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

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority under 35 U.S.C. §119(e) on U.S. Provisional Patent Application No. 61/133,713 filed Jul. 1, 2008 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 for connecting multiple conductors to a main conductor. 
     2. Brief Description of Prior Developments 
     U.S. Pat. No. 4,985,003 discloses an electrical connector with a nut and bolt for compressing two jaws together. U.S. Pat. No. 5,704,816 discloses a hinged electrical connector having a nut and bolt connecting two jaw members. 
     SUMMARY 
     The following summary is merely intended to be exemplary. The summary is not intended to limit the scope of the claimed invention. 
     In accordance with one aspect of the invention, an electrical connector is provided including a first connection section adapted to connect to a first electrical conductor; and a second connection section adapted to connect to a second electrical conductor. The first and second connection sections include a first member, a second member and a compression member for compressing the second member towards the first member. The second member is pivotably connected to the first member at a rotating pivot which is spaced from the compression member and the second connection section. 
     In accordance with another aspect of the invention, an electrical connector is provided comprising a first member and a second member. The first member comprises a first end and a second end. The first member comprises a metal plate with insulation piercing teeth at the first end for connection to a first conductor and a second conductor connection section at the second end. