Abstract:
A flexible electrical connector for electrical equipment is provided. The flexible electrical connector includes a flexible electrical conductor, a terminated end electrically and mechanically connected to the flexible electrical conductor, and a captive fastener for electrically and mechanically connecting the electrical equipment to the terminated end. The captive fastener is operably connected to the terminated end and includes a shaft operably connected to the terminated end, a rotatable member operably connected to the shaft, and a resilient member operably connected to the shaft and disposed between the rotatable member and the terminated end.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 61/700,116, filed on Sep. 12, 2012, which is incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to flexible busbar connectors, and more particularly, flexible busbar connectors having captive fasteners. 
         [0003]    Flexible busbar connectors are well known in the art. For example, U.S. Patent Application Publication No. 2003/0040215 discloses flexible busbar connector  100 . However, flexible busbar connector  100  is installed using bolts  140 , which is difficult because bolts  140  are separate from flexible busbar connector  100  and connection point  22 . 
         [0004]    Therefore, there is a need for flexible busbar connectors having captive fasteners. 
       SUMMARY OF THE INVENTION 
       [0005]    A flexible electrical connector for electrical equipment is provided. The flexible electrical connector includes a flexible electrical conductor, a terminated end electrically and mechanically connected to the flexible electrical conductor, and a captive fastener for electrically and mechanically connecting the electrical equipment to the terminated end. The captive fastener is operably connected to the terminated end and includes a shaft operably connected to the terminated end, a rotatable member operably connected to the shaft, and a resilient member operably connected to the shaft and disposed between the rotatable member and the terminated end. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIGS. 1-4  illustrate a flexible busbar connector according to a first embodiment of the present invention; 
           [0007]      FIG. 5  illustrates a flexible busbar connector according to a second embodiment of the present invention; 
           [0008]      FIGS. 6 and 7  illustrate a flexible busbar connector according to a third embodiment of the present invention; 
           [0009]      FIGS. 8 and 9  illustrate a flexible busbar connector according to a fourth embodiment of the present invention; 
           [0010]      FIG. 10  illustrates a flexible busbar connector according to a fifth embodiment of the present invention; 
           [0011]      FIG. 11  illustrates a flexible busbar connector according to a sixth embodiment of the present invention; 
           [0012]      FIGS. 12-15  illustrates a flexible busbar connector according to a seventh embodiment of the present invention; 
           [0013]      FIGS. 16-19  illustrates a flexible busbar connector according to an eighth embodiment of the present invention; 
           [0014]      FIG. 20  illustrates a flexible busbar connector according to a ninth embodiment of the present invention; 
           [0015]      FIG. 21  illustrates a flexible busbar connector according to a tenth embodiment of the present invention; 
           [0016]      FIGS. 22 and 23  illustrate a flexible busbar connector according to an eleventh embodiment of the present invention; 
           [0017]      FIG. 24  illustrates a flexible busbar connector according to a twelfth embodiment of the present invention; 
           [0018]      FIGS. 25 and 26  illustrate a flexible busbar connector according to a thirteenth embodiment of the present invention; 
           [0019]      FIG. 27  illustrates a flexible busbar connector according to a fourteenth embodiment of the present invention; 
           [0020]      FIG. 28  illustrates a flexible busbar connector according to a fifteenth embodiment of the present invention; 
           [0021]      FIG. 29  illustrates a flexible busbar connector according to a sixteenth embodiment of the present invention; 
           [0022]      FIG. 30  illustrates a flexible busbar connector according to a seventeenth embodiment of the present invention; and 
           [0023]      FIGS. 31 and 32  illustrate a flexible busbar connector according to an eighteenth embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    As shown in  FIGS. 1-4 , captive fastener  100  includes press-fit threaded stud  110 , nut  120 , Belleville washer  130 , and compression spring  140 . Terminated ends  12   a  of flexible busbar connector  10   a  include holes (not shown) for receiving captive fastener  100 , and more particularly, press-fit threaded stud  110 . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   a , and more particularly, captive fastener  100 . When captive fastener  100 , and more particularly, nut  120  is loose, compression spring  140  provides clearance for sliding flexible busbar connector  10   a  onto busbar  20   a . However, when captive fastener  100 , and more particularly, nut  120  is tight, flexible busbar connector  10   a  is secured to busbar  20   a.    
