Compression connectors with insulating cover

The present disclosure provides embodiments of insulated compression-type electrical connectors used to connect one or more branch wires or conductors to one or more run wires or conductors.

BACKGROUND

Field

The present disclosure relates generally to insulated electrical compression connectors for electrically and compressively connecting two or more solid or stranded wires or conductors together. More specifically, the present disclosure relates to compression-type electrical connectors for electrically and compressively connecting two or more solid or stranded wires or conductors together.

Description of the Related Art

Tap connectors have been used to establish an electrical connection between a continuous main power conductor to a branch conductor. Similarly, tap connectors have been used to establish an electrical connection between a distribution power conductor (also referred to as a run) and one or more main power conductors. Compression type tap connectors are typically adapted to receive a branch or tap conductor, to engage a continuous run conductor, and to be compressed by means of a crimping tool to achieve the desired connection. Such connectors are not coated with an insulating cover.

SUMMARY

The present disclosure provides embodiments of compression-type electrical connectors used to connect one or more branch wires or conductors to one or more run wires or conductors. In an exemplary embodiment, the compression connector includes a connector body and an insulating coating surrounding the connector body. The connector body is preferably made of compressible material adapted to be inserted into a crimping tool. The connector body includes a run conductor portion and a branch conductor portion. The run conductor portion includes a pair of side walls joined by a bottom wall, a run conductor opening between the pair of side walls and the bottom wall, and at least one insulation piercing member extending from at least one of the pair of side walls and the bottom wall into the run conductor opening. The branch conductor portion includes at least one branch conductor opening having a lead-in with a rib adjacent the lead-in, and a hinge portion between the branch conductor opening and the connector body. The insulation coating surrounds the connector body such that an interior wall of the at least one branch conductor opening and the at least one insulation piercing member are not covered by the insulation coating.

DETAILED DESCRIPTION

The present disclosure provides embodiments of compression connectors that are covered with a flexible insulating jacket and used to electrically and compressively connect, for example, one or more branch or tap conductors to one or more run or main conductors in such a way that either the entire solid branch conductor or one or more wire strands of the branch conductor remain within their respective opening, port, slot, channel, aperture or the like. For ease of description, the compression connector may be referred to as the “connector” in the singular and the “connectors” in the plural. The branch or tap conductors may be referred to as the “branch conductor” in the singular and the “branch conductors” in the plural. The main or run conductors may be referred to as the “run conductor” in the singular and the “run conductors” in the plural. The port, slot, channel, aperture or other opening that receives the branch conductors may also be referred to as the “branch opening” in the singular and the “branch openings” in the plural. The port, slot, channel, aperture or other opening that receives the run conductors may also be referred to as the “run opening” in the singular and the “run openings” in the plural.

Referring toFIGS.1-3and6, an exemplary embodiment of a compression connector according to the present disclosure is shown. In this exemplary embodiment, the connector10includes a body20having a run conductor portion22and a branch conductor portion24. The run conductor portion22includes two side walls26and28, a run opening30between the two side walls and a bottom wall32between the two side walls26and28that define a portion of the run opening30. The bottom wall32in this exemplary embodiment is a rounded bottom wall. One of the walls26or28may include a more rounded shape at its free end than the other wall so that when the connector10is compressed, e.g., crimped, the more rounded end can overlay the run conductor. In the exemplary embodiment shown, the run conductor portion22is substantially a U-shaped structure with the rounded bottom wall32shaped to receive a run conductor. The configuration of the opening30can vary depending upon the size of the run conductor. As a non-limiting example, the run conductor can be a round cable having a gauge in the range from about 250 Kcmil to about 750 Kcmil. The walls26,28and32may include one or more channels34that extend along a width “W1” of the body20. The channels34have a width “W2” and are configured and dimensioned to receive and releasably hold an insulation piercing member100to the body20as described in more detail below. In the exemplary embodiment shown, a channel34extends along a width “W1” of the bottom wall32.

Continuing to refer toFIGS.1-3and6, the run conductor portion22of the body20also includes one or more insulation piercing members100extending from an inner surface of one or more walls26,28and/or32. In the embodiment shown inFIGS.1-3, an insulation piercing member100extends from the bottom wall32into the opening30. In this exemplary embodiment, the insulation piercing member100includes a base102and a tip member104. The base102is configured and dimensioned to fit within the channel34in wall26,28and/or32of the body20, as shown, so that the insulation piercing member100is removably attached to the body20. More specifically, as noted above, in the exemplary embodiment shown, the channel34extends along the width “W1” of the bottom wall32of the body20and forms the mortise portion of a sliding dove-tail type connection joint. The base102of the insulation piercing member100is tapered to form the tenon or tongue of the sliding dove-tail connection joint. Preferably, there is sufficient friction between the channel34and the base102so that after the base102is inserted into the channel34, the insulation piercing member100remains in position within the channel34for the subsequent insulation coating process described below. The base102has a length “L1” that is substantially the same as the width “W1” of the body20, and a width “W3” that is substantially the same as the width “W2” of the channel34so that the base102can slide into the channel34and remain fixed in position due to friction between the walls of the base102and the walls of the channel34.

The tip member104is, in this exemplary embodiment, a triangular shaped member extending from the base102into the opening30in the body20. More specifically, the tip member104includes a base side104athat is integrally or monolithically formed into the base102and two side walls104band104cextending away from the base side104aand joined to form a piercing tip104d. The piercing tip104dis configured and dimensioned to pierce or cut through the insulation jacket surrounding the electrical wire in the run conductor700when the connector10is crimped, and to contact the electrical wire within the run conductor700to create an electrical path between the connector10and the run conductor700, as shown inFIG.8. The tip member104has a length “L2” that is less that the length “L1” of the base102. The length “L2” of the tip member104should be sufficiently less than the length “L1” of the base102so that the insulation jacket120, seen inFIG.7, applied to the body20surrounds the base side104aof the tip member104. By having the length of the tip member104less than the length of the base102, a seal can form between the connector10and the run conductor700when the run conductor700is crimped to the connector10. This seal minimizes and possibly prevents water and/or gas from contacting the tip member104of the insulation piercing member100. As a non-limiting example, if the length “L1” of the base102is 1 inch, the length “L2” of the tip member104would preferably be ½ inch and the tip member would be centered along the width of the body20as shown inFIGS.1and2. As such, in this exemplary embodiment, the length “L2” of the tip member104is ½ the length “L1” of the base102. In this exemplary embodiment, the body20is typically formed by, for example, an extrusion process, a metal casting process or a machining process where the channel34is formed as part of the process used to fabricate the body. The insulation piercing member100is typically formed by, for example, a stamping process, a metal casting process or a machining process and hardened using conventional hardening processes, such as heating and rapidly cooling the insulation piercing member.

It is noted, however, that the insulation piercing members100may come in different shapes and sizes configured and dimensioned to pierce or cut through insulation surrounding electrical wires, such as a cone-shaped member or a member with a pointed tip. Further, the insulation piercing members100may include a serrated tip to assist in the piercing through insulation surrounding the electrical wires. The insulation piercing members100are preferably made of a hardened material that is sufficient to pierce through insulation surrounding the run conductors400. Non-limiting examples of such hardened material include 6000 series aluminium, stainless steel or hardened brass.

Referring toFIG.6, another exemplary embodiment of the body20of the connector10is shown. In this exemplary embodiment, the body20is substantially the same as the body described above except that the body20includes one or more insulation piercing members110integrally or monolithically formed into one or more walls26,28and32of the body. As shown, the insulation piercing member110extends from the bottom wall32into the opening30. In this exemplary embodiment, the insulation piercing member110includes tip member112, which is substantially similar to the tip member104described above. The tip member112is, in this exemplary embodiment, a triangular shaped member extending from the bottom wall32of the body into the opening30. More specifically, the tip member112includes two side walls112aand112bextending away from the bottom wall32of the body20and joined to form a piercing tip112c. The piercing tip112cis configured and dimensioned to pierce or cut through the insulation jacket surrounding the electrical wire in the run conductor700when the connector10is crimped, and to contact the electrical wire within the run conductor700to create an electrical path between the connector10and the run conductor700, similar to the connection shown inFIG.8. The tip member112has a length “L2” that is less that the width “W1” of the body20. The length “L2” of the tip member112should be sufficiently less than the width “W1” of the body20so that the insulation jacket120, seen inFIG.7, applied to the body20surrounds the junction between the bottom wall32and the insulation piercing member110. By having the length of the tip member112less than the width of the body20, a seal can form between the connector10and the run conductor700when the run conductor is crimped to the connector10. This seal minimizes and possibly prevents water and/or gas from contacting the tip member112of the insulation piercing member110. As a non-limiting example, if the width “W1” of the body20is 1 inch, the length “L2” of the tip member112would preferably be ½ inch and the tip member would be centered along the width “W1” of the body20as shown inFIG.6. As such, in this exemplary embodiment, the length “L2” of the tip member112is ½ the width “W1” of the body20. In this exemplary embodiment, the body20is typically formed by an extrusion process, metal casting process or a machining process where the insulation piercing member110is formed as part of the extrusion process, metal casting process or the insulation piercing member is machined as part of the body. In order to harden the insulation piercing member110, the insulation piercing member is put through a conventional hardening process, such as heating and then rapidly cooling the insulation piercing member.

It is noted, however, that the insulation piercing members110may come in different shapes and sizes configured and dimensioned to pierce or cut through insulation surrounding electrical wires, such as a cone-shaped member or a member with a pointed tip. Further, the insulation piercing members110may include a serrated tip to assist in the piercing through insulation surrounding the electrical wires.

Referring again toFIGS.1-3, the branch connector portion24includes one or more branch openings. Each branch opening can be configured and dimensioned to receive one or more branch conductors. In the embodiment shown, the branch conductor portion24includes four branch conductor openings40,50,60and70, and the branch conductors702,704,706and708, seen inFIG.4, are round cables. However, there may be less than four branch openings or there may be more than four branch openings.

In the exemplary embodiment shown inFIGS.3and6, the branch opening40extends along the width “W1” of the body20as shown and has a lead-in42defined by a rib44. The rib44helps retain a branch conductor within the branch opening40until the connector10is compressed, e.g., crimped. The branch conductor portion24also includes a first hinge portion46that enables rib44to more easily bend or deflect in a direction toward the bottom wall32of the body20when being compressed. The branch opening50extends along the width “W1” of the body20as shown and has a lead-in52defined by a rib54. The rib54helps retain a branch conductor within the branch opening50until the connector10is compressed, e.g., crimped. The branch conductor portion24also includes a second hinge portion56that enables rib54to more easily bend or deflect in a direction toward the bottom wall32of the body20when being compressed. The branch opening60extends along the width “W1” of the body20as shown and has a lead-in62defined by a rib64. The rib64helps retain a branch conductor within the branch opening60until the connector10is compressed, e.g., crimped. The branch conductor portion24also includes a third hinge portion66that enables rib64to more easily bend or deflect in a direction toward the bottom wall32of the body20when being compressed. Branch opening70extends along the width “W1” of the body20as shown and has a lead-in72defined by a rib74. The rib74helps retain a branch conductor within the branch opening70until the connector10is compressed, e.g., crimped. The branch conductor portion24also includes a fourth hinge portion76that enables rib74to more easily bend or deflect in a direction toward the bottom wall32of the body20when being compressed. Each branch opening includes an interior wall that is configured to contact an electrical wire within a respective branch conductor to create an electrically conductive path between the branch conductor and the connector body20.

When the connector10is compressed, using for example a standard hydraulic crimping tool (not shown), the hinge portions46,56,66and76of the branch conductor portion24bend or deflect first to prevent the branch conductors or strands of the branch conductors from exiting the respective opening via lead-ins42,52,62and72. It is noted that the branch openings40,50,60and70shown are substantially the same size. As a result, the branch openings would be configured to receive branch conductors702,704,706and708having a size or gauge that falls with the same predefined range of, for example, #22 AWG to 4/0 AWG. However, the present disclosure also contemplates that one or more the branch openings40,50,60and70may have different sizes. For example, one or more branch openings could be configured to receive branch conductors having a first size or gauge that falls with a first predefined range of, for example, 1/0 AWG, and one or more branch openings could be configured to receive branch conductors having a second size or gauge that falls with a second predefined range of, for example, 4/0 AWG.

Referring toFIGS.4and5, it is noted that the run conductors700are typically greater in size or gauge than the branch conductors702,704,706and708. The run conductors700and the branch conductors include electrical wires surrounded by an insulating jacket. Further, the electrical wires in the run conductors700and the branch conductors702,704,706and708can be solid wires so that the run or branch conductors would be known as solid conductors. Alternatively, the electrical wires in the run conductors700and the branch conductors702,704,706and708can be stranded wires so that the run or branch conductors would be known as stranded conductors. Typically, the run conductors and branch conductors are stranded conductors, as shown.

Once the connector body20is formed, the connector body, including the insulation piercing members100or110, is coated with a flexible insulating material to form the insulation jacket120around the connector body20. At the same time, branch conductor portals122that are aligned with the branch openings40,50,60and70are formed in the insulation jacket120to provide a seal between the insulation jacket surrounding the electrical wire in the branch conductors. This seal minimizes and possibly prevents water and/or gas from entering the branch conductor openings. Non-limiting examples of the flexible insulating material include Polyvinyl Chloride (PVC), ethylene propylene diene monomer (EPDM) rubber, Santoprene and Plastisol.

To coat the conductor body20with the flexible insulating material and to form the branch conductor portals122, pegs124are first inserted into the branch openings40,50,60and70, as seen inFIGS.3and6. Each peg124includes a first portion124aand a second portion124b. In this exemplary embodiment, the first portion124ais a cylindrical member shaped to conform to the branch openings40,50,60and70. The first portion124ahas an outer diameter configured to fit within the respective branch opening. However, the first portion may have other shapes to conform to the shape of the branch openings40,50,60and70. Similarly, the second portion124bis a cylindrical member shaped to conform to the insulation jacket surrounding electrical wire in the branch conductors702,704,706and/or708. The second portion124bof each peg124has an outer diameter configured to form the branch conductor portals122made of the flexible insulating material. In this configuration, the inner diameter of the branch conductor portals122would be the same or slightly less than the outer diameter of the insulation jacket surrounding the electrical wire in the branch conductors702,704,706and/or708so that when the branch conductors are inserted into the branch conductor portals122a seal is formed between the branch conductor insulating jacket and the branch conductor portal122. This seal minimizes and possibly prevents water and/or gas from entering the branch conductor openings. However, the second portion124bmay have other shapes to conform to the shape of the insulation jacket surrounding the electrical wires in branch conductors702,704,706,708.

With the pegs124inserted into the branch openings40,50,60and70, the conductor body20is coated with the flexible insulating material, by for example, dipping the conductor body into a vat of liquid insulating material and then allowing the coating of insulating material to harden to form the insulation jacket120, or by an injection moulding process. Once the coating hardens, the portion of the insulating jacket120covering the tip member104or112of the insulation piercing member100or110, respectively, is removed to expose the insulation piercing member, as seen inFIG.7.

Referring now toFIGS.4,5and8, to secure the run and branch conductors to the connector10, the connector is placed in a standard crimping tool (not shown), such as a hydraulic 12-ton or 15-ton hand held power tool, that has die surfaces500and502, seen inFIGS.4and5, in a working head of the tool. An example of a hydraulic power tool is the PAT46-18V manufactured by Burndy, LLC. When the tool is actuated, the connector10would come into contact with the interior surfaces of the dies, such that a compressive force applied to the dies is transferred to the connector10causing the connector to compress. As the tool is compressing the connector10, the hinges46,56,66, and76would typically bend or deflect first securing the branch conductors702,704,706and708within their respective branch openings40,50,60and70and preventing strands of the branch conductors from exiting the openings. As additional compressive force is applied to the connector10, the wall26folds and then the wall28folds to secure the run conductor700to the connector. In addition, the insulation piercing members100or110would pierce through the run conductor insulation jacket so that an electrical path is formed between the electrical wire in the run conductor and the body20. The conductors provided in branch openings30,40,50,60and70will receive direct compressive loads due to the unique geometric relationship between the connector10and the dies of the tool. After the crimping process is completed, the conductors700,702,704,706and708provided in their respective openings would be secured in place, i.e., crimped to the connector10.

The body20of the connector10described in the present disclosure can be manufactured from copper, aluminum or similar metallic materials which would appropriately deform when pressure is applied in standard mechanical, hydraulic and pneumatic crimping tools and devices to crimp the conductors to the connectors. The insulation piercing members described herein are preferably made of a hardened material or hardened so that the insulation piercing members are sufficient to pierce through the insulation jacket surrounding the run conductors. Further, the branch openings disclosed and described herein may also include one or more insulation piercing members, similar to the insulation piercing members described herein, that are configured and dimensioned to pierce the insulation jacket surrounding electrical wire in the branch conductors.

Referring toFIGS.9-12a, another exemplary embodiment of a body202of a connector200is shown. In this exemplary embodiment, the body202is substantially the same as the body20described above except that the branch connector portion24of the body202includes one or more branch openings, e.g., branch openings40,50,60and70, and each branch opening includes one or more insulation piercing members210integrally or monolithically formed into the branch opening. As shown inFIGS.9and10, each insulation piercing member210extends from an interior wall of the respective branch opening. In the embodiment shown, the branch conductor portion24includes four branch openings40,50,60and70, and the branch conductors702,704,706and708, seen inFIG.12, are round cables. However, there may be less than four branch openings or there may be more than four branch openings. The branch opening40includes an interior wall48and one or more insulation piercing members210extending from the interior wall48into the branch opening40. The branch opening50includes an interior wall58and one or more insulation piercing members210extending from the interior wall58into the branch opening50. The branch opening60includes an interior wall68and one or more insulation piercing members210extending from the interior wall68into the branch opening60. The branch opening70includes an interior wall78and one or more insulation piercing members210extending from the interior wall78into the branch opening70. For ease of description, the one or more insulation piercing members210extending from the interior wall78into the branch conductor opening70will be described in more detail. However, this description applies to branch openings40,50and60as well.

Referring toFIGS.9and10, one or more insulation piercing members are shown extending from an interior wall of the respective branch opening. As shown inFIG.9, one insulation piercing member210extends from the interior wall78into the branch opening70. The insulation piercing member210may have a length that is substantial equal to the width “W1” of the body202, seen inFIG.9, or the insulation piercing member210may have a length that is less than the width “W1” of the body202. In other embodiments, the insulation piercing member210extending from the interior wall78into the branch opening70may be segmented so that more than one insulation piercing members may extend from the interior wall78into the branch opening70.

Referring again toFIGS.9-12a, in this exemplary embodiment, each insulation piercing member210includes tip member212. The tip member212is, in this exemplary embodiment, a triangular shaped member extending from the interior wall of the respective branch opening, e.g. interior wall78of branch opening70. More specifically, the tip member212includes two side walls212aand212bextending away from the interior wall78of the branch conductor opening70and are joined to form a piercing tip212c. The piercing tip212cis configured and dimensioned to pierce or cut through the insulation jacket surrounding the electrical wire of the branch conductor, e.g., branch conductor708, when the connector200is crimped, and to contact the electrical wire within the branch conductor708to create an electrical path between the connector200and the respective branch conductor, similar to the connection shown inFIGS.12and12a.

Although the insulation piercing members210are described herein as a triangular shaped member, the insulation piercing members210may come in different shapes and sizes configured and dimensioned to pierce or cut through insulation surrounding electrical wires, such as a cone-shaped member or a member with a pointed tip. Further, the insulation piercing members210may include a serrated tip to assist in the piercing through insulation surrounding the electrical wires.

Once the connector body202is formed, the connector body is coated with a flexible insulating material to form the insulation jacket120around the connector body202, seen inFIG.11. At the same time, branch conductor portals122that are aligned with the branch openings40,50,60and70are formed in the insulation jacket120to provide a seal between the insulation jacket surrounding the electrical wire of the branch conductors and the insulation jacket120. This seal minimizes and possibly prevents water and/or gas from entering the branch openings. Non-limiting examples of the flexible insulating material include Polyvinyl Chloride (PVC), ethylene propylene diene monomer (EPDM) rubber, Santoprene and Plastisol. The insulation jacket120and the branch conductor portals122can be formed in a similar manner as described above, except that the first portion124aof each peg124inserted into a branch opening40,50,60and/or70to facilitate the formation of the branch conductor portals122differ slightly. More specifically, the first portion124aof each peg124includes a notch124cconfigured to receive the insulation piercing members210within the respective branch opening40,50,60and/or70.

