors  12 . The body  14  also has holes (or openings)  26  for receiving the set screw assemblies  18 . The holes  24  are substantially perpendicular to the holes  26 . However, alternate embodiments may comprise any suitable configuration. The cover  16  is preferably overmolded onto the body  14 . The cover is comprised of an electrically insulating material such as a polymer material. The cover  16  has holes (or openings)  28  for receiving the conductors  12  and the sealing members  22 . The cover  16  also has holes (or openings)  30  for receiving the set screw assemblies  18 . The holes  28  are substantially perpendicular to the holes  30 . However, alternate embodiments may comprise any suitable configuration. 
     Referring also to  FIGS. 3-6 , each of the set screw assemblies  18  generally comprise a screw body  32  and a screw head  34 . Referring also to  FIGS. 7-10 , the screw body, or body part,  32  is preferably comprised of metal and comprises a first end  36  for contacting the conductor  12  or the adapter  20 , a threaded shaft (or threaded section)  38  and a second end  40 . The second end  40  has a general hexagon shape with a channel  42  therein. The channel  42  extends in a direction substantially transverse to a central axis  39  of the threaded section  38 . 
     The screw head  34  is preferably comprised of an electrically insulating material, such as a molded plastic or polymer material. The screw head  34  is preferably overmolded onto the second end  40  of the screw body  32 . During overmolding, material forming the screw head  34  extends into the channel  42  and surrounds a portion of an outer surface of the second end  42 . This interlocks the screw head  34  onto the screw body  32  as a non-removable connection forms the screw body  32  and the screw head  34  into a one-piece member. In an alternate embodiment the connection might be removable, such as if the screw head is connected to the screw body after the screw head is formed. 
     The screw head, or head part,  34  generally comprises a locking section  44  located in the channel  42 , a sealing ring section  46 , and a top hexagon section  48 . The locking section  44  is integrally formed with the screw head  34  during the overmolding. The top hexagon section  48  is aligned with the hexagon shape of the second end  40  of the screw body  32  such that the material of the screw head  34  at the top hexagon section  48  has a substantially uniform thickness. During overmolding, the screw body  32  is precisely located in one of six positions in the molding device to align the hexagon shapes. The uniform thickness of the material at the top hexagon section  48  provides the benefit of better strength of the section  48  and helps to prevent cracks from developing. The hexagon shape is provided for a hexagon shaped tool or a wrench to screw the set screw assembly  18  into the body  14  and cover  16 . In alternate embodiments, other shapes could be provided. 
     When the set screw assembly  18  is inserted into one of the holes  30 ,  26 , the threaded shaft  38  can thread into the threaded hole  26  and the sealing ring section  46  can make a sealing engagement with the cover  16 . 
     Referring also to  FIGS. 11-12 , one alternate embodiment of a set-screw assembly  100  is shown. Similar to the set-screw assembly  18 , the set-screw assembly  100  comprises a screw body  132  and a screw head  134 . 
     The screw body, or body part,  132  is preferably comprised of metal and comprises a first end  136  for contacting the conductor  12  or the adapter  20 , a threaded shaft (or threaded section)  138  and a second end  140 . The second end  140  may have a general hexagon shape. However, any suitable shape may be provided. The second end further comprises an opening  141  and channels  142 . The channels  142  extend radially from the opening  141  to an outer surface of the body part  132 . The channels  142  extend in a direction substantially transverse to a central axis  139  of the threaded section  138 . Additionally, the channels  142  extend in a direction substantially perpendicular to the opening  141 . Similar to the set-screw assembly  18 , the second end  140  comprises a smaller diameter than the threaded shaft  138 . However, any suitable configuration may be provided. 
