Powder actuated tool and connector

Disclosed herein is an electrical wedge connector wedge. The electrical wedge connector wedge includes a first end, a second end, a first conductor groove, and an opening. The second end is opposite the first end. The wedge includes a generally tapered shape from the second end to the first end. The first conductor groove extends between the first end and the second end. The opening extends into the second end. The opening is adapted to receive at least a portion of an explosive charge for driving the wedge into an electrical wedge connector shell.

BACKGROUND

1. Field of the Invention

The invention relates to an electrical connector tool and connector and, more particularly, to a powder actuated electrical connector tool and connector.

2. Brief Description of Prior Developments

U.S. Pat. Nos. 4,722,189, and 7,328,751, which are hereby incorporated by reference in their entireties, disclose explosively-operated tools. These tools generally provide an assembly to connect an electrical wedge connector to conductors of electrical power distribution systems. As maintenance and installation operations for the electrical power distribution systems become increasingly difficult, the added time required for these operations can increase operating costs for the utility company.

Accordingly, there is a need for an improved electrical connector tool and electrical connector which allows for facilitated installation while maintaining a robust and reliable product configuration.

SUMMARY

The foregoing and other problems are overcome, and other advantages are realized, by the use of the exemplary embodiments of this invention.

In accordance with one aspect of the invention, an electrical wedge connector wedge is disclosed. The electrical wedge connector wedge includes a first end, a second end, a first conductor groove, and an opening. The second end is opposite the first end. The wedge includes a generally tapered shape from the second end to the first end. The first conductor groove extends between the first end and the second end. The opening extends into the second end. The opening is adapted to receive at least a portion of an explosive charge for driving the wedge into an electrical wedge connector shell.

In accordance with another aspect of the invention, an electrical wedge connector installation tool is disclosed. The electrical wedge connector installation tool includes a main section and a firing ram. The firing ram extends from the main section in a first direction. The tool is adapted to impact an electrical wedge connector wedge in the first direction. The firing ram is adapted to receive gasses of an explosive charge in a direction opposite the first direction.

In accordance with another aspect of the invention, an electrical wedge connector wedge is disclosed. The electrical wedge connector wedge includes a body and a firing pin. The body has a first end, a second end opposite the first end, and a middle section between the first end and the second end. The body includes a generally tapered shape from the second end to the first end. The body includes a first conductor groove extending along a side of the body between the first end and the second end. The wedge is adapted to be inserted into an electrical wedge connector shell by an installation tool. The firing pin is at the middle section. The firing pin is adapted to contact an explosive charge of the installation tool.

In accordance with another aspect of the invention, an electrical wedge connector installation tool is disclosed. The electrical wedge connector installation tool includes a main section and a firing ram. The firing ram includes a first end and a second end. The first end is at the main section. The second end is spaced from the main section. The second end is adapted to be received by an electrical wedge connector wedge. The second end includes a cartridge receiving area. The cartridge receiving area is adapted to receive an explosive cartridge used in the tool.

In accordance with another aspect of the invention, a method of using an electrical wedge connector installation tool is disclosed. An end of a firing ram is located proximate an opening of an electrical wedge connector wedge. An explosive cartridge is installed between the end of the firing ram and the electrical wedge connector wedge. The ram is moved towards the wedge. The explosive cartridge is struck with a firing pin in response to the moving of the ram.

DETAILED DESCRIPTION

Referring toFIG. 1, there is shown a perspective view of a tool10incorporating features of the invention. 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.

The tool10is used for connecting a branch or tap wire12to a main power line14. The electrical wedge connector16includes a wedge18and a C-shaped sleeve20. The tool10uses a charge (or cartridge/load)15to drive the wedge18into the sleeve (or shell)20sandwiching the wire12and line14against opposite ends of the sleeve20. The tool is fired by a user striking the rear end22of the tool10with a hand-held hammer19.

Referring also toFIG. 2, there is shown an enlarged perspective view of the tool10. The tool10may be a hammer actuated connecting tool. The tool10includes a frame24and a tool body26. The frame24comprises an anvil section28. The tool body26is adjustably connected to the frame24. The tool body26is fitted through a support sleeve30at an end of the anvil section28to position the ram32along the longitudinal axis of the tool10. The tool body26comprises the ram32which is adapted to contact the charge15in order to initiate the advancement of the wedge16, to wedge the two cables12,14into the shell20to drive the wedge18into its final position.

The tool body26includes a main section34, and a movable outer section36. The main section34has a threaded section38inserted into the support sleeve30for adjustment of the tool body26with respect to the anvil section by means of a threaded connection40. This adjustable connection can be used for advancing and retracting the tool body26and the ram32relative to the opposite side of the anvil section for engagement with the connector. The main section34is threaded along its forward surface at the threaded section38. The main section34includes a longitudinal axial bore for slidably receiving the ram32.

The main section34comprises a general cylindrical shape. The movable outer section36is slidably fitted over the main section34. The movable outer section36may also comprise a general cylindrical shape. A striker42may further be provided at the rear end22of the movable section36. The striker42is adapted to be hit by the hand-held hammer19(seeFIG. 1). According to one embodiment of the invention, when the striker42is hit by the hammer19, this causes the movable outer section36to move in a direction towards the frame24, wherein an interior end portion of the section36contacts an end44of the ram32. According to another embodiment of the invention, the striker42may be movably connected to the outer section36such that when the striker42is hit by the hammer19, this causes the striker42to move in a direction towards the frame24, wherein an opposite end of the striker42contacts the end44of the ram32. However, any suitable configuration for advancing the ram may be provided.

Referring now also toFIG. 3, the ram32comprises a firing pin portion46at the end48of the ram32. The firing pin portion46is suitably located to be aligned with the cartridge15. Additionally, a seal50is provided at the ram32proximate the end48.

The electrical wedge connector wedge18includes a front end52, a middle section54, and a rear end56. The rear end56is opposite the front end52. The middle section54is between the front end52and the rear end56. The wedge18comprises a generally tapered shape from the rear end56to the front end52. Additionally, the wedge18includes conductor grooves58on sides of the wedge18extending between the front end52and the rear end56. The wedge18further includes an opening60extending into the rear end56. The opening60is adapted to receive the explosive charge for driving the wedge into the electrical wedge connector shell.

The opening60includes a first portion62and a second portion64. The first portion62forms a ram receiving channel adapted to receive the firing ram32. The second portion64forms a cartridge receiving seat adapted to removably receive the explosive cartridge15. The receiving seat64may be suitably sized and shaped to receive the cartridge15in a press fit or friction fit for example.

When the firing ram32is inserted in to the ram receiving channel62, the seal50, which may be an O-ring seal for example, contacts the ram receiving channel62and forms a gas expansion area (or cavity)66between the end48of the ram32and the end68of the channel66(as the O-ring50forms a seal between the ram32and the channel62). In this embodiment, the gas expansion area has a general cylindrical shape to direct expanding gases from a fired cartridge against the end48of the ram32. However, it should be noted that in an alternate embodiment the gas expansion area might not be provided.

To use the tool10to connect the electrical wedge connector16to the conductors12,14, the connector sleeve20, the wedge18and the two conductors12,14(seeFIG. 1) are located and positioned at the anvil section28. The tool body26is rotated by the operator relative to the anvil section28. This causes the threads38of the main section34and the support sleeve30to move the tool body26towards the anvil section28. The operator stops rotating the tool body26when the anvil section28and the ram32sandwich the connector sleeve, conductors, and wedge therebetween such that the front end48of the ram32is in the receiving channel62and proximate the cartridge15.

The operator may then strike the striker42(or the end22of the movable outer section36) with a hand held tool, such as the hand-held hammer19. This causes the movable outer section36to move forward and apply a force to the end44of the movable firing ram32. The force applied to the ram32causes the firing pin portion46at the end48of the ram32to come into contact with the cartridge15. This causes the firing pin portion46to ignite a primer of the cartridge15to thereby fire the cartridge15. The gases from the cartridge15move into the cavity66and push against the wedge18(at the end68of the ram receiving channel62) to thereby drive the wedge18into the connector sleeve20with the cables12,14therebetween in a very tight electrical and mechanical connection. This, for example, provides a firing ram32adapted to impact the electrical wedge connector wedge18in a first direction70, and wherein the firing ram is adapted to receive gasses of the explosive charge in a second direction72. According to one embodiment, the cartridge may comprise a vented rim to allow for the gasses to move from the cartridge15to the cavity66. However, any suitable configuration may be provided.

Once the connection is completed, the tool body26is unscrewed from the anvil28, thus backing the ram off of the connector wedge. The tool10is then removed from the completed connection. The spent cartridge15may then be removed from the wedge.

Referring now also toFIG. 4, an electrical wedge connector116in accordance with an alternate embodiment of the invention is shown. The electrical wedge connector116is similar to the electrical wedge connector16and similar features are similarly numbered. Similar to the embodiment described above, the electrical wedge connector116includes a wedge118and the sleeve20. Also similar to the embodiment described above, the tool10is configured to drive the wedge118into the sleeve20to sandwich the wire12and line14against opposite ends of the sleeve20. It should be noted that the sleeve20is not shown inFIG. 4for the purposes of clarity.

The wedge118comprises a similar configuration as the wedge18. For example, the wedge118includes a front end52, a middle section54, and a rear end56. The wedge118also comprises a generally tapered shape from the rear end56to the front end52and includes conductor grooves58on sides of the wedge118. The wedge118further includes an opening60extending into the rear end56. The opening60is adapted to receive the explosive charge15for driving the wedge118into the electrical wedge connector shell20.

However, one difference between the wedge118and the wedge18is that the wedge118is configured to receive a bushing at the opening. The opening60includes a first portion62and a second portion64. The first portion62forms a ram receiving channel adapted to receive the firing ram32. The second portion164forms a bushing receiving area to receive the bushing190. The bushing190may be a vented bushing, wherein the bushing190comprises openings192vented to the cavity66. However, in alternate embodiments, any suitable type bushing may be provided. The bushing190comprises a cartridge receiving seat194adapted to removably receive the explosive cartridge15. The receiving seat194may be suitably sized and shaped to receive the cartridge15in a press fit or friction fit for example.

In this embodiment, the gases from the cartridge15move into the cavity66through the openings192in the bushing and push against the wedge118(at the end68of the ram receiving channel62) to thereby drive the wedge118into the connector sleeve20with the cables12,14therebetween in a very tight electrical and mechanical connection. This, for example, provides a firing ram32adapted to impact the electrical wedge connector wedge118in the first direction70, and wherein the firing ram32is adapted to receive gasses of the explosive charge15in a second direction72. Although this embodiment describes the vented bushing as allowing for the gasses to move from the cartridge15to the cavity66, it should be noted that a cartridge with a vented rim may also be used instead of, or in addition to, the vented bushing. However, these are merely provided as non-limiting examples, and any suitable configuration may be provided.

Referring now also toFIG. 5, a tool200and electrical wedge connector216in accordance with another embodiment of the invention are shown. The tool200and the electrical wedge connector216are similar to the tool10and the electrical wedge connector16,116and similar features are similarly numbered. Similar to the embodiments described above, the electrical wedge connector216includes a wedge218and the sleeve20. Also similar to the embodiment described above, the tool200is configured to drive the wedge218into the sleeve20to sandwich the wire12and line14against opposite ends of the sleeve20. It should be noted that the sleeve20is not shown inFIG. 5for the purposes of clarity.

As mentioned above, the tool200is similar to the tool10. For example the tool200comprises a hammer actuated connecting tool including the frame24and the tool body26. It should be noted that the frame24and portions of the tool body24are not shown inFIG. 6for the purposes of clarity.

One difference between the tool200and the tool10is that the tool200is configured to receive the charge at an end of the ram. In this embodiment, the ram32comprises an opening274at the end48of the ram32. An end of the opening forms a cartridge receiving seat276. The opening274is suitably sized and shaped to receive the cartridge15. Additionally, the cartridge receiving area276is substantially aligned with an opening of the electrical wedge connector wedge218. The opening274may further comprise a cavity portion278adapted to receive gasses of the explosive charge15. The opening274is adapted to receive the explosive charge15for driving the wedge218into the electrical wedge connector shell20.

The wedge218comprises a similar configuration as the wedge18,118. For example, the wedge218includes a front end52, a middle section54, and a rear end56. The wedge218also comprises a generally tapered shape from the rear end56to the front end52and includes conductor grooves58on sides of the wedge218. The wedge218further includes an opening60extending into the rear end56.

The opening60includes a first portion62and a second portion64. The first portion62forms a ram receiving channel adapted to receive the firing ram32. However, one difference between the wedge218and the wedge18,118is that the wedge218is configured to receive an end17of the cartridge such that the second portion64forms a cartridge receiving seat adapted to receive the end17of the explosive cartridge15. The receiving seat64may be suitably sized and shaped to receive the end17of the cartridge15.

Another difference between the wedge218and the wedge18,118is that the wedge218comprises a firing pin280at the middle portion54of the wedge218. An end282of the firing pin280is at the second portion of the opening60. The firing pin280is suitably located to be aligned with the cartridge15.

To use the tool200to connect the electrical wedge connector216to the conductors12,14, the connector sleeve20, the wedge218and the two conductors12,14are located and positioned at the anvil section as described above.

When the operator strikes the striker42(or the end22of the movable outer section36) with a hand held tool, such as the hand-held hammer19. This causes the movable outer section36to move forward and apply a force to the end44of the movable firing ram32. The force applied to the ram32causes the end48of the ram to fully enter the receiving area62, and with the cartridge15at the cartridge receiving seat276of the ram32, the firing pin280of the wedge218comes into contact with the cartridge15. This causes the firing pin280to ignite a primer of the cartridge15to thereby fire the cartridge15. The gases from the cartridge15move into the cavity278, which causes pressure between the end17of the cartridge15and the wedge218to push against the wedge218to thereby drive the wedge218into the connector sleeve20with the cables12,14therebetween in a very tight electrical and mechanical connection. This, for example, provides a firing ram32adapted to impact the electrical wedge connector wedge218in the first direction70, and wherein the cavity278of the firing ram32is adapted to receive gasses of the explosive charge15in a second direction72.

According to another embodiment, the ram32may comprise the seal50as shown inFIG. 2and the cartridge15may comprise a vented rim to allow for the gasses to move from the cartridge to the cavity66between the end48of the ram32and the end68of the channel62(formed with the seal between the ram32and the ram receiving channel62). According to another embodiment, the end48of the ram32may comprise a vented bushing (such as inFIG. 4) at the opening274. This together with the seal50at proximate end48of the ram (as inFIGS. 3 and 4) to allow for the gasses to move from the cartridge15to the cavity66between the end48of the ram32and the end68of the channel62(formed with the seal between the ram32and the ram receiving channel62). In these alternate embodiments, the cavity66would form a gas expansion area to direct expanding gases from the fired cartridge15against the end68of the wedge218to drive the wedge218into the shell20. However, any suitable configuration may be provided.

Once the connection is completed, the ram32is removed from the ram receiving section62and the spent cartridge15may then be removed from the ram32.

It should be noted that the cartridge15may be any suitable cartridge such as a metallic shell cartridge manufactured by Winchester Ammunition, for example. The cartridge may further comprise a standard industrial blank 0.27 caliber cartridge; where the powder level of the cartridge corresponds to the size of the connector. However, in alternate embodiments, the invention could be adapted to incorporate use of any suitable size of cartridge; standard or specifically designed.

According to another example of the invention, a method of using the electrical wedge connector installation tool is disclosed. The method includes the following steps. Locating an end of a firing ram proximate an opening of an electrical wedge connector wedge. Installing an explosive cartridge between the end of the firing ram and the electrical wedge connector wedge. Moving the ram towards the wedge. Striking the explosive cartridge with a firing pin in response to the moving of the ram. It should be noted that any of the above steps may be performed alone or in combination with one or more of the steps.

Below are provided further descriptions of various non-limiting, exemplary embodiments. The below-described exemplary embodiments are separately numbered for clarity and identification. This numbering should not be construed as wholly separating the below descriptions since various aspects of one or more exemplary embodiments may be practiced in conjunction with one or more other aspects or exemplary embodiments. That is, the exemplary embodiments of the invention, such as those described immediately below, may be implemented, practiced or utilized in any combination (e.g., any combination that is suitable, practicable and/or feasible) and are not limited only to those combinations described herein and/or included in the appended claims.

(1) In one exemplary embodiment, an electrical wedge connector wedge comprising: a first end; a second end opposite the first end, wherein the wedge comprises a generally tapered shape from the second end to the first end; a first conductor groove extending between the first end and the second end; and an opening extending into the second end, wherein the opening is adapted to receive at least a portion of an explosive charge for driving the wedge into an electrical wedge connector shell.

An electrical wedge connector wedge as above, wherein the opening comprises a first portion and a second portion, wherein the first portion is adapted to receive a firing ram, and wherein the second portion is adapted to receive the portion of the explosive charge.

An electrical wedge connector wedge as above, further comprising a second conductor groove extending between the first end and the second end.

An electrical wedge connector wedge as above, wherein the wedge is adapted to be insertable into an electrical wedge connector sleeve.

An electrical wedge connector wedge as above, further comprising a second conductor groove extending between the first end and the second end, and wherein the opening comprises a first portion and a second portion, wherein the first portion is adapted to receive a firing ram, and wherein the second portion is adapted to receive the portion of the explosive charge.