         [0025]    As shown in  FIG. 5 , captive fastener  200  includes screw  210 , Belleville washer  230 , and compression spring  240 . Terminated ends  12   b  of flexible busbar connector  10   b  include tapped holes  14   b  for receiving captive fastener  200 , and more particularly, screw  210 . Preferably, screw  210  includes threads. Busbars  20   a  include open ended-slots  22   a  for receiving flexible busbar connector  10   b , and more particularly, captive fastener  200 . When captive fastener  200 , and more particularly, screw  210  is loose, compression spring  240  provides clearance for sliding flexible busbar connector  10   b  onto busbar  20   a . However, when captive fastener  200 , and more particularly, screw  210  is tight, flexible busbar connector  10   b  is secured to busbar  20   a.    
         [0026]    As shown in  FIGS. 6 and 7 , terminated ends  12   a  of flexible busbar connector  10   a  include reactive boding layer  16   a , such as NanoFoil®. 
         [0027]    Additionally, as shown in  FIGS. 6 and 7 , or alternatively, as shown in  FIGS. 8 and 9 , terminated ends  12   a  of flexible busbar connector  10   a  include brazing/soldering perform  18   a.    
         [0028]    As shown in  FIG. 10 , the terminated end  12   c  on the right side of flexible busbar connector  10   c  is connected to busbar  20   a , for example, using captive fasteners  100 , as described above with respect to  FIGS. 1-4 . However, the terminated end  12   c  on the left side of flexible busbar connector  10   c  is connected to busbar  20   b , for example, using reactive bonding, brazing, soldering, or other such techniques. 
         [0029]    As shown in  FIG. 11 , busbars  20   c  include holes (not shown) for receiving captive fastener  100 , and more particularly, press-fit threaded stud  110 , and terminated ends  12   d  of flexible busbar connector  10   d  include open-ended slots  14   d  for receiving flexible busbar connector  10   d , and more particularly, captive fastener  100 . 
         [0030]    As shown in  FIGS. 12-15 , captive fastener  300  includes press-fit threaded stud  310 , acorn nut  320 , clip  330 , and compression spring  340 . Terminated ends  12   e  of flexible busbar connector  10   e  include holes  14   e  for receiving captive fastener  300 , and more particularly, press-fit threaded stud  310 . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   e , and more particularly, captive fastener  300 . When captive fastener  300 , and more particularly, nut  320  is loose, compression spring  340  provides clearance for sliding flexible busbar connector  10   e  onto busbar  20   a . However, when captive fastener  300 , and more particularly, nut  320  is tight, flexible busbar connector  10   e  is secured to busbar  20   a . Preferably, clip  330  includes hook  332  and tab  334 , which further secure flexible busbar connector  10   e  to busbar  20   a , for example, during a short circuit. 
         [0031]    As shown in  FIGS. 16-19 , captive fastener  400  includes press-fit threaded stud  410 , acorn nut  420 , clip  430 , and spring finger  440 . Terminated ends  12   e  of flexible busbar connector  10   e  include holes  14   e  for receiving captive fastener  400 , and more particularly, press-fit threaded stud  410 . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   e , and more particularly, captive fastener  400 . When captive fastener  400 , and more particularly, nut  420  is loose, spring finger  440  provides clearance for sliding flexible busbar connector  10   e  onto busbar  20   a . However, when captive fastener  400 , and more particularly, nut  420  is tight, flexible busbar connector  10   e  is secured to busbar  20   a . Preferably, clip  430  includes hook  432  and tab  434 , which further secure flexible busbar connector  10   e  to busbar  20   a , for example, during a short circuit. 
         [0032]    As shown in  FIG. 20 , flexible busbar connector  10   e  includes sleeve  500 , such as heat shrink sleeve or fire sleeve, for protecting flexible busbar connector  10   e , and more particularly, flexible electrical conductors  13   e , such as braided strap or laminated stacked plates, for example, from contaminants, such as dirt, and hazards, such as fire. 
         [0033]    As shown in  FIG. 21 , busbars  20   c  include holes (not shown) for receiving captive fastener  300 , and more particularly, press-fit threaded stud  310 , and terminated ends  12   f  of flexible busbar connector  10   f  include open-ended slots  14   f  for receiving flexible busbar connector  10   f , and more particularly, captive fastener  300 . 
         [0034]    As shown in  FIGS. 22 and 23 , captive fastener  600  includes carriage bolt  610 , nut  620 , Belleville washer  630 , flat washer  640 , compression spring  650 , and e-clip  660 . Terminated ends  12   g  of flexible busbar connector  10   g  include square holes  14   g  for receiving captive fastener  600 , and more particularly, carriage bolt  610 . Preferably, carriage bolt  610  is threaded and sized to press fit into square hole  14   g . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   g , and more particularly, captive fastener  600 . When captive fastener  600 , and more particularly, nut  620  is loose, compression spring  650  provides clearance for sliding flexible busbar connector  10   g  onto busbar  20   a . However, when captive fastener  600 , and more particularly, nut  620  is tight, flexible busbar connector  10   g  is secured to busbar  20   a . Preferably, the end of carriage bolt  610  is not threaded and includes groove  612  for receiving e-clip  660 , which prevents removal of nut  620  from carriage bolt  610 , further securing flexible busbar connector  10   g  to busbar  20   a.    
         [0035]    As shown in  FIG. 24 , captive fastener  700  includes carriage bolt  710 , nut  720 , Belleville washer  730 , flat washer  740 , compression spring  750 , and push-on-clip  760 . Terminated ends  12   g  of flexible busbar connector  10   g  include square holes  14   g  for receiving captive fastener  700 , and more particularly, carriage bolt  710 . Preferably, carriage bolt  710  is threaded and sized to press fit into square hole  14   g . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   g , and more particularly, captive fastener  700 . When captive fastener  700 , and more particularly, nut  720  is loose, compression spring  750  provides clearance for sliding flexible busbar connector  10   g  onto busbar  20   a . However, when captive fastener  700 , and more particularly, nut  720  is tight, flexible busbar connector  10   g  is secured to busbar  20   a . Preferably, the end of carriage bolt  710  is not threaded and receives push-on clip  760 , which prevents removal of nut  720  from carriage bolt  710 , further securing flexible busbar connector  10   g  to busbar  20   a.    
         [0036]    Alternatively, as shown in  FIGS. 25 and 26 , captive fastener  800  includes carriage bolt  810 , quarter-turn nut  820 , Belleville washer  830 , flat washer  840 , compression spring  850 , and pin  860 . Terminated ends  12   g  of flexible busbar connector  10   g  include square holes  14   g  for receiving captive fastener  800 , and more particularly, carriage bolt  810 . Preferably, carriage bolt  810  is not threaded and sized to press fit into square hole  14   g . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   g , and more particularly, captive fastener  800 . When captive fastener  800 , and more particularly, quarter-turn nut  820  is loose, compression spring  850  provides clearance for sliding flexible busbar connector  10   g  onto busbar  20   a . However, when captive fastener  800 , and more particularly, quarter-turn nut  820  is tight, flexible busbar connector  10   g  is secured to busbar  20   a . Preferably, the end of carriage bolt  810  includes hole  812  for receiving pin  860 , which engages ramp/cam surfaces  822  of quarter turn nut  820  to prevent removal of quarter turn nut  820  from carriage bolt  820 , further securing flexible busbar connector  10   g  to busbar  20   a.    
         [0037]    As shown in  FIG. 27  captive fastener  900  includes carriage bolt  910 , nut  920 , Belleville washer  930 , flat washer  940 , compression spring  950 , countersunk washer  960 , and flat-head screw  970 . Terminated ends  12   g  of flexible busbar connector  10   g  include square holes  14   g  for receiving captive fastener  900 , and more particularly, carriage bolt  910 . Preferably, carriage bolt  910  is threaded and sized to press fit into square hole  14   g . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   g , and more particularly, captive fastener  900 . When captive fastener  900 , and more particularly, nut  920  is loose, compression spring  950  provides clearance for sliding flexible busbar connector  10   g  onto busbar  20   a . However, when captive fastener  900 , and more particularly, nut  920  is tight, flexible busbar connector  10   g  is secured to busbar  20   a . Preferably, the end of carriage bolt  910  includes a threaded hole  912  for receiving flat-head screw  970 , which prevents removal of nut  920  from carriage bolt  910 , further securing flexible busbar connector  10   g  to busbar  20   a . The threads of flat head screw  910  are reversed, which resists removal when nut  920  is tightened. 