     The screw head  134  is preferably comprised of an electrically insulating material, such as a molded plastic or polymer material. The screw head  134   1 s preferably overmolded onto the second end  140  of the screw body  132 . During overmolding, material forming the screw head  134  extends through the opening  141  and into the channels  142 , and surrounds a portion of an outer surface of the second end  142 . This interlocks the screw head  134  onto the screw body  132  as a non-removable connection forms the screw body  132  and the screw head  134  into a one-piece member. In an alternate embodiment the connection might be removable, such as if the screw head is connected to the screw body after the screw head is formed. It should be noted that although the figures illustrate two channels  142 , any suitable number of channels may be provided. 
     The screw head, or head part,  134  generally comprises locking sections  144  located in the channels  142 , sealing ring sections (or sealing flanges)  146 , and a top hexagon section  148 . The locking sections  144  are integrally formed with the screw head  134  during the overmolding. Although the figures illustrate the top section  148  as having a hexagon shape, any suitable shape for engaging with a tool may be provided. For example, the top section may comprise a torx or square shape. Additionally, the insulation to metal drive area  151  may comprise any suitable shape such as a hex, torx, or square shape (with cross holes/channels) for example. 
     Referring also to  FIGS. 13-14 , another alternate embodiment of a set-screw assembly  200  is shown. Similar to the set-screw assemblies  18 ,  100  the set-screw assembly  200  comprises a screw body  232  and a screw head  234 . 
     The screw body, or body part,  232  is preferably comprised of metal and comprises a first end  236  for contacting the conductor  12  or the adapter  20 , a threaded shaft (or threaded section)  238  and a second end  240 . The second end  240  may have a general hexagon shape. However, any suitable shape may be provided. The second end further comprises an opening  241  and channels  242 . The channels  242  extend radially from the opening  241  to an outer surface of the body part  232 . The channels  242  extend in a direction substantially transverse to a central axis  239  of the threaded section  238 . Additionally, the channels  242  extend in a direction substantially perpendicular to the opening  241 . In this embodiment, the second end  240  comprises substantially the same diameter as that of the threaded shaft  238 . Additionally, the threaded section may extend the full length of the body part  232  between the first end  236  and the second end  240 . However, any suitable configuration may be provided. 
     The screw head  234  is preferably comprised of an electrically insulating material, such as a molded plastic or polymer material. The screw head  234  is preferably overmolded onto the second end  140  of the screw body  232 . During overmolding, material forming the screw head  134  extends through the opening  141  and into the channels  142 . The material extending through the opening also extends from an end portion of the screw head  234  in a general cantilever fashion. This interlocks the screw head  234  onto the screw body  232  as a non-removable connection forms the screw body  232  and the screw head  234  into a one-piece member. In an alternate embodiment the connection might be removable, such as if the screw head is connected to the screw body after the screw head is formed. It should be noted that although the figures illustrate two channels  242 , any suitable number of channels may be provided. 
     The screw head, or head part,  234  generally comprises locking sections  244  located in the channels  242 , sealing ring sections (or sealing flanges)  246 , and a top hexagon section  248 . The locking sections  244  are integrally formed with the screw head  234  during the overmolding. Although the figures illustrate the top section  248  as having a hexagon shape, any suitable shape for engaging with a tool may be provided. For example, the top section may comprise a torx or square shape. Additionally, the insulation to metal drive area  251  may comprise any suitable shape such as a hex, torx, or square shape (with cross holes/channels) for example. Additionally, as shown in  FIG. 14 , the screw head  234  may comprise a threaded section adjacent the threaded shaft  238 . However, any suitable configuration may be provided. 
     With embodiments of the invention, a screw with an insulated head/seal flange and a metal threaded body can be provided. The purpose of the screw is to replace the existing metal screw and insulating sealing cap (two components) with a single component that clamps the conductor, provides insulation and provides sealing. 
     Some existing attempts of insulating/sealing head screws are made completely from plastic materials. These existing attempts have failed as the plastic threads have yielded when the connector reaches operating temperature, and the electrical connection is compromised. With the insulating head and metal thread of the invention, the metal threads do not yield when the connector reaches operating temperature, and the electrical connection is not compromised. The insulating head is only torqued when it is at room temperature; where the properly selected insulating material will not fail. 
     It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.