Referring now toFIGS.13and14, another exemplary embodiment of a connector according to the present disclosure is shown. In this exemplary embodiment, the connector220is an H-shape like member having a body224. The body224includes a run conductor portion226and a branch conductor portion228. The run conductor portion226includes two side walls230and232, an opening234between the side walls230and232, and a bottom wall236between the side walls230and232that define a portion of the opening234. One of the walls230or232may include a more rounded shape at its free end than the other wall so that when the connector220is compressed, e.g., crimped, the more rounded end can overlay a conductor within the opening234. The first conductor portion226of the connector220also includes one or more insulation piercing members238integrally or monolithically formed into one or more walls230,232and/or236and extending into the opening234. However, the one or more insulation piercing members238may be separate members secured to the connector body224using, for example, the above-described sliding dove-tail type connection joint. In the embodiment shown, a single insulation piercing member238is monolithically formed in the connector body224so that the insulation piercing member extends from the bottom wall236into the opening234.

The branch conductor portion228of the body224includes two side walls250and252, an opening254between the side walls250and252, and a bottom wall256between the side walls250and252that define a portion of the opening254. It is noted that the bottom wall256is opposite the bottom wall236. One of the walls250or252may include a more rounded shape at its free end than the other wall so that when the connector220is compressed, e.g., crimped, the more rounded end can overlay a conductor within the opening254. The second conductor portion228of the connector220also includes one or more insulation piercing members238integrally or monolithically formed into one or more walls250,252and/or256and extending into the opening254. However, the one or more insulation piercing members238may be separate members secured to the connector body224using, for example, the above-described sliding dove-tail type connection joint. In the embodiment shown, a single insulation piercing member238is monolithically formed in the connector body224so that the insulation piercing member extends from the bottom wall256into the opening254.

Each insulation piercing member238includes a tip member240that is, in this exemplary embodiment, a triangular shaped member extending from the bottom wall236or256of the body224into the opening234or254. More specifically, the tip member240includes two side walls240aand240bextending away from the bottom wall236or356of the body224and are joined to form a piercing tip240c. The piercing tip240cis configured and dimensioned to pierce or cut through the insulation jacket surrounding the electrical wire in a run conductor700or a branch conductor710when the connector10is crimped, and to contact the electrical wire within the run conductor700or the branch conductor710to create an electrical path between the connector220and the conductors700and710, similar to the connection shown inFIG.18.

The tip member240has a length “L3” that is less that the width “W1” of the body224. The length “L3” of the tip member240should be sufficiently less than the width “W1” of the body224so that the insulation jacket120applied to the body224surrounds the junction between the bottom wall236and256and the insulation piercing member238. By having the length of the tip member240less than the width “W1” of the body224, a seal can form between the connector220and a run conductor710or a branch conductor712when the conductor is crimped to the connector220. This seal minimizes and possibly prevents water and/or gas from contacting the insulation piercing member238. As a non-limiting example, if the width “W1” of the body224is 1 inch, the length “L3” of the tip member240would preferably be ½ inch and the tip member238would be centered along the width “W1” of the body224as shown inFIG.13. As such, in this exemplary embodiment, the length “L3” of the tip member240is ½ the width “W1” of the body224. In this exemplary embodiment, the body224is typically formed by an extrusion process, metal casting process or a machining process where each insulation piercing member238is formed as part of the extrusion process, metal casting process, or each insulation piercing member is machined as part of the body224. In order to harden the insulation piercing members238, the insulation piercing members may be put through a conventional hardening process, such as heating and then rapidly cooling the insulation piercing member.

Although the insulation piercing members238are described above as a triangular shaped member, the insulation piercing members238may come in different shapes and sizes configured and dimensioned to pierce or cut through insulation surrounding electrical wires, such as a cone-shaped member or a member with a pointed tip. Further, the insulation piercing members238may include a serrated tip to assist in the piercing through the insulation jacket surrounding the electrical wires.

Once the connector body224is formed, the connector body, including the insulation piercing members238, are coated with a flexible insulating material to form the insulation jacket120around the connector body224that permits a seal to form between the connector body224and a run conductor710or a branch conductor712when the conductors are crimped to the connector220. This seal minimizes and possibly prevents water and/or gas from contacting the insulation piercing members238. Non-limiting examples of the flexible insulating material include Polyvinyl Chloride (PVC), ethylene propylene diene monomer (EPDM) rubber, Santoprene and Plastisol.

In one exemplary embodiment, to coat the conductor body224with the flexible insulating material, the conductor body224is, for example, dipped into a vat of liquid insulating material and then removed allowing the coating of insulating material to harden to form the insulation jacket120. In another exemplary embodiment, the conductor body224may be coated with the flexible insulating material by an injection moulding process. Once the coating hardens, the portion of the insulating jacket120covering the tip members240of the insulation piercing members238is removed to expose the tip members240, as seen inFIG.13.

Referring now toFIGS.15and16, another exemplary embodiment of a connector according to the present disclosure is shown. In this exemplary embodiment, the connector300includes a body310having a run conductor portion312and a branch conductor portion314. The body310is a C-shaped like member having a first wall316, a second wall318and a third wall320joining the first wall to the second wall. As such, the first wall316and a portion of the third wall320form the run conductor portion312, and the second wall318and a portion of the third wall320form the branch conductor portion314. The first, second and third walls316,318and320may be a unitary or monolithic structure, or the walls316,318and320may be separate walls joined together by, for example, welds. The body310also includes an opening322and a lead-in324between the first and second walls316and318. The lead-in324is configured and dimensioned to permit a run conductor710and a branch conductor712to pass into and be received by the opening322. It is noted that in the exemplary embodiment shown inFIGS.15and16, the run conductor portion312and the branch conductor portion314are configured and dimensioned with inner surfaces316aand318ashaped to receive conductors, e.g., a run conductor710and a branch conductor712. The configuration of the openings322and the lead-in324can vary depending upon the size of the conductor to be crimped. As a non-limiting example, the conductor can range from about 250 Kcmil to about 750 Kcmil.

The first wall316, in this exemplary embodiment, is a U-shaped like structure configured such that when a run conductor710is passed into the opening322via lead-in324, the connector300can rest on the run conductor710prior to a crimping operation. The second wall318, in this exemplary embodiment, is a U-shaped like structure configured to receive at least partially a branch conductor712passed into the opening322via lead-in324, as seen inFIG.19. This permits a technician to set-up and operate a crimping tool without having to hold the connector300as well.

The connector300may also include one or more insulation piercing members330extending from an inner surface of the one or more walls316,318and/or320of the body310. In the embodiment shown, a single insulation piercing member330extends from an inner surface316aof the first wall316into the opening322, and a single insulation piercing member330extends from an inner surface318aof the second wall318into the opening322. The one or more insulation piercing members330may be integrally or monolithically formed into one or more walls316,318and/or320and extend into the opening322. However, the one or more insulation piercing members330may be separate members secured to the connector body310using, for example, the above-described sliding dove-tail type connection joint. In the embodiment shown, a single insulation piercing member330is monolithically formed in the first wall316of the connector body310, and a single insulation piercing member330is monolithically into the second wall318of the conductor body310so that the insulation piercing members330extend from the respective walls316and318into the opening322.

Each insulation piercing member330includes a tip member332that is configured and dimensioned to pierce or cut through the insulation jacket surrounding a run conductor710or the branch conductor712when the connector300is crimped such that the electrical wires within the conductors710and712contact the respective insulation piercing member330to create an electrical path between the connector300, the run conductor710and the branch conductor712, similar to the connection shown inFIG.16. Each tip member332is, in this exemplary embodiment, a triangular shaped member extending from the respective wall316or318of the body310into the opening322. More specifically, the tip member332includes two side walls332aand332bextending away from the wall316or318of the body310and are joined to form a piercing tip332c. The piercing tip332cis configured and dimensioned to pierce or cut through the insulation jacket surrounding the electrical wire in a run conductor710or a branch conductor712as noted above.

Each tip member332has a length “L3” that is less that the width “W1” of the body310. The length “L3” of the tip member332should be sufficiently less than the width “W1” of the body310so that the insulation jacket120applied to the body310surrounds the junction between the walls316and318and the insulation piercing members330. By having the length “L3” of the tip members332less than the width of the body310, a seal can form between the connector300and a run conductor710or a branch conductor712when the conductor is crimped to the connector300. This seal minimizes and possibly prevents water and/or gas from contacting each insulation piercing member330. As a non-limiting example, if the width “W1” of the body310is about 1 inch, the length “L3” of the tip member332would preferably be about ½ inch and the tip member332would be centered along the width “W1” of the body310as shown inFIG.15. As such, in this exemplary embodiment, the length “L3” of the tip member332is ½ the width “W1” of the body310. In this exemplary embodiment, the body332is typically formed by an extrusion process, metal casting process or a machining process where the insulation piercing members310are formed as part of the extrusion process, metal casting process or the insulation piercing member is machined as part of the body310. In order to harden the insulation piercing members330, the insulation piercing members can be put through a conventional hardening process, such as heating and then rapidly cooling the insulation piercing member.

Although the insulation piercing members330are described above as a triangular shaped members, the insulation piercing members330may come in different shapes and sizes configured and dimensioned to pierce or cut through insulation surrounding electrical wires, such as a cone-shaped member or a member with a pointed tip. Further, the insulation piercing members330may include a serrated tip to assist in the piercing through insulation surrounding the electrical wires.

Once the connector body310is formed, the connector body, including the insulation piercing members330, are coated with a flexible insulating material to form the insulation jacket120around the connector body310that permits a seal to form between the connector body310and a run conductor700or a branch conductor710when the conductors are crimped to the connector300. This seal minimizes and possibly prevents water and/or gas from contacting the insulation piercing members330. Non-limiting examples of the flexible insulating material include Polyvinyl Chloride (PVC), ethylene propylene diene monomer (EPDM) rubber, Santoprene and Plastisol.

In one exemplary embodiment, to coat the conductor body310with the flexible insulating material, the conductor body310is, for example, dipped into a vat of liquid insulating material and then removed allowing the coating of insulating material to harden to form the insulation jacket120. In another exemplary embodiment, the conductor body310may be coated with the flexible insulating material by an injection moulding process. Once the coating hardens, the portion of the insulating jacket120covering the tip members332of the insulation piercing members330is removed to expose the tip members332, as seen inFIG.15.

Referring now toFIGS.17and18, another exemplary embodiment of a connector according to the present disclosure is shown. In this exemplary embodiment, the connector350includes a body360having a run conductor portion362and a branch conductor portion364. The body360is an S-shaped like member having a first wall366, a second wall368and a third wall370joining the first wall to the second wall. As such, the first wall366and a portion of the third wall370form the run conductor portion362, and the second wall368and a portion of the third wall370form the branch conductor portion364. The first, second and third walls366,368and370may be a unitary or monolithic structure, or the walls366,368and370may be separate walls joined together by, for example, welds. The body360includes a run opening372and a first lead-in374between the first wall366and a portion of the third wall370. The first lead-in374is configured and dimensioned to permit a run conductor710pass into and be received within the run opening372. The body360also includes a branch opening376and a second lead-in378between the second wall368and a portion of the third wall370. The second lead-in378is configured and dimensioned to permit a branch conductor712pass into and be within the branch opening376.

The first wall366, in this exemplary embodiment, is a U-shaped like structure configured such that when a run conductor710is passed into the opening372via lead-in374, the connector350can rest on the run conductor710prior to a crimping operation. The second wall368, in this exemplary embodiment, is a U-shaped like structure configured to receive at least partially a branch conductor712passed into the opening376via lead-in378, as seen inFIG.17. This permits a technician to set-up and operate a crimping tool without having to hold the connector350as well.

The connector350may also include one or more insulation piercing members380extending from an inner surface of the one or more walls366,368and/or370of the body360. In the embodiment shown, a single insulation piercing member380extends from an inner surface366aof the first wall366into the first opening372, and a single insulation piercing member380extends from an inner surface368aof the second wall368into the second opening376. Each insulation piercing member380may be integrally or monolithically formed into one or more walls366,368and/or370and extend into the first opening372and/or the second opening376. Each insulation piercing member380includes a tip member382that is configured and dimensioned to pierce or cut through insulation surrounding a run conductor710or the branch conductor712when the connector350is crimped such that the electrical wires within the conductors710and712contact the respective insulation piercing member380to create an electrical path between the connector350, the run conductor710and the branch conductor712. Each tip member382is, in this exemplary embodiment, a triangular shaped member extending from the respective wall366or368of the body360into the respective opening372or376. More specifically, each tip member382includes two side walls382aand382bextending away from the wall of the body360and are joined to form a piercing tip382c. The piercing tip382cis configured and dimensioned to pierce or cut through the insulation jacket surrounding the electrical wire in a run conductor710or a branch conductor712when the connector350is crimped, and to contact the electrical wire within the run conductor710or the branch conductor712to create the electrical path between the connector350and the conductors710and712, similar to the connection shown inFIG.18.

Each tip member382has a length “L3” that is less that the width “W1” of the body360. The length “L3” of the tip member382should be sufficiently less than the width “W1” of the body360so that the insulation jacket120applied to the body360surrounds the junction between the walls366and368and the insulation piercing members380. By having the length “L3” of the tip members382less than the width of the body360, a seal can form between the connector350and a run conductor710or a branch conductor712when the conductor is crimped to the connector350. This seal minimizes and possibly prevents water and/or gas from contacting each insulation piercing member380. As a non-limiting example, if the width “W1” of the body360is about 1 inch, the length “L3” of the tip member382would preferably be about ½ inch and the tip member382would be centered along the width “W1” of the body360as shown inFIG.21. As such, in this exemplary embodiment, the length “L3” of the tip member382is about ½ the width “W1” of the body360. In this exemplary embodiment, the body360is typically formed by an extrusion process, metal casting process or a machining process where the insulation piercing members380are formed as part of the extrusion process, metal casting process or the insulation piercing member is machined as part of the body360. In order to harden the insulation piercing members380, the insulation piercing members can be put through a conventional hardening process, such as heating and then rapidly cooling the insulation piercing member.

Although the insulation piercing members380are described above as a triangular shaped member, the insulation piercing members380may come in different shapes and sizes configured and dimensioned to pierce or cut through insulation surrounding electrical wires, such as a cone-shaped member or a member with a pointed tip. Further, the insulation piercing members380may include a serrated tip to assist in the piercing through insulation surrounding the electrical wires.

It is noted that in the exemplary embodiment shown inFIGS.17and18, the first conductor portion362and the second conductor portion364are configured and dimensioned with inner surfaces366aand368ashaped to receive conductors, e.g., a run conductor710or a branch conductor712. The configuration of the first opening372and the first lead-in374and the configuration of the second opening376and the second lead-in378can vary depending upon the size of the conductor to be crimped. As a non-limiting example, the conductor can range from about 250 Kcmil to about 750 Kcmil.

Referring now toFIGS.19and20, another exemplary embodiment of the connector of the present disclosure is shown. In this exemplary embodiment, the connector400includes a body410having a run conductor portion412and a branch conductor portion414. The run conductor portion412of the body410is a C-shaped like member having a first wall416, a common wall418and a third wall420joining the first wall416to the common wall418. The branch conductor portion414of the body410is a circular, oval or other shaped member having a second wall422, the common wall418, a side walls424and426joining the second wall422to the common wall418. The walls416,418,420,422,424and426may be a unitary or monolithic structure, or the walls416,418,420,422,424and426may be separate walls joined together by, for example, welds. The run conductor portion412of the body410also includes a first opening428and a first lead-in430between the first wall416and a portion of the common wall418. The lead-in430is configured and dimensioned to permit a run conductor710to pass through the lead-in430into the opening428. The branch conductor portion414of the body410also includes a second opening432between the second wall422and a portion of the common wall418.

The first wall416, in this exemplary embodiment, is a U-shaped like structure configured such that when a run conductor710is passed into the opening428via the lead-in430, the connector400can rest on the run conductor710prior to a crimping operation, as seen inFIG.19.

Continuing to refer toFIGS.19and20, the run conductor portion412of the body410may also include one or more insulation piercing members440extending from an inner surface of the one or more walls416,418and/or420toward the first opening428. Each insulation piercing member440may be integrally or monolithically formed into the one or more walls416,418and/or420, or each insulation piercing member may be a separate structure secured to the one or more walls416,418and/or420using, for example, a friction fit or welds. In the embodiment shown, a single insulation piercing member440extends from an inner surface416aof the first wall416into the first opening428. The branch conductor portion412of the body410may also include one or more insulation piercing members440extending from an inner surface of the one or more walls418,420and/or422toward the second opening432. Each insulation piercing member440may be integrally or monolithically formed into the one or more walls418,420and/or422, or each insulation piercing member may be a separate structure secured to the one or more walls418,420and/or422using, for example, a friction fit or welds. In the embodiment shown, a single insulation piercing member440extends from an inner surface418aof the common wall418into the second opening432.

Each insulation piercing member440includes a tip member442that is configured and dimensioned to pierce or cut through insulation surrounding a run conductor710or the branch conductor712when the connector400is crimped such that the electrical wires within the conductors710and712contact the respective insulation piercing member440to create an electrical path between the connector400, the run conductor710and the branch conductor712. Each tip member442is, in this exemplary embodiment, a triangular shaped member extending from the respective wall416or418of the body410into the respective opening428or432. More specifically, each tip member442includes two side walls442aand442bextending away from the wall of the body410and are joined to form a piercing tip442c. The piercing tip442cis configured and dimensioned to pierce or cut through the insulation jacket surrounding the electrical wire in a run conductor710or a branch conductor712when the connector400is crimped, and to contact the electrical wire within the run conductor710or the branch conductor712to create the electrical path between the connector400and the conductors710and712, similar to the connection shown inFIG.20.

Each tip member442has a length “L3” that is less that the width “W1” of the body360. The length “L3” of the tip member442should be sufficiently less than the width “W1” of the body410so that the insulation jacket120applied to the body410surrounds the junction between the walls416and418and the insulation piercing members440. By having the length “L3” of the tip members442less than the width of the body410, a seal can form between the connector400and a run conductor710or a branch conductor712when the conductor is crimped to the connector400. This seal minimizes and possibly prevents water and/or gas from contacting each insulation piercing member440. As a non-limiting example, if the width “W1” of the body410is about 1 inch, the length “L3” of the tip member442would preferably be about ½ inch and the tip member442would be centered along the width “W1” of the body410as shown inFIG.19. As such, in this exemplary embodiment, the length “L3” of the tip member442is about ½ the width “W1” of the body410. In this exemplary embodiment, the body410is typically formed by an extrusion process, metal casting process or a machining process where the insulation piercing members440are formed as part of the extrusion process, metal casting process or the insulation piercing member is machined as part of the body410. In order to harden the insulation piercing members440, the insulation piercing members can be put through a conventional hardening process, such as heating and then rapidly cooling the insulation piercing member.

Although the insulation piercing members440are described above as a triangular shaped member, the insulation piercing members440may come in different shapes and sizes configured and dimensioned to pierce or cut through insulation surrounding electrical wires, such as a cone-shaped member or a member with a pointed tip. Further, the insulation piercing members440may include a serrated tip to assist in the piercing through insulation surrounding the electrical wires.

It is noted that in the exemplary embodiment shown inFIGS.19and20, the first conductor portion412and the second conductor portion414are configured and dimensioned with inner surfaces shaped to receive conductors, e.g., a run conductor710or a branch conductor712. The configuration of the first opening428and the first lead-in430and the configuration of the second opening432can vary depending upon the size of the conductor to be crimped. As a non-limiting example, the conductor can range from about 250 Kcmil to about 750 Kcmil.

As shown throughout the drawings, like reference numerals designate like or corresponding parts. While illustrative embodiments of the present disclosure have been described and illustrated above, it should be understood that these are exemplary of the disclosure and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is not to be considered as limited by the foregoing description.