Abstract:
In accordance with one aspect of the invention, an electrical wedge connector assembly is disclosed. The assembly comprises a shell, an eye bolt and a wedge sized and shaped to be inserted into the shell for connecting two conductors to each other. The eye bolt comprises a swivel joint adapted to be inserted into the wedge.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to electrical clamps and, more particularly, to a wedge connector assembly. 
     2. Background Information 
     U.S. Pat. No. 4,339,942 discloses an electric tap connector with a wedge that is moved into the shell by a bolt. U.S. Pat. No. 5,367,251 discloses a tool for grasping an electrical power conductor. The tool has a plurality of pointed pins mounted on a movable platform to pierce cable sheathing and insulation and contact a conductor of a cable held in place by the tool. U.S. Pat. No. 5,916,001 discloses a wedge connector with a shell and a wedge. The shell has insulation piercing sections to pierce through insulation of electrical conductor cables. 
     Despite the above advances, there is a desire for an improved wedge hot line clamp or wedge connector assembly suitable for connecting an overhead distribution current carrying conductor to another. The present invention addresses this need and others. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, an electrical wedge connector assembly is disclosed. The assembly comprises a shell, an eye bolt and a wedge sized and shaped to be inserted into the shell for connecting two conductors to each other. The eye bolt comprises a swivel joint adapted to be inserted into the wedge. 
     In accordance with another aspect of the present invention, an electrical wedge connector assembly is disclosed. The assembly comprises a shell, a wedge and an eye bolt. The shell is a one-piece member having a general “0” shaped cross-section and tapers from a first end to a more narrow second end. The wedge is sized and shaped to be inserted into the shell for connecting two conductors to each other. The eye bolt comprises a swivel joint adapted to be inserted into the wedge. 
     In accordance with a further aspect of the invention, a method of connecting two conductors using a wedge connector assembly is disclosed. The method comprises providing an electrical wedge connector. The wedge connector comprises a shell and a wedge sized and shaped to be inserted into the shell for connecting the two conductors to each other, wherein the shell comprises a protrusion having a first end and a second end. The method also comprises providing an eye bolt comprising a first end and second end and inserting the second end of the eye bolt through the protrusion so that the second end of the eye bolt extends from the second end of the protrusion. The method further comprises securing a first end of a swivel joint to the second end of the eye bolt and securing a second end of the swivel joint to the wedge; and rotating the eye bolt to position the wedge between the two conductors. Advantageously, the wedge rubs against the conductors creating a wiping action in which surface oxides are removed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein: 
         FIG. 1  is a perspective view an electrical wedge conductor assembly incorporating features of an embodiment of the invention; 
         FIG. 2  is a cross-sectional view of  FIG. 1 , also showing cables A and B; 
         FIG. 3  is a top view of  FIG. 2   
         FIG. 4  is a bottom view of  FIG. 2 ; 
         FIG. 5  shows view B of  FIG. 4 ; and 
         FIG. 6  shows a screw and wire assembly, in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIGS. 1 and 2 , there is shown an electrical wedge connector assembly  10  incorporating features of the present invention. Although the present invention will be described with reference to the embodiments shown in the drawings, it should be understood that the present 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 wedge connector assembly  10  comprises a shell  12  and a wedge  14 . The shell  12  is typically a one-piece member that may be made of any suitable material of significant strength to withhold the clamping forces during operation, including sheet metal. The shell  12  may also be a cast, drawn or extruded member. Preferably, shell  12  is a cast, copper body. The shell  12  has two opposing channel sections  16  and  18  interconnected by a middle section, or cavity  20  to form a general “0” or oval shape with a receiving area  22  for receiving the wedge  14  and the cables A, B. The “0” shape tapers from a first end  24  to a more narrow second end  26 , as shown in FIG.  1 . The thickness of the shell  12  may also be any suitable thickness capable of withstanding internal forces created by wedge  14  during operation, including electromechanical forces typically experienced during high fault current conditions. 
     Located at the first end  24  typical ly is a protrusion  28 , which is preferably cast with the shell  12  as part of the one-piece member. The protrusion  28  may be of any suitable shape and size having a threaded aperture  30  therein through which an eye bolt  32  may be inserted. Preferably, the protrusion  28  is of a width larger that the diameter of the eye bolt  32 , as shown in  FIGS. 1-2  and  5 , and cast in block form as a threaded block along with the casting of shell  12 . 
     The eye bolt  32  has a first end  34 , a second end  36  and a ring  38 , as also shown in  FIGS. 1-2  and  5 . The ring  38  may be engaged by a suitable tool and turned during installation or removal of the wedge connector assembly  10 . Preferably, the ring  38  is welded to the first end  34  of the eye bolt  32 . Alternatively, the ring  38  may be forged and cast as a continuous piece of the eye bolt  32 . 
     The second end  36  of the eye bolt  32  may be inserted into a first end  37  of the protrusion or threaded block  28  such that the second end  36  of the eye bolt  32  protrudes through a second end  39  of the protrusion, or threaded block  28 , as shown in FIG.  2 . The second end  36  of the eye bolt  32  also includes a threaded aperture  40  through which a swivel joint  42  may be inserted, as shown in FIG.  2 . The swivel joint  42  may be made of any suitable material and is preferable made of a metal, such as steel. The swivel joint  42  includes a first end  44  and a second end  46 , which are interconnected by a ball bearing mechanism  48  including a cup or socket and a ball. The ball may be snapped into the socket to create a joint in which the ball moves within the socket to allow rotary motion of the second end  46  of the swivel joint  42  at low coefficient friction. Advantageously, swivel joint  42  allows the forward motion of the wedge  14  during operation and provides a direct drive action as opposed to a worm drive mechanism of action. As the eye bolt  32  moves forward during operation friction is advantageously reduced. The negative effect of friction translates into lower contact force between cable A or tap conductor, wedge  14  and cable B or bail. Advantageously, the ball bearing mechanism  48 , may have a lower coefficient property several times that of a rotating threaded rod on a fixed surface of similar material. The ball bearing mechanism  48  transfers greater torque into desired clamping forces by reducing friction. 
     The first end  44  of swivel joint  42  may be secured to the eye bolt  32  by insertion into the threaded aperture  40 , as shown in  FIGS. 1-2  and  5 . The second end  46  of swivel joint  42  may be secured to the wedge  14 , as described below. The first end  44  and the second end  46  are preferably in the form of threaded pins, or a rod. 
     The wedge  14  generally comprises a frame  50  and is preferably a one-piece copper member with two cable contact surfaces  52 ,  54 . The wedge  14  preferably comprises a threaded aperture  58  into which the second end  46  of the swivel joint  42  may be inserted. 
     As shown in  FIGS. 3-4 , the wedge connector assembly  10  may also comprise a drain hole  56  preferably extending through the length of the wedge  14  for the draining of any residual water or fluid. 
     During operation, the wedge connector assembly  10  may be conventionally mounted on an elongated pole (not shown). Similarly, a non-conductive material may be used for turning of the eye bolt  32  by an operator working at a distance from an overhead cable. For example, an elongated pole of non-conductive material, such as glass fiber reinforced plastic, may be employed for manipulating the wedge connector assembly  10 . The elongated pole typically has a retractable hook for engaging the ring  38  or eye. Rotation of the elongated pole serves to rotate the hook on the pole and to screw the eye bolt  32  typically upwards or downwards for positioning the wedge  14 , which may also move in an upwards or downwards position, in the receiving area  22 . 
     As also shown in  FIGS. 1-2 , the cable A or tap conductor, as well as cable B or bail, may be secured within shell  12  by placing the cables within shell  12  and tightening eye bolt  32  until the wedge  14  compresses against the opposing channel sections  16  and  18  of the shell. While the eye bolt  32  is being so tightened, the second end  46  of the swivel joint  42  transfers force into the wedge  14  to ensure a tight press-fit therewithin. Several turns of the eye bolt  32  may be all that is needed to ensure the desired clamping forces between cable A or tap conductor, the wedge  14 , and cable B or bail. Eye bolt  32  may then be turned in the opposite direction to withdraw the fixed components of the wedge  14 , steel swivel  42  with both ends  46  and  40 . This will reduce the contact forces from cable A or tap conductor and cable B or bail. This will allow connector assembly  14  to be isolated from fixed cable B or bail. 
     The cable A or lead conductor may also be securely attached to the channel section  16  of the shell  12  by any suitable device prior to operation of the eye bolt  32 . For example, as shown in  FIG. 6 , a screw and wire device  60  may be employed for securing the cable A to the shell  12 . In particular, attached to outer shell  12  with use of a self tapping screw may be a flexible thin wire. The wire may be wrapped several times by the installer around cable A or tap conductor and continue back to the tap screw. Several additional wraps of the flexible thin wire around the tap screw may restrain or tightly secure cable A or tap conductor to connector assembly  10 . This will allow the installer to approach the cable B or bail for connection with the connector assembly  10  and secured cable A or tap connector with use of the afore-mentioned elongated pole, in accordance with an embodiment of the invention. 
     The design of the wedge connector assembly  10  offers many advantages. For example, use of swivel joint  42  reduces friction and transfers more torque from the eye bolt  32  to the wedge  14  creating a greater clamping force. The eye bolt  32  also advantageously transfers torque from a hot stick or other conventional elongated pole through the swivel joint  42  to directly drive the wedge  14  tightly between the cables, such as a bail and lead wire or conductor. 
     Additionally, use of wedge  14  mechanically driven between the afore-described cables with use of swivel joint  42  provides oxide removing abrasion action or a wiping action on both of the cables. This is particularly advantageous when a copper cast wedge  14  is mechanically driven between a bail and lead conductor. Often, conductors must be wire brushed prior to application of a clamping mechanism to remove surface oxides. Surface oxides are known to increase electrical resistance at contacts points. Such oxide films may cause poor electrical contact and result in disadvantageous overheating. The afore-described wiping action provided by embodiments of the invention provides a much needed solution to a problem encountered with some prior clamping mechanisms. 
     Another advantage of embodiments of the invention is that Applicant&#39;s hot line clamp or wedge connector assembly may be used by operators to efficiently mechanically connect an overhead distribution current carrying conductor to another. 
     Further advantages of embodiments of the invention include use of a fully enclosed copper case housing or shell  12  that may produce secureness properties greater then a “C” shaped housing, which is advantageous during high mechanical stress periods created by fault current on the electrical distribution lines. 
     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. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.