Grounding connector

A grounding connector for interconnecting a pair of uninsulated conductors such as wires includes an outer body member having diverging tabs extending from upper extents of vertical walls of a U-shaped channel, the tabs being crimpable toward each other when applied to the wires. An inner body member includes a base section crossing the top of the U-shaped channel and diverging inner tabs extending along the inside surfaces of the outer body member to assured stops at the ends of the outer tabs. When the outer tabs are crimped to a vertical orientation, the inner tabs are also crimped to a vertical orientation and urge the base section against the wires in the U-shaped channel. The inner body member presses the wires against upper and lower surfaces of a conductive insert so that arrays of penetrating spikes along the insert surfaces break through corrosion of the wires and assuredly electrically interconnect the wires. The insert is shaped to accommodate interconnecting a pair of flat wires, a pair of round wires, or one of each, or a wire and a rod or pipe.

FIELD OF THE INVENTION 
This relates to the field of electrical connectors and more particularly to 
grounding connectors. 
BACKGROUND OF THE INVENTION 
In certain electrical wiring arrangements such as in utilities or in 
telecommunications, it is necessary to interconnect a pair of uninsulated 
conductors to establish a system ground. Where the conductors are 
uninsulated for long periods of time prior to being interconnected, a 
substantial layer of corrosion forms on the conductor surfaces having a 
thickness of about 0.001 inches and in spots up to about 0.0035 inches. It 
is necessary for the connector selected to interconnect a pair of such 
corrosion-encrusted conductors, to establish an assured electrical 
connection with the conductive portion of the conductors beneath the 
corrosion layer, sufficient to establish a ground connection. It is also 
necessary for the connector to remain firmly secured to the conductors and 
assuredly electrically interconnecting them over long in-service use, 
while exposed to the environment. 
It is desirable to be able to apply a connector directly to the 
corrosion-encrusted conductors rather than involve a procedure to remove 
the corrosion prior to application. It is further desirable for such a 
connector to be easily applied without special tools or involving an 
operator-sensitive procedure. It is also desirable for the connector to 
provide a visual indication of an assured electrical connection. 
It is additionally desirable for such a connector to be applicable either 
round wires or flat wires, or one of each, or of a wire to a larger 
diameter rod or pipe. 
SUMMARY OF THE INVENTION 
The present invention is an assembly which includes a pair of cooperable 
body members together defining a conductor-receiving region between 
opposed clamping surfaces; when the body members are manipulated or 
squeezed into an applied configuration, the clamping surfaces are urged 
toward each other and against the conductors such as wires, and the wires 
are pressed against corrosion-penetrating means such as small spikes which 
break through the corrosion and dig deeply into uncorroded metal 
thereunder, and thereby establish a ground connection with the conductive 
metal therebeneath. Preferably an insert member is disposed in the 
conductor-receiving region between the clamping surfaces against which the 
wires are clamped and which includes arrays of penetration spikes 
extending toward the clamping surfaces. The assembly defines a pair of 
separate passageways through which the wires are inserted, after which the 
assembly is deformed such as by pliers to clamp the wires against the 
penetration spikes of the insert. The plurality of penetration spikes upon 
clamping penetrate the corrosion on the adjacent surfaces of both wires to 
reach the uncorroded conductive material therewithin, thereby electrically 
interconnecting the wires to each other sufficient to establish an assured 
grounding connection. 
The outer body member includes a first base section, vertical walls 
coextending upwardly from the first base section to form a U-shaped 
channel into which the insert member is disposed, and an outer extension 
such as a tab extends upwardly and outwardly from each of the walls at a 
selected angle. The inner body member is disposed between the diverging 
outer tabs and includes a second base section adjacent the insert member 
and inner extensions such as tabs extending therefrom along inside 
surfaces of the outer tabs. The inside surfaces of the first and second 
base sections define opposed first and second clamping surfaces, which 
face respective first and second wire-proximate faces of the insert member 
and define the first and second wire-receiving passageways. 
When wires have been disposed in the wire-receiving passageways, the 
diverging outer tabs are squeezed toward each other such as by pliers 
until rotated into a vertical orientation about the upper extents of the 
vertical walls of the U-shaped channel; the outer tabs cause the inner 
tabs to be likewise rotated into a vertical alignment about the integral 
joints with the second base section. The outer tabs include means such as 
bent-back free ends which cooperate with associated means of the inner 
tabs such as free ends thereof which are disposed within the bent-back 
free ends, cooperable during crimping of the outer tabs together to 
constrain the inner tabs to be translated toward the wires during 
crimping; the inner tabs urge the second base section toward the first 
base section and press the wires in the passageways against the plurality 
of penetration spikes arrayed along the wire-proximate faces of the insert 
member. 
The insert member is adapted to provide passageways and penetration spikes 
for either round wires or flat wires of selected dimensions. The insert 
member preferably includes a planar body section and raised platforms 
extending upwardly and downwardly from the four corners of the planar body 
section. The raised platforms are spaced from each other a distance just 
larger than the diameter of the round wire for which the connector is 
fabricated to be used, while the height of the platforms is less than the 
round wire diameter; the region between the platforms is thus adapted for 
round wire so that the wire extends upwardly beyond the outer ends of the 
platforms to be engaged by the first or second base section. The insert 
member is also usable with flat wire having a width about as wide as the 
insert member so that the outer ends of the raised platforms engage the 
flat wire near both edges. The arrays of penetration spikes are disposed 
along the outer surface portions of the raised platforms to engage flat 
wire, and along the central region of the planar body section to engage 
round wire, of each wire-proximate face of the insert member. 
Preferably the insert member includes four legs extending upwardly from 
lateral edges of the planar body section and along edges of the vertical 
walls of the outer body member defining the U-shaped channel. Free ends of 
the legs include outwardly extending latching sections above the upper 
extents of the vertical walls to latch along outer surfaces of the outer 
tabs after the tabs have been squeezed together and thereby rotated into 
vertical orientation, thus providing a visual indication of the completed 
electrical connection and a means to deter relaxation of the outer tabs. 
While the insert member is made of low resistance copper alloy, the outer 
and inner body members can be made of copper alloy or made of deformable 
stainless steel. 
The outer and inner body members may be adapted to provide for 
appropriately locating the inner body member centered therewithin just 
prior to crimping, such as providing locating bosses extending from 
central portions of the free ends of the tabs of the inner body member 
which are received in apertures through the bends of the tabs of the outer 
body member and centered therealong. The free ends of the tabs of the 
outer body member may also be adapted to engage each other upon full 
crimping and lock together, mechanically assuring that the connector 
remains applied to the conductors after crimping. 
In another embodiment of the grounding connector of the present invention, 
the outer and inner body members and the insert member are adapted to 
groundingly connect a round wire to a larger diameter ground rod (or 
pipe). The base section of the outer body member is essentially V-shaped 
with the apex of the V being round to receive the smaller diameter wire 
therealong, while the base section of the inner body member is convex 
upwardly with a radius approximately matching the diameter of the rod. The 
insert member may have a planar upper surface with at least two rows of 
corrosion-penetrating spikes to establish a connection with the rod upon 
crimping, while the lower surface can have opposing angled ridges 
depending from side edges thereof to correspond both with the sides of the 
V-shaped base section of the outer body member and to extend partially 
around the small diameter wire thereunder, with arrays of 
corrosion-penetrating spikes along the surface portion between the ridges. 
Also the tabs of the outer body member may include lances extending 
inwardly from central portions thereof to engage and support the inner 
body member for uniform bending during crimping; the tabs of the outer 
body member preferably include means for free ends thereof to lock 
together upon full crimping for an assured mechanical connection to the 
wire and rod. 
It is an objective of the present invention to provide an electrical 
grounding connector easily applied to uninsulated conductors of certain 
dimensions to establish a grounding connection therebetween without 
requiring special tools or particular skill. 
It is another objective for the connector to be especially adapted to be 
applied to corroded conductors and penetrate the corrosion upon simple 
application to establish an assured grounding connection therebetween. 
It is yet another objective for the connector to be usable with either 
round wire or flat wire or both, or to a wire and a large diameter rod or 
pipe. 
It is additionally an objective for such connector to be previously 
assembled into a self-secured connector assembly which can if desired be 
easily disassembled on site to be easily reassembled around intermediate 
portions of continuous conductors upon application. 
It is still another objective for the connector to provide a mechanical, 
visual and audible indication of assured connection. 
It is also an objective of the connector of the present invention to be 
fabricated at low cost.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Grounding connector assembly 10 is shown in FIG. 1 after being applied to a 
pair of uninsulated conductors such as wires 12,14 to establish a 
grounding connection therebetween. As shown in FIG. 2, outer body member 
20, inner body member 50 and insert member 70 comprising connector 
assembly 10 can be previously assembled prior to application, so that ends 
of wires 12,14 are insertable into respective wire-receiving passageways 
16,18 of assembly 10. If assembly 10 is to be applied to intermediate 
portions of both wires 12,14 where both wires are continuous, outer and 
inner body members 20,50 and insert member 70 can be assembled around the 
wires, by placing wire 14 in U-shaped channel 22, then placing insert 
member 70 thereover, then placing wire 12 thereabove, and finally 
inserting inner body member 50 into outer body member 20 above wire 12. 
Where one of wires 12,14 is continuous, inner body member 50 is easily 
removed from assembly 10, the continuous wire is lowered into position 
atop insert member 70, inner body member 50 is slid back into place atop 
the wire, and the end of the other wire is inserted into passageway 18. 
FIG. 3 illustrates the connector assembly 10 after being disposed around 
wires 12,14 but prior to being crimpingly deformed into its final 
wire-clamping configuration as in FIGS. 1 and 6. 
Outer body member 20 includes a first base section 24, vertical wall 
sections 26 extending upwardly therefrom to define U-shaped channel 22, 
and outer projections such as tabs 28 extending upwardly from bends 30 
defining upper extents of wall sections 26 and diverging outwardly 
therefrom at selected angles .alpha. (FIG. 5). Preferably notches are 
formed at bends 30 into outer surfaces of outer body member 20 to enhance 
controlled bending thereat during crimping. Free ends 32 are bent back to 
form slots 34. 
Inner body member 50 includes a second base section 52 and inner 
projections such as tabs 54 extending upwardly and outwardly from lateral 
edges thereof at selected angles .beta. (FIG. 5) which are greater than 
angles .alpha. of outer tabs 28. Free ends 56 of inner tabs 54 are of a 
length to be disposed within slots 34 of free ends 32 of outer tabs 28 
when inner body member 50 is assembled into outer body member 20 above 
insert member 70. Second base section 52 is narrower than first base 
section 24 and is dimensioned to be no wider than U-shaped channel 22 
defined between vertical wall sections 26 of outer body member 20. Grooves 
58 are formed into the upwardly facing surface 60 of inner body member 50 
to facilitate controlled bending of inner tabs 54 at selected positions 
across second base section 52. 
Downwardly facing surface 62 of second base section 52 of inner body member 
50 opposes upwardly facing surface 36 of first base section 24 which forms 
the bottom of U-shaped channel 22, and surfaces 36,62 are opposed 
wire-clamping surfaces to engage and clamp adjacent surfaces of wires 
12,14 when connector assembly 10 is crimpingly deformed during 
application. Wire-clamping surfaces 36,62 press wires 12,14 against 
wire-proximate surfaces of insert member 70 positioned in U-shaped channel 
22. Crimping is easily performed by squeezing bent-back free ends 32 
toward each other such as by pliers; outer tabs 28 are rotated about 
notched bends 30 which define pivot points. After crimping begins, free 
ends 56 of inner tabs 54 firmly engage bottoms of slots 34; continued 
rotation of outer tabs 28 toward each other during crimping in turn 
rotates inner tabs 54 toward each other about grooves 58 which define 
pivot points, until both outer and inner tabs attain a vertical 
orientation. During crimping, free ends 56 of inner tabs 54 are trapped in 
bent-back free ends 32 of outer tabs 28; rotation of inner tabs 54 to 
vertical causes second base section 52 to move relatively downwardly 
toward first base section 24, since inner tabs 54 are rotated through a 
greater angle than are outer tabs 28. 
As seen in FIGS. 2 and 4, insert member 70 includes a planar base section 
72, four raised platforms 74 extending upwardly from upper surface 76 of 
base section 72 at the four corners thereof, four raised platforms 78 
extending downwardly from lower surface 80 at the four corners thereof, 
and preferably four legs 82 extending upwardly from lateral edges of base 
section 72 outwardly of the four corners. Planar base section 72 has a 
width about as large as the width of U-shaped channel 22 so that lateral 
edges of said planar base section abut inside surfaces of vertical wall 
sections 26 of outer body member 20 proximate bends 30 to support vertical 
wall sections 26 during crimping and facilitate rotation of outer tabs 28 
at bends 30. Outer surface portions 84,86 of raised platforms 78,82 are 
respectively coplanar and face wire-clamping surfaces 36,62 of outer and 
inner body members 20,50 respectively and include arrays of small 
penetration spikes 88 associated with a flat wire such as wire 12; 
wire-proximate portions 90,92 of upper and lower surfaces 76,80 of base 
section 72 also include an elongate array of small penetration spikes 88 
associated with a round wire such as wire 14. Each spike 88 is pyramidal 
in shape and having a height of about 0.020 inches high at its very small 
radiused or rounded apex. 
As seen in FIGS. 4 through 8, the arrays of penetration spikes 88 at 
surface portions 84,86,90,92 are positioned to engage an adjacent surface 
of a wire whether the wire be flat such as wire 12 or round such as wire 
14 in either upper passageway 16 or lower passageway 18 of connector 
assembly 10. Upon connector assembly 10 being crimped to press 
wire-clamping surfaces 36,62 of outer and inner body members 20,50 against 
outwardly facing surfaces of wires 12,14, the plurality of penetration 
spikes break into and through a layer of corrosion averaging up to about 
0.0035 inches thick and dig deeply into uncorroded metal substrates of the 
wires to establish a plurality of electrical connections for an assured 
grounding connection of the insert member 70 with each wire 12,14 thereby 
interconnecting the wires. In FIG. 6 a flat wire 12 is interconnected with 
a round wire 14 by arrays of spikes 88 of surface portions 84 of upper 
raised platforms 74 and surface portion 92 of base section 72; in FIG. 7 
two round wires 14 are disposed between upper raised platforms 74 and 
lower raised platforms 78 and interconnected by arrays of spikes 88 of 
surface portions 90,92 of base section 72; and in FIG. 8 two flat wires 
12,12 are interconnected by arrays of spikes 88 of surface portions 84,86 
of upper and lower raised platforms 74,78. 
As best seen in FIG. 1, legs 82 are spaced far enough apart to coextend 
along edges 38 of vertical wall sections 26 of outer body member 20 at the 
ends of U-shaped channel 22 upon assembly. Feet 94 extend outwardly from 
legs 82 to extend past edges 40 of outer tabs 28, and include latching 
surfaces 96 adapted to engage and latch behind outer surfaces 42 of outer 
tabs 28 when outer tabs 28 have been deformed into a vertical orientation. 
Slightly angled surfaces 98 facilitate outer tabs 28 to slightly deflect 
legs 82 outwardly during crimping to enable edges 40 of outer tabs 28 to 
pass beside the enlarged ends of feet 94 during crimping, after which feet 
94 will resile to engage the latching surfaces 96 behind outer surfaces 
42. When engaged in a latched condition, feet 94 of legs 82 provide a 
visual indication or assurance that the connector assembly has been fully 
applied to the wires and that it remains fully applied when examined 
later, without a need for electrical testing. 
Assembly 10 can retain itself in an assembled condition prior to 
application, with careful fabrication of members 20,50,70 as follows: the 
width of planar base section 72 of insert member 70 is incrementally 
larger than the width of U-shaped channel 22 to establish a force fit when 
inserted into the top thereof; the finally-formed inner body member 50 can 
then be inserted between outer tabs 28 of outer body member 20 and drop 
into position between pairs of leg sections 82 of insert member 70. Upon 
careful manipulation, inner body member 50 and the insert member 70 can be 
disassembled on-site to be applied to one or two continuous wire lengths. 
Insert member 70 is preferably cast from low resistance copper such as 
Copper Alloy No. C81700 heat treated to a Brinnel hardness of 195 minimum. 
Each penetration spike can have sides sloped at about 14.degree. from 
vertical and a height of about 0.020 inches; spikes 88 of each array may 
be spaced apart with their apices about 0.028 to 0.030 inches from each 
other. It is preferred that insert member 70 include about thirty-two 
penetration spikes engageable with each wire: each elongate array 90,92 
may have two rows of sixteen spikes, and each of the outer surface 
portions 84 of the four upper raised platforms 74 and outer surface 
portions 86 of the four lower raised platforms 78 may have two rows of 
four spikes. Planar base section 72 may have a thickness of about 0.10 
inches; each of the raised platforms 74,76 may be rectangular and have 
outer surface portions of about 0.114 by 0.063 inches. 
Outer body member 20 may be preferably stamped or optionally extruded in 
its final shape, having a general thickness of about 0.060 inches, from 
for example Copper. Alloy No. 110 half hard temper, while base section 24 
would have the same thickness or may have a thickness of about 0.150 
inches and thus be reinforced if desired. The outer tabs preferably are 
extruded at an angle .alpha. of about 30.degree. and bent-back free ends 
have partially open slots 34 with radiused bottoms at least as wide as the 
thickness of inner body member 50. Inner body member 50 may be extruded 
flat, having a thickness of about 0.090 inches, from for example Copper 
Alloy No. 110, with grooves 58 about 0.045 inches deep formed during 
extrusion to have sides angled at about 30.degree.; thereafter, inner tabs 
54 are controllably bent about grooves 58 to the desired angle .beta. 
which may be 45.degree.; preferably free ends 56 are radiused 
corresponding to the bottoms of slots 34 of outer tabs 28 of outer body 
member 20. The outer and inner body members may also be formed of 
stainless steel needing less thickness. The outer and inner body members 
may also be made of other materials of similar mechanical properties which 
need not be good electrical conductors since the inner and outer body 
members are not relied upon as part of the grounding path interconnecting 
the wires. 
FIG. 9 illustrates another embodiment of connector 100 in longitudinal 
section, wherein the outer body member 120 has a constant thickness and 
the reinforcement of base section 124 is attained by stamping base section 
124 to have a plurality of transverse strength ribs 125. The inner body 
member 150 and insert member 170 may be identical to those of connector 10 
in FIGS. 1 to 8. 
In FIGS. 10 to 12, another embodiment of grounding connector 200 is 
illustrated with respect to a pair of flat wires or conductors 12, having 
outer body member 202, inner body member 204 and insert member 206. Insert 
member 206 includes embossments 208 formed to extend laterally outwardly 
from bases of respective legs 210 extending upwardly at the four corners 
thereof, which become disposed within recesses 212 into side edges of tabs 
214 near the bases thereof, thus maintaining insert member 206 located 
within outer body member 202. Inner body member 204 includes locating 
embossments 216 formed to extend upwardly from free ends of tabs 218, 
which become disposed within apertures 220 through bends 222 of tabs 214 
of outer body member, when inner body member 204 is placed therewithin 
during initial stages of crimping thus locating inner body member 
appropriately between tabs 214 during crimping. Lower raised platforms 215 
preferably extend laterally outwardly to almost about inside surfaces of 
tabs 214 which serves to disallow undesirable rotation about a round lower 
conductor which otherwise could lead to nonsymmetric bending of the outer 
and inner tabs 214,218. 
Also shown in connector 200 is a means for locking the connector together 
upon full crimping, as seen in FIG. 12. Free ends 224,230 of respective 
ones of tabs 214 of outer body member 202 extend from bends 222 at angles 
in order to engage upon full crimping, and are machined to provide 
formations which interlock upon engagement when tabs 214 are urged into 
their vertical orientation indicative of full crimping. One free end 224 
includes a flange 226 behind which is defined a groove 228, while the 
other free end 230 is slightly longer and includes an upturned flange 232 
behind which is an undercut groove 234. Undercut groove 232 is adapted to 
receive flange 226 of free end 224 thereinto to lock behind upturned 
flange 232 of free end 230. Free ends 224,230 are adapted to bearingly 
engage to deflect apart under spring bias while flange 226 rides over 
flange 232, with bearing surface 236 of free end 224 and bearing surface 
238 of free end 230 being beveled to prevent stubbing and to initiate 
deflection of the free ends in the appropriate opposite directions, and 
the deflected free ends 224,230 resile for flanges 226,232 to interlock 
behind each other in respective grooves 234,228. 
A third embodiment of connector 300 is illustrated in FIGS. 13 to 15, 
adapted to connect a round wire with a larger diameter rod or pipe. Outer 
body member 302 is generally V-shaped with tabs 304 extending at an angle 
upwardly and outwardly from a rounded base section 306 to bent-back free 
ends 308, which are adapted to interlock upon full crimping similarly to 
connector 200 in FIGS. 10 to 12. Base section 306 has a radius about equal 
to the diameter of a standard size round wire with which connector 300 is 
to be used. Inner body member 310 is similar to member 204 of FIG. 10, 
preferably including locating bosses 312 at free ends of tabs 314; base 
section 316 is formed to arc upwardly about a radius equal to that of the 
larger diameter rod or pipe with which the connector is to be used, to 
define a concave downwardly facing rod-clamping surface 318 between 
bendable joints 320 of tabs 314 to base section 318. Insert member 322 is 
formed to a substantially different shape from that of insert member 70 of 
FIG. 2 and insert member 206 of FIG. 10, but includes axially aligned rows 
of corrosion-penetrating spikes 324 on upper rod-engaging surface 326 and 
lower wire-engaging surface 328. Rod-engaging surface 326 is essentially 
flat with two rows of spikes 324; wire-engaging surface 328 includes a 
pair of spike rows along the center thereof, and a pair of pointed ridges 
330 depend from both lateral sides. At ends of ridges 330 and downwardly 
and laterally outwardly therefrom extend projections 332 which are 
received within corresponding recesses 334 of outer body member 302 along 
end edges of V-shaped base section 306, for locating insert member 322 
therewithin and therealong. Outwardly facing surfaces 336 of ridges 330 
are angled to coincide with inside surfaces of V-shaped base section 304 
upon full crimping, as seen in FIG. 15, while inwardly facing surfaces are 
shaped to be free of engagement with a wire disposed therebetween. 
In FIG. 14, connector 300 has been assembled about a portion of a small 
diameter wire 350 disposed along the inner surface 338 of V-shaped outer 
body member 302 below insert member 322, and a portion of a large diameter 
grounding rod 352 disposed atop rod-engaging surface 326 of insert member 
322 and between tabs 304 of outer body member 302. Inner body member 310 
has been placed above grounding rod 352 between tabs 304 similarly to the 
positioning of inner body member 204 in FIG. 11, with locating bosses 312 
disposed in apertures 340. Lances 342 have been struck from middle 
portions of tabs 304 of outer body member 302 to extend at an angle 
inwardly and upwardly to free ends 344, with free ends 344 formed to 
oppose bottom surfaces of bendable joints 320 of inner body member 310; 
lances 342 also are proximate portions of grounding rod 352. 
In FIG. 15, tabs 304 have been urged toward each other by pliers until 
vertical, bending generally about grounding rod 352, urging inner body 
member 310 downwardly for concave lower surface 318 of base section 316 to 
clamp against the top surface of grounding rod 352 and in turn urge rod 
352 against corrosion-penetrating spikes 324 of insert member 322, which 
in turn is clamped against wire 350 to press it tightly against inner 
surface 338 of V-shaped base section 306 of outer body member 302. Free 
ends 308 of tabs 304 are interlocked by means of flanges 346. Arrays of 
corrosion-penetrating spikes 324 on rod-engaging surface 326 and 
wire-engaging surface 328 establish electrical connections with conductive 
material of grounding rod 352 and with wire 352, respectively, thus 
groundingly connecting them. 
Other variations may be devised which are within the spirit of the 
invention and the scope of the claims. For example, other shapes of 
penetrating formations may be included which break through the corrosion 
of the wires, and shapes of outer and/or inner extensions other than tab 
shapes, could easily be devised. Also, especially in view of the grounding 
rod embodiment of FIGS. 13 to 15, connectors may be formed which are 
adapted to engage a pair of flat wires only, or a pair of round wires 
only, simply by simplifying the structure of the insert member. It is also 
within the spirit of the invention to utilize other structures which when 
crimped together, clamp a pair of wire-clamping surfaces of the connector 
against a pair of wires and cause arrays of penetration spikes of a common 
insert member or of the wire-clamping surfaces themselves to break through 
the wire corrosion and interconnect the wires to establish an assured 
grounding path.