         [0038]    As shown in  FIG. 28 , captive fastener  1000  includes carriage bolt  1010 , lock nut  1020 , Belleville washer  1030 , flat washer  1040 , and compression spring  1050 . Terminated ends  12   g  of flexible busbar connector  10   g  include square holes  14   g  for receiving captive fastener  1000 , and more particularly, carriage bolt  1010 . Preferably, carriage bolt  1010  is threaded and sized to press fit into square hole  14   g . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   g , and more particularly, captive fastener  1000 . When captive fastener  1000 , and more particularly, lock nut  1020  is loose, compression spring  1050  provides clearance for sliding flexible busbar connector  10   g  onto busbar  20   a . However, when captive fastener  1000 , and more particularly, lock nut  1020  is tight, flexible busbar connector  10   g  is secured to busbar  20   a . Preferably, lock nut  1020  includes a thread locker, such as Nyloc® or Loctite®, which prevents removal of nut  1020  from carriage bolt  1010 , further securing flexible busbar connector  10   g  to busbar  20   a.    
         [0039]    As shown in  FIG. 29 , captive fastener  1100  includes carriage bolt  1110 , nut  1120 , Belleville washer  1130 , flat washer  1140 , and elastomeric sleeve  1150 . Terminated ends  12   g  of flexible busbar connector  10   g  include square holes  14   g  for receiving captive fastener  1100 , and more particularly, carriage bolt  1110 . Preferably, carriage bolt  1110  is threaded and sized to press fit into square hole  14   g . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   g , and more particularly, captive fastener  1100 . When captive fastener  1100 , and more particularly, nut  1120  is loose, elastomeric sleeve  1150  provides clearance for sliding flexible busbar connector  10   g  onto busbar  20   a . However, when captive fastener  1100 , and more particularly, nut  1120  is tight, flexible busbar connector  10   g  is secured to busbar  20   a.    
         [0040]    As shown in  FIG. 30 , captive fastener  1200  includes carriage bolt  1210 , nut  1220 , Belleville washer  1230 , flat washer  1240 , and three rubber o-rings  1250   a ,  1250   b ,  1250   c . Terminated ends  12   g  of flexible busbar connector  10   g  include square holes  14   g  for receiving captive fastener  1200 , and more particularly, carriage bolt  1210 . Preferably, carriage bolt  1210  is threaded and sized to press fit into square hole  14   g . Rubber o-ring  1250   a  supports carriage bolt  1210  in square hole  14   g . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   g , and more particularly, captive fastener  1200 . Rubber o-ring  1250   b  centers carriage bolt  1210  in open-ended slots  22   a . When captive fastener  1200 , and more particularly, nut  1220  is loose, rubber o-ring  1250   c  provides clearance for sliding flexible busbar connector  10   g  onto busbar  20   a . However, when captive fastener  1200 , and more particularly, nut  1220  is tight, flexible busbar connector  10   g  is secured to busbar  20   a.    
         [0041]    As shown in  FIGS. 31 and 32 , captive fastener  1300  includes carriage bolt  1310 , nut  1320 , Belleville washer  1330 , flat washer  1340 , compression spring  1350 , and pin  1360 . Terminated ends  12   g  of flexible busbar connector  10   g  include square holes  14   g  for receiving captive fastener  1300 , and more particularly, carriage bolt  1310 . Preferably, carriage bolt  1310  is threaded and sized to press fit into square hole  14   g . Busbars  20   a  include open-ended slots  22   a  for receiving flexible busbar connector  10   g , and more particularly, captive fastener  1300 . When captive fastener  1300 , and more particularly, nut  1320  is loose, compression spring  1350  provides clearance for sliding flexible busbar connector  10   g  onto busbar  20   a . However, when captive fastener  1300 , and more particularly, nut  1320  is tight, flexible busbar connector  10   g  is secured to busbar  20   a . Preferably, the end of carriage bolt  1310  is not threaded and includes hole  1312  for receiving pin  1360 , which prevents removal of nut  1320  from carriage bolt  1310 , further securing flexible busbar connector  10   g  to busbar  20   a.    
         [0042]    While the components/features of the busbars, the flexible busbar connectors, and the captive fasteners are described above with respect to specific exemplary embodiments, it is likewise contemplated that these components/features may be combined. For example, elastomeric sleeve  1150  of captive fastener  1100  may be combined with captive fastener  600 , replacing compression spring  650 . 
         [0043]    While this invention has been described in conjunction with the exemplary embodiments outlined above, various alternatives, modifications, variations, and/or improvements, whether known or presently unforeseen, may become apparent. Accordingly, the exemplary embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention.