Electrical connector

An electrical connector including a first connection section adapted to connect to a first electrical conductor; and a second connection section adapted to connect to a second electrical conductor. The first and second connection sections include a first member, a second member and a compression member for compressing the second member towards the first member. The second member is pivotably connected to the first member at a rotating pivot which is spaced from the compression member and the second connection section.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to an electrical connector and, more particularly, to an electrical connector for connecting multiple conductors to a main conductor.

2. Brief Description of Prior Developments

U.S. Pat. No. 4,985,003 discloses an electrical connector with a nut and bolt for compressing two jaws together. U.S. Pat. No. 5,704,816 discloses a hinged electrical connector having a nut and bolt connecting two jaw members.

SUMMARY

In accordance with one aspect of the invention, an electrical connector is provided including a first connection section adapted to connect to a first electrical conductor; and a second connection section adapted to connect to a second electrical conductor. The first and second connection sections include a first member, a second member and a compression member for compressing the second member towards the first member. The second member is pivotably connected to the first member at a rotating pivot which is spaced from the compression member and the second connection section.

In accordance with another aspect of the invention, an electrical connector is provided comprising a first member and a second member. The first member comprises a first end and a second end. The first member comprises a metal plate with insulation piercing teeth at the first end for connection to a first conductor and a second conductor connection section at the second end. The second end comprises a pivot post extending from the second end. The second member is rotatably connected to the first member on the pivot post. The second member is adapted to press the first conductor into the teeth of the metal plate.

In accordance with another aspect of the invention, an electrical connector is provided comprising a first connection section adapted to connect to a first electrical conductor; and a second connection section adapted to connect to a second electrical conductor. The first and second connection sections comprise a first member, a second member pivotably connected to the first member, and a compression member for compressing the second member towards the first member. The second member is adapted to compress the first conductor against the first member. The first member is adapted to connect to the second electrical conductor without the second member contacting the second conductor.

DETAILED DESCRIPTION OF EMBODIMENTS

Referring toFIGS. 1 and 2, there is shown an electrical connector10incorporating features of the invention. Although the invention will be described with reference to the example embodiments shown in the drawings, it should be understood that the invention can be embodied in many alternate forms of embodiments and concepts of electrical contacts. In addition, any suitable size, shape or type of elements or materials could be used.

The connector10is configured to connect tap conductors14to a main conductor12. The main conductor12could be a cable in a power distribution system for example. The main conductor12includes an electrically conductive core16(such as wound conductor strands for example) and outer electrical insulation18. The tap conductors14each also include an electrically conductive core16(such as wound conductor strands for example) and outer electrical insulation18.

The connector10generally comprises a first member or jaw20, a second member or jaw22, and a compression connector24. Referring also toFIGS. 3-6, the first member20comprises a first end26, an opposite second end28, and a hole30between the two ends26,28. A top side of the first end26has insulation piercing teeth32arrange in a channel. The teeth32form a first connection section. The middle section has a post31extending from the top side. The hole30extends through the post31. The second end28has conductor receiving holes34extending into a bottom side of the second end28. Threaded holes36intersect with the holes34. The threaded holes36extend into two opposed lateral sides of the second end28. A top side of the second end28has two upward extending, laterally spaced pivot posts44. Each post44has a pivot pin receiving area in its top side.

In this embodiment, as best seen inFIG. 4, the first member20comprises metal plates38,40and an overmolded body42of plastic material. The plates38have the teeth32at one end and intersect the holes34at an opposite end. The teeth32of the first plate38are generally spaced and parallel to the teeth32of the second plate38. The plates40form fastener plates with the threads for the holes36. The holes34are generally orthogonal to the holes36, and are located between one of the conductor plates38and one of the fastener plates40at each lateral side. However, in an alternate embodiment any suitable arrangement of members could be used to form the first member20.

The second member22is preferably a one piece member, such as made of metal for example. The second member22comprises a first end46, a second end48and a hole50in a middle section. The first end46has a bottom side with a conductor contact surface52. The second end48has pivot posts54which extend laterally outward from opposite sides of the second end48. The hole50has a general oval shape when viewed from above, but a funnel shape when viewed in cross section as seen inFIGS. 3 and 6.

The compression connector24comprises a bolt56and a fastener58. The bolt56has a head57located on the bottom side of the first member20. The bolt58extends through the hole30. The fastener58is screwed onto the bolt56. The fastener58has a flat washer60and an O-ring friction member62. The bolt56extends through the hole50. A portion of the post31having the hole30extends into the hole50. The flat washer60contacts the top surface of the second member22at lateral sides of the top of the hole50.

The pivot posts54are located in respective ones of the receiving pivot slots of the pivot posts44. The pivot posts44,54form a rotating pivot which is spaced from the compression connector24and the second connection section formed at the fasteners64.

The main conductor12is captured between the surface52and the channel having the teeth32. When the nut58is tightened on the bolt56, the main conductor12is pressed into the teeth32of the plates38by the second member22. The teeth32pierce through the insulation18and make electrical contact with the conductor core16of the main conductor12. Thus, the plates38are electrically connected to the main conductor12. The hole50provides sufficient spacing for the post31to allow pivotal movement of the second member22on the first member20as the fastener58is being tightened on the bolt56.

The connector10includes threaded fasteners64, such as bolts. The fasteners64are threaded into the holes36. Ends of the tap conductors14, having their insulation18removed at those ends, are inserted into the holes34. The fasteners64contact the ends of the tap conductors14and press the ends against the outward facing lateral sides of the metal plates38. Thus, this forms a mechanical gripping of the ends of the conductors14in the holes34, and electrical connection of the tap conductors14to the main conductor12via the plates38.

Referring also toFIG. 7, an alternate embodiment of the electrical connector is shown. In the embodiment shown inFIGS. 1-6, the second end28and tap conductor receiving holes34where arranged in an array of four 2-by-2 holes. In this embodiment, the electrical connector has a first member20′, the second member22and the connector24. The first member20′ is identical to the first member20, but it has a second end28′ which has four tap conductor receiving holes arranged in an array as a series in line with each other. The threaded holes36′ for the fasteners64all extend into a same side of the second end28′. The first end of the plates38′ have the teeth32(seeFIG. 3), and the opposite second ends of the plates38′ have bent sections for the fasteners64to press the conductors14against.FIG. 21shows an example of one of the plates38′.

Referring also toFIGS. 8-14another alternate embodiment of the invention is shown. In this embodiment the electrical connector66has the same second member22and fastener24, but a different first member68. The first member68has the first end26and post31with the hole30in the middle section.

The first member68has two metal plates72and the overmolded plastic housing or body74. Each metal plate72has a first end with the teeth32at the first end26and a second end having two sets of teeth76. The teeth76are sized and shaped to pierce through the insulation18of the tap conductors14to electrically and mechanically connect with the conductive cores16of the tap conductors14. The body74has slots78extending inward from the lateral and top sides of the body74. The metal plates72are located in the slots78. Thus, the tap conductors14can be inserted into the slots78from a top side of the body74, into the teeth76, and extend out lateral sides of the body. Caps80can be used to cover the top sides of the slots78. The caps are shown connected to the second end70′ of the first member by living hinges. However, the caps80could be separate members. The caps80can be used to push the tap conductors14into the teeth76. In this embodiment the caps80have snap-lock latches82which can engage latch teeth84in the slots78to retain the caps80. The latch teeth84extend downward for a distance to allow the attachment of the caps80to be range taking for different size conductors14. For example,FIGS. 8-14show different size diameter conductors14. The arrangement of the teeth76is also range taking to enable use with the different size diameter conductors14. Thus, the teeth76are provided for piercing through insulation18for connection to the tap conductors14. This allows connection with the tap conductors14without having to first remove the insulation18from the ends of the conductors14as is done in the first and second embodiments described above.

Referring also toFIG. 15, an alternate embodiment of the electrical connector100is shown. The electrical connector100includes a first member102, the second member22and the connector24. The first member102is identical to the first member68except for its second end. In the embodiment shown inFIGS. 8-14, the second end70and tap conductor receiving slots78where arranged in an array of 2-by-2 slots. In this embodiment, the second end70′ has four tap conductor receiving slots arranged in an array as a series in line with each other. The second end70′ is arranged as two spaced block sections to save material. The tap conductors14can all exit a same side of the second end70′. The second ends of the metal plates72′, thus, have a bent or “L” shape as opposed to the straight shape of the second ends of the metal plates72. However, each metal plate72′ has the teeth76(seeFIG. 14for the tap conductors14).FIG. 22shows an example of one of the plates72′.

Referring also toFIGS. 16-19another alternate embodiment of the invention is shown. In this embodiment the electrical connector86has the same second member22and fastener24, but a different first member88. The first member88has the first end26and post31with the hole30in the middle section. The second end90of the first member88is configured with insulation displacement areas for connection to the tap conductors14. This allows connection with the tap conductors14without having to first remove the insulation18from the ends of the conductors as is done in the first embodiment described above.

The first member88has two metal plates92and the overmolded plastic housing or body94. Each plate92has a first end with the teeth32at the first end26and a second end having two sets of insulation displacement connections (IDC)96. The IDCs96are sized and shaped to slice through opposite side of the insulation18of the tap conductors14to electrically and mechanically connect with the conductive cores16of the tap conductors14. The body94has slots98extending inward from the lateral and top sides of the body94. The IDCs are located in the slots98. Thus, the tap conductors14can be inserted into the slots98from a top side of the body94, into the IDCs, and extend out lateral sides of the body. Caps80can be used to cover the top sides of the slots98. The caps80can be used to push the tap conductors14into the IDCs. In this embodiment the caps80have latches82which can engage latch teeth84in the slots78to retain the caps80.

Referring also toFIG. 20, an alternate embodiment of the connector is shown. In the embodiment shown inFIGS. 16-19, the second end90and tap conductor receiving slots98where arranged in an array of 2-by-2 slots. In this embodiment, the second end90′ has four tap conductor receiving slots arranged in an array as a series in line with each other. The second end90′ is arranged as two spaced block sections to save material.FIG. 23shows an example of one of the plates92′ used in the connector. The tap conductors14can all exit a same side of the second end90′.

Embodiments of the invention allow a common upper connector member, such as22for example, to be used with a variety of different lower connector members, such as20, or20′ or68for example. Even though an embodiment of the invention can use two connector parts (20and22for example) to clamp onto a first conductor, one of these connector parts (22for example) is not used to connector to the second conductors14. The wire connections for the second conductors14are merely with the first connector part (20for example).

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. For example, features recited in the various dependent claims could be combined with each other in any suitable combination(s). In addition, features from different embodiments described above could be selectively combined into a new embodiment. Accordingly, the invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.