Electrical connector for aluminum conductor composite core (ACCC) cable

A dead end electrical connector assembly including a dead end connector member, a collet, wedges and an outer sleeve. The dead end connector member has a first end section and a second end section. The second end section includes a threaded section. The first end section is adapted to be connected to another member and includes a general bolt head section adapted to be turned by a powered tool to axially rotate the dead end connector member. The front end of the collet includes a threaded section adapted to be threaded onto the threaded section of the dead end connector member. The wedges are inserted directly between the collet and a core member of a cable conductor. The second end section of the dead end connector member is adapted to push the wedges into the collet. The outer sleeve is crimped onto the dead end connector member and the cable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to an electrical connector and, more particularly, to an electrical connector for an aluminum conductor composite core (ACCC) cable.

1. Brief Description of Prior Developments

Aluminum conductor steel reinforced (ACSR) and other traditional energy cables utilize a steel wire core around which aluminum conductor wires are wrapped; a design originally introduced in 1898. Composite Technology Corporation (CTC) of Irvine, Calif. sells a new type of transmission and distribution energy cable; an Aluminum Conductor Composite Core (ACCC) cable. U.S. patent publication Nos. 2004/0132366 A1 and 2005/0129942 A1 describe Aluminum Conductor Composite Core (ACCC) cables. ACCC cables incorporate a light-weight advanced composite core around which aluminum conductor wires are wrapped in a manner similar to traditional energy cables. The composite core replaces the traditional steel wire core. The composite core's lighter-weight, smaller size, and enhanced strength and other performance advantages over traditional steel core allows a ACCC cable to double the current carrying capacity over existing transmission and distribution cables and virtually eliminate high-temperature sag.

There is a need for an electrical connector which can be quickly attached to a cable having a composite core, without crushing or significantly damaging the composite core, and which can provide a good tensile connection between the cable and the connector to allow the cable/connector assembly to be suspended by attachment to transmission towers.

SUMMARY OF THE INVENTION

In accordance with one aspect of the invention, an electrical connector assembly is provided comprising a connector member, a collet, a wedge and an outer sleeve. The connector member has a first end section and a second end section. The first end section comprises a head section adapted to be axially turned by a powered tool to axially rotate the connector member. The collet has a general tube shape. The collet comprises a front end and a rear end. The front end of the collet is fixedly mounted onto the second end section of the connector member. The wedge is located directly between the collet and a core member of a cable conductor. The second end section of the connector member pushes the wedge into the collet as the connector member and the collet are being connected with each other. The outer sleeve is located around the collet. The outer sleeve has a front end which is crimped onto the connector member.

In accordance with another aspect of the invention, a dead end electrical connector assembly is provided including a dead end connector member, a collet, wedges and an outer sleeve. The dead end connector member has a first end section and a second end section. The second end section includes a threaded section. The first end section is adapted to be connected to another member and includes a general bolt head section adapted to be turned by a powered tool to axially rotate the dead end connector member. The front end of the collet includes a threaded section adapted to be threaded onto the threaded section of the dead end connector member. The wedges are inserted directly between the collet and a core member of a cable conductor. The second end section of the dead end connector member is adapted to push the wedges into the collet. The outer sleeve is crimped onto the dead end connector member and the cable.

In accordance with one method of the invention, a method of connecting an electrical connector to an aluminum conductor composite core (ACCC) cable is provided comprising removing conductor wires from an end of the cable to expose a length of a composite core of the cable; locating the exposed composite core inside a collet; inserting wedges between the exposed composite core and the collet; screwing a connector member into the collet, wherein the connector member pushes the wedges into the collet as the collet is screwed with the connector member, and wherein the connector member comprises a general nut shaped end section which is located in a power tool and rotated to axially rotate the connector member and thereby screw the connector member into the collet; and locating an outer sleeve around the collet and crimping the outer sleeve to the connector member and the cable.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIG. 1, there is shown a perspective view of an end of an Aluminum Conductor Composite Core (ACCC) cable2. The ACCC cable incorporate a light-weight advanced composite core4, such as a carbon composite, around which conductor wires6, such as made of aluminum, are wrapped. In the embodiment shown, the wires6include inner strands7surrounded by outer strands8. New transmission conductors with composite cores, as apposed to steel cores, are both lighter and have greater current carrying capacity, allowing more power to flow in existing rights-of way.

Referring also toFIG. 2, a cable and connector assembly10is shown incorporating features of the invention. Although the invention will be described with reference to the exemplary embodiments shown in the drawings, it should be understood that the invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used.

The assembly10includes the cable2and an electrical connector12. In this embodiment the connector12is a dead end connector adapted to mechanically connect the end of the cable2to another member, such as a transmission tower. In alternate embodiments, the connector could comprise any suitably connector function, such as a splice connector for example. Referring also toFIGS. 3 and 4, the connector12generally comprises a dead end connector member14, a collet16, wedges18and an outer sleeve20. In the embodiment shown inFIGS. 3 and 4the outer sleeve20comprises an integral tap or connection plate22for electrically connecting a connector24of another cable assembly26to the assembly10. However, as seen inFIG. 2, the connection plate22need not be provided.

The dead end connector member14comprises a one-piece metal member, such as steel or aluminum, having an eyelet28at a first end section and an opposite second end section30with a threaded section32. The dead end connector member14also comprises a ridge section34. The eyelet28is adapted to be connected to another member, such as a transmission tower. The collet16is preferably a one piece metal member, such as a steel conduit. The collet16has a general tube shape with an inner channel36having a threaded section38at a first end and a tapered section40extending away from the threaded section38.

The wedges18comprise two wedges each having a general C shaped cross-section. However, in alternate embodiments, more than two wedges could be provided. The outer sides of the wedges are smooth to be able to slide against the inside surface of the tapered section40. The inner sides of the wedges are adapted to grip onto the exterior surface of the core4of the cable2. The wedges18are adapted to contact each other when fully inserted into the collet16to prevent crushing of the composite core4. The wedges18have a suitable length, such as about 11 inches in one example, to provide a large contact area with the composite core4to provide a good friction grip which will not come loose at high tensile force, such as about 21 tons.

The outer sleeve20is made of electrically conductive metal, such as aluminum. The outer sleeve20has a general tube shape. The outer sleeve20is located around the collet16. A first end42of the outer sleeve20is located over the ridge section34of the dead end connector member14and crimped or compressed onto the ridge section34to form an electrical and mechanical connection between the outer sleeve20and the dead end connector member14. A second end44of the outer sleeve20is located over the wires6of the cable2and crimped or compressed onto the wires6to form a mechanical and electrical connection with the wires6. Preferably, the force used to crimp the outer sleeve20to the wires6is less than 3000 psi to prevent damage to the composite core4. In the embodiment shown inFIG. 4, the assembly includes a filler sleeve48between the outer sleeve20and the cable2. However, in an alternate embodiment the filler sleeve might not be provided.

Referring now also toFIGS. 5-14, one method of attaching the connector12to the ACCC cable2will be described. As seen inFIG. 5, the filler sleeve48is installed or slid over the ACCC cable. The outer sleeve20is then a slid over the filler sleeve48. As seen inFIG. 6, the inner and outer strands7,8of the wires6are cut to expose a length46of the composite core4. In the embodiment shown, the length46is about 12 inches. The outer strands8can best be cut with a pipe cutter. The installer can install a cable tie to keep the strands together. The inner strands7can be cut with a hacksaw, cutting through a third of the strands and then bending the strands back-and-forth to break them off. In this fashion, the composite core4is not damaged in any way.FIG. 7shows the cable and sleeves ready for installation with the rest of the assembly.

FIG. 8shows the connector member14, wedges18, and collet16ready for installation onto the exposed composite core4. As seen inFIGS. 9 and 10, the collet16is located over the exposed end of the composite core4and the wedges18are inserted into the collet16with the exposed composite core4being located between the wedges18. In the preferred method, a gap50is provided between the rear end52of the collet16and the front end of the wires6. When the wedges18are inserted between the collet16and the composite core4, a small portion of the core4extends past the front end of the wedges, such as about ¼ inch.

As seen inFIG. 11, the dead end connector member14is positioned on the end of the exposed composite core4with the second end30located against the front end of the wedges18. The collet16is then pulled or slid towards the dead end connector member14as illustrated by a arrow54. This helps to push the wedges18inside the collet16and readies the assembly for threading of the collet16to the threaded section32of the dead end connector member14. As seen inFIG. 12, the dead end connector member14can be screwed together with the collets16. A tool can be placed inside the eyelet28and a wrench can be attached to the flat sections56(seeFIG. 9) of the collet to rotate the two members14,16relative to each other. This tightens the dead end connector member14to the collet16to set the wedges18. In a preferred embodiment, the dead end connector member will bottom out at a predetermined distance of the threaded section32, such as about 1 inch.

As seen inFIG. 13, with the collet16threaded onto the dead end connector member14, the wedges18extend slightly past the rear end of the collet16. The gap50provides a space for the ends of the wedges18to move into without encountering interference from the wires6. The gap50also provides a space for aluminum sleeve compression/expansion of the wires6during crimping of the outer sleeve20and filler sleeve48to the wires. Referring toFIG. 14, the cable tie can be cut away from the wires6. The outer sleeve20and filler sleeve48can be slid forward with the outer sleeve20stopping against a butt stop on the dead end connector member14. Referring also toFIG. 2, the front end58of the outer sleeve20can be crimped onto the dead end connector member14. The rear end60of the outer sleeve20can be crimped with the filler sleeve48onto the wires6of the cable2. This completes assembly of the electrical connector12with the cable2. The outer sleeve20provides an electrical connection of the wires6to another member. The connector member14, collet16and wedges18provide a mechanical connection of the composite core4to another member.

Referring now toFIG. 15, a cross sectional view of a splice electrical connector62for connecting two of the ACCC cables2,3to each other is shown. The electrical connector62generally comprises a middle connector member64having a first end66with a first threaded section68and an opposite second end70with a second threaded section72. The electrical connector62also comprises a first section74and a second section76.

The first section74generally comprises a first collet78and a first set of wedges80. The first collet78has a general tube shape. The first collet78comprises a first end82with a threaded section adapted to be threaded onto the first threaded section68of the middle connector member64. The first wedges80are adapted to be inserted directly between the first collet78and a core member of a first cable conductor2. The first end66of the middle connector member64is adapted to push the first wedges80into the first collet78as the middle connector member and the first collet are threaded with each other.

The second section76generally comprises a second collet84and a second set of wedges86. The second collet84has a general tube shape. The second collet84comprises a first end88with a threaded section adapted to be threaded onto the second threaded section72of the middle connector member64. The second wedges86are adapted to be inserted directly between the second collet84and a core member of a second cable conductor3. The second end70of the middle connector member is adapted to push the second wedges86into the second collet84as the middle connector member and the second collet are threaded with each other. In this embodiment, the second collet84and the second set of wedges86are identical to the first collet78and the first set of wedges80. However, in alternate embodiments they could be different.

In the embodiment shown inFIG. 15, each section74,76also comprises a filler sleeve48. The splice connector also comprises two outer sleeves20; one at each of the sections74,76. Assembly of the slice connector62with the two cables2,3is the same as noted above with reference to the dead end connector. The outer sleeves20are crimped onto the ridge sections34of the middle connector member64, and crimped onto the wires of the cables at the filler sleeves48. Thus, the two cables are mechanically connected to each other for high tension by the members64,78,80,84and86, and electrically connected to each other by the outer sleeves20, filler sleeves48and middle member64which could be aluminum. In an alternate embodiment, a single outer sleeve could be provided for both sections74,76.

Referring now also toFIGS. 16 and 17, an alternate embodiment of the dead end connector is shown. The dead end connector90is substantially the same as the dead end connector14. The dead end connector90comprises a one-piece metal member, such as steel or aluminum, having an eyelet28at a first end section and an opposite second end section30with a threaded section32. The dead end connector90also comprises a ridge section34. The eyelet28is adapted to be connected to another member, such as a transmission tower. The dead end connector90also comprises a general bolt head section or general nut shaped end section92. The bolt head section92is adapted to be turned by a powered tool to axially rotate the dead end connector90. For example, the powered tool could comprise an impact, hydraulic or pneumatic wrench. Alternatively, the bolt head section92could be rotated by a non-powered tool, such as a ratchet wrench. In other embodiments the bolt head section92could have a general Allen wrench shape, or Phillips screw driver shape, or slotted screw driver shape, or any other suitable type of shape for relatively quick axial rotation of the dead end connector by a tool.

The bolt head section92can be attached to the rest of the dead end connector90, such as by welding or brazing, or can be formed with the dead end connector as a single member, such as being cast or forged in a single mold. The bolt head section92is located at the end of the eyelet28for relatively easy connection of the tool to the connector90and relatively easy axial rotation of the connector90by the tool, such that the connector90can be quickly screwed into the collet16(seeFIGS. 3,4and8). In this embodiment the exterior of the bolt head section has six flat sides for relatively easy attachment of a mating socket or an adjustable wrench. However, any suitable exterior shape for mating attachment to a socket to allow for joint axial rotation could be provided.

With use of a power wrench and mating socket, the connector90can be more quickly axially rotated than by hand with a manual hand tool. In addition, the torque of the power tool can result in faster screwing of the connector90into the collet16and pushing of the wedges18into the collet. Resistance of the wedges18to be pushed into the collet might otherwise slow down insertion of the wedges into their final position if only a manual hand tool is used to screw the connector into the collet. Thus, with the invention and a suitable power tool, the connector90can be screwed into the collet faster than with a non-powered screwing of the connector into the collet. The head92allows for the attachment of the connector to a standard type of power tool as described about without any specially designed connector head for the power tool. The power tool can use a convention socket in its working head.

Referring now also toFIG. 18, another alternate embodiment of the dead end connector is shown. In this embodiment the dead end connector94has a clevis section96rather than the eyelet section28shown inFIG. 16. The clevis section96has two arms98separated by a slot100. The ends of the arms98have holes102for removably receiving a connector pin or bolt (not shown). The dead end connector94also comprises a general bolt head section or general nut shaped end section92. The bolt head section92is adapted to be turned by a powered tool to axially rotate the dead end connector94. For example, the powered tool could comprise an impact, hydraulic or pneumatic wrench. Alternatively, the bolt head section92could be rotated by a non-powered tool, such as a ratchet wrench. In other embodiments the bolt head section92could be adapted to have a general Allen wrench shape, or Phillips screw driver shape, or slotted screw driver shape, or any other suitable-type of shape for relatively quick axial rotation of the dead end connector by a tool. Attachments to power tools having an Allen wrench shapes, Phillips screw driver shapes, and slotted screw driver shapes are convention in the power tool technologies. In an alternate embodiment the head section92might not be provided. Instead, a power tool working head attachment could be used with a power tool which is specially designed to mate with the eyelet section28of the connector for allowing joint axial rotation of the attachment with the eyelet28by the power tool.

The bolt head section92can be attached to the rest of the dead end connector94, such as by welding or brazing, or can be formed with the dead end connector as a single member, such as being cast or forged in a single mold. The bolt head section92is located at the end of the clevis section96for relatively easy connection of the tool to the connector94and relatively easy axial rotation of the connector94by the tool.

Referring now also toFIG. 19, another alternate embodiment of the invention is shown. In this embodiment the dead end connector110is substantially the same as the dead end connector90. The dead end connector110comprises a one-piece metal member, such as steel or aluminum, having an eyelet28at a first end section and an opposite second end section with a threaded section. The dead end connector110also comprises a ridge section. The eyelet28is adapted to be connected to another member, such as a transmission tower. The dead end connector110also comprises a general bolt head section or general nut shaped end section112. The bolt head section112is adapted to be turned by a powered tool to axially rotate the dead end connector110. For example, the powered tool could comprise an impact, hydraulic or pneumatic wrench.

In this embodiment, the bolt head section112also comprises a hole114. The hole114is adapted to receive a tool, such as an Allen wrench. In another embodiment for example, hole114′ (shown inFIG. 20) may be adapted to receive a Phillips screw driver. In yet another embodiment for example, hole114″ (shown inFIG. 21) may be adapted to receive a slotted screw driver. Thus, the hole is keyed to have a tool inserted into the hole and axially rotated to axially rotate the dead end connector110. In an alternate embodiment, the hole114could be located inside the frame of the eyelet28without having the bolt head section112.