An electrical wedge connector wedge as above, wherein the wedge is adapted to be insertable into an electrical wedge connector sleeve.

An electrical wedge connector wedge as above, further comprising a bushing, wherein the bushing is adapted to be fitted between the second portion of the opening and the explosive charge.

An electrical wedge connector comprising: an electrical wedge connector sleeve; and an electrical wedge connector wedge as above, wherein the wedge is insertable into the sleeve, and wherein the connector is adapted to receive a conductor between the wedge and the sleeve.

(2) In another exemplary embodiment, an electrical wedge connector installation tool comprising: a main section; and a firing ram extending from the main section in a first direction, wherein the tool is adapted to impact an electrical wedge connector wedge in the first direction, and wherein the firing ram is adapted to receive gasses of an explosive charge in a direction opposite the first direction.

An electrical wedge connector installation tool as above, further comprising a seal on the firing ram, wherein the seal is adapted to contact the electrical wedge connector wedge.

An electrical wedge connector installation tool as above, wherein the firing ram comprises a cavity adapted to receive the gasses of the explosive charge.

An electrical wedge connector installation tool as above, wherein an end of the firing ram is adapted to be received by on opening of the electrical wedge connector wedge.

An electrical wedge connector installation tool as above, wherein the main section is connected to a frame.

(3) In another exemplary embodiment, an electrical wedge connector wedge comprising: a body having a first end, a second end opposite the first end, and a middle section between the first end and the second end, wherein the body comprises a generally tapered shape from the second end to the first end, wherein the body comprises a first conductor groove extending along a side of the body between the first end and the second end, and wherein the wedge is adapted to be inserted into an electrical wedge connector shell by an installation tool; and a firing pin at the middle section, wherein the firing pin is adapted to contact an explosive charge of the installation tool.

An electrical wedge connector wedge as above, wherein the body comprises an opening at the second end.

An electrical wedge connector wedge as above, wherein the opening comprises a first portion and a second portion, wherein the first portion is adapted to receive a firing ram, and wherein the second portion is adapted to receive a portion of the explosive charge.

An electrical wedge connector wedge as above, wherein the firing pin is at the second portion of the opening.

An electrical wedge connector wedge as above, wherein the body comprises a second conductor groove extending along another side of the body between the first end and the second end.

An electrical wedge connector comprising: an electrical wedge connector sleeve; and an electrical wedge connector wedge as above, wherein the wedge is insertable into the sleeve, and wherein the connector is adapted to receive a conductor between the wedge and the sleeve.

(4) In another exemplary embodiment, an electrical wedge connector installation tool comprising: a main section; and a firing ram comprising a first end and a second end, wherein the first end is at the main section, wherein the second end is spaced from the main section, wherein the second end is adapted to be received by an electrical wedge connector wedge, wherein the second end comprises a cartridge receiving area, and wherein the cartridge receiving area is adapted to receive an explosive cartridge used in the tool.

An electrical wedge connector installation tool as above, wherein the firing ram comprises a cavity adapted to receive the gasses of the explosive charge.

An electrical wedge connector installation tool as above, wherein the cartridge receiving area is adapted to be aligned with a firing pin of the electrical wedge connector wedge.

An electrical wedge connector installation tool as above, wherein the firing ram is adapted to surround a majority of the explosive cartridge at the receiving area.

An electrical wedge connector installation tool as above, further comprising a frame, wherein the main section is movably connected to the frame.

(5) In another exemplary embodiment, a method of using an electrical wedge connector installation tool comprising: locating an end of a firing ram proximate an opening of an electrical wedge connector wedge; installing an explosive cartridge between the end of the firing ram and the electrical wedge connector wedge; moving the ram towards the wedge; and striking the explosive cartridge with a firing pin in response to the moving of the ram.

A method of using an electrical wedge connector installation tool as above, wherein the installing of the explosive cartridge further comprises installing the explosive cartridge in the opening of the electrical wedge connector wedge.

A method of using an electrical wedge connector installation tool as above, wherein the installing of the explosive cartridge further comprises installing the explosive cartridge in an opening at the end of the firing ram.

A method of using an electrical wedge connector installation tool as above, wherein the firing pin is at the end of the firing ram.

A method of using an electrical wedge connector installation tool as above, wherein the firing pin is at the opening of the electrical wedge connector wedge.