Abstract:
An electrical connector including a first connection section adapted to connect the electrical connector to a first conductor; and a second connection section connected to the first connection section. The second connection section includes a lug with a plurality of lug portions with at least one weakened section between the lug portions. Each lug portion has a hole adapted to be located onto a respective mounting post. A first one of the lug portions can be removed from a second one of the lug portions at the weakened section to reconfigure the second connection section to have one less lug portion.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit under 35 U.S.C. §119(e) of U.S. provisional patent application No. 60/897,604 filed on Jan. 26, 2007 which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to an electrical connector and, more particularly, to an electrical connector having a connector lug which can be modified. 
     2. Brief Description of Prior Developments 
     Electrical contacts which have a lug with one or more holes for connecting two electrical conductors to each other are well known in the art. For example, FCI USA, Inc. sells BURNDY® one hole and two hole HYLUG™ electrical conductors for connecting a wire or cable to another electrical conductor having one or two connection posts, respectively. The connection post(s) are received in the hole(s) of the lugs. 
     In cases where a two-hole lug is too long for a particular application, installers are cutting the two-hole lugs with saws to make a one-hole lug. The problem is that only the two-hole lug is UL (Underwriters Laboratory, Inc.) approved. Modifications to the two-hole lug could void the UL approval, especially if an installer gets a bit aggressive while removing the extra lug hole portion of the two-hole lug and removes too much material. 
     U.S. Pat. No. 4,753,609 teaches a first metal contact and a second metal contact. The contacts are stamped from the same sheet of metal, and the second contacts are subsequently broken away from the first contacts along a crease. Other art teaches break-away portions to shorten (or extend) overall length. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the invention, an electrical connector is provided including a first connection section adapted to connect the electrical connector to a first conductor; and a second connection section connected to the first connection section. The second connection section includes a lug with a plurality of lug portions with at least one weakened section between the lug portions. Each lug portion has a hole adapted to be located onto a respective mounting post. A first one of the lug portions can be removed from a second one of the lug portions at the weakened section to reconfigure the second connection section to have one less lug portion. 
     In accordance with another aspect of the invention, an electrical connector is provided comprising a first connection section adapted to connect the electrical connector to a first conductor; and a second connection section connected to the first connection section. The second connection section comprises a lug with a plurality of lug portions with at least one weakened section between the portions. Each lug portion has a hole adapted to be located onto a respective mounting post. The electrical connector has a first predetermined electrical quality or performance certification. A first one of the lug portions can be removed from a second one of the lug portions at the weakened section to reconfigure the second connection section to have one less lug portion and provide a modified electrical connector having a second different predetermined electrical quality or performance certification. 
     In accordance with another aspect of the invention, a method of manufacturing an electrical connector is provided comprising providing a first connection section adapted to be connected to a first conductor and a second connection section connected to the first connection section, wherein the second connection section comprises a lug having at least two mounting holes adapted to be mounted onto respective mounting posts; providing the lug with a first lug portion having a first one of the mounting holes and a second lug portion having a second one of the mounting holes, wherein the first lug portion is connected to the first connection section by the second lug portion; and providing a weakened section between the first and second lug portions, wherein the first lug portion is adapted to be broken off of the second lug portion at the weakened section. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing aspects and other features of the invention are explained in the following description, taken in connection with the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of a conventional electrical connector; 
         FIG. 2  is an illustration showing the electrical connector of  FIG. 1  being used to connect two conductors to each other; 
         FIG. 3  is a perspective view of another embodiment of a conventional electrical connector; 
         FIG. 4  is a perspective view of an electrical connector comprising features of the present invention; 
         FIG. 5  is a side view of the electrical connector shown in  FIG. 4  being used to connect two conductors together; 
         FIG. 6  is a side view of the electrical connector shown in  FIG. 4  with a front lug portion removed and being used to connect two conductors together; 
         FIG. 7  is a side view of the electrical connector shown in  FIG. 4 ; 
         FIG. 8  is a side view of an alternate embodiment of the electrical connector shown in  FIG. 7 ; 
         FIG. 9  is a side view of another alternate embodiment of the electrical connector shown in  FIG. 7 ; and 
         FIG. 10  is a perspective view of another alternate embodiment of the electrical connector shown in  FIG. 4 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , there is shown a perspective view of a conventional electrical connector  10 . The connector  10  is a BURNDY® one hole HYLUG™ electrical conductor. The connector  10  generally comprises a tube section  12  forming a cable receiving area with an inspection window  14 , and a lug section  16  with a single hole  18 . As seen with reference to  FIG. 2 , the connector  10  can be mounted on a mounting post  20  of another member  22  to electrically connect a wire or cable  24  to the member  22 . The tube section  12  can be crimped onto the cable  24 . The lug section  16  can be retained on the post  20  by a fastener  26 , such as a threaded nut. 
     Referring also to  FIG. 3 , a perspective view of another conventional electrical connector  28  is shown. The connector  28  is a BURNDY® two hole HYLUG™ electrical conductor. The connector  10  generally comprises a tube section  12  forming a cable receiving area with an inspection window  14 , and a lug section  30  with two holes  18 . The lug section  30  is mounted to another member by receiving two mounting posts; one in each one of the holes  18 . 
     The two hole connector  28  is used rather than the one hole connector  10  because a larger surface area of contact between the connector and the other member (such as along the bottom surface of the lug section) is needed for electrical reasons. However, the one hole connector  10  can be used in some circumstances rather than the two hole connector  28  because the one hole connector  10  can be less expensive than the two hole connector  28 . 
     As can be seen with reference to  FIG. 2 , in some circumstances, because of the environment, only enough space is available for a one hole connector to be used. For example, the distance D between the post  20  and portion  23  of the member  22  might not allow the lug section  30  to be installed. The size of the lug section  30  of the two hole connector  28  would be too large for use in the available area for the connector. However, a user might only have the two hole connector  28  available. In this instance, as noted above, installers are cutting the two-hole lug section  30  with a saw to make a one-hole lug section. The problem is that only the whole connector having the two-hole lug section is UL approved. Modifications to the two-hole lug could void the UL approval, especially if an installer gets a bit aggressive while removing the extra lug hole portion of the two-hole lug. 
     Referring now to  FIG. 4 , a perspective view of a portion of an electrical connector  32  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 connector  32  generally comprises a one-piece metal member having a first connection section  34  and a second connection section  36 . The first connection section  34  could comprise any suitable connection section for connection to another member, such as a tube section to be crimped onto a wire or cable for example. The second connection section  36  is a lug section or pad or tongue having two mounting holes  18  similar to the connector  28  shown in  FIG. 3 . However, the lug section  36  has a front portion  38  and a rear portion  40  connected by a weakened section  42 . The weakened section  42  comprises laterally extending recesses  60 ,  62  along the top and bottom sides of the lug section  36  between the front portion  38  and the rear portion  40 . The weakened section  42  provides a section of the lug which has a different cross section than the rest of the lug. Preferably, this reduced cross section is weaker than the cross section of the lug at the holes  18 . In alternate embodiments, only the top side recess  60  or the bottom side recess  62  could be provided. In another alternate embodiment one or both recesses could comprise a series of non-connected indentations or holes through the height of the lug section. In alternate embodiments, any suitable type or shape of weakened section could be provided. 
     The weakened section  42  allows a user to separate the front portion  38  from the rear portion  40  in a controlled manner. With multiple connectors  32 , the separation can be performed in a repeatable manner. As shown in  FIG. 5 , the connector  32  can be used to connect the cable  24  to the member  22 ′ without separating the front portion  38 . The lug section  36  can be mounted to the two posts  20  with the fasteners  26 . However, as shown in  FIG. 6 , the same connector can be modified by a user/installer by removing the front portion  38  to form the connector  32 ′ for connection to the member  22 . 
     The separation of the front portion  38  from the rear portion  40  could comprise, for example, the use of pliers to bend the lug section at the weakened section and, through metal fatigue, break the weakened section. As another example, a saw could be used to cut the weakened section with the groove(s) of the weakened section forming a guide for the saw. In an alternate embodiment, more than two lug portions could be provided and more than one weakened section could be provided. 
     With the invention, an existing two-hole lug can be fitted or re-designed with one or more grooves  60 ,  62  so that the two-hole lug can be modified into a one-hole lug as described above. In a preferred method, the connector will be UL approved in both its one-hole version, such as  32 ′ for example, and its multi-hole version, such as  32  for example. Thus, with the invention, a two-hole lug can be modified, in a controlled, reproducible manner into a one-hole lug without voiding the UL approval. 
     Two-hole lugs are known. Cutting two-hole lugs with a saw to make one-hole lugs is also known. Using break-away segments to decrease (or increase) length of an object is also known. However, with the invention, the unexpected result of a guaranteed UL approval for both the two-hole lug and the modified one-hole lug can be provided.  FIGS. 7-9  illustrate that features of the invention can be used with the first and second connection sections angled at different angles relative to each other. 
       FIG. 10  is a partial perspective view of another embodiment of the invention. In this embodiment, The connector  44  generally comprises a one-piece metal member having a first connection section  34  and a second connection section  46 . The first connection section  34  could comprise any suitable connection section for connection to another member, such as a tube section to be crimped onto a wire or cable for example. The second connection section  46  is a lug section having two mounting holes  18  similar to the connector  28  shown in  FIG. 3 . The lug section  46  has a front portion  48  and a rear portion  50  connected by a weakened section  52 . The weakened section  52  comprises inwardly extending recesses  54  at lateral sides of the lug section  46  between the front portion  38  and the rear portion  40 . The weakened section  52  allows a user to separate the front portion  48  from the rear portion  50  in a controlled manner. With multiple connectors  44 , the separation can be performed in a repeatable manner. 
     There are many instances during connector installations in which there is a need to quickly modify a pad or tongue of an electrical connector in order to suit limitations in the installation or in the overall application. Specifically, it is necessary to modify the length or size of a pad/tongue so that a long size pad can be modified to create a short size pad. 
     Current solutions to this dilemma include the use of a vice, hacksaw or other means to cut, shear and remove the material. These are time consuming and “ugly” solutions that could result in inconsistent results at best, or unacceptable results as worst. A solution is needed that will allow for easy modification of existing designs that will provide consistently modified product, safely and still with electrical continuity. 
     The solution is integrated into the design of the invention. A preferred embodiment would include the inclusion of a crease or seam in the pad, which still provides the necessary electrical cross-section if the pad was to be used as-is, but will also allow the user to easily remove the excess pad that may not be needed in the application. The use of a pair of channel-lock pliers or other non-cutting means will allow for an easy, safe, and electrically compliant installation and solve the dilemma faced by installers in the field. 
     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). Accordingly, the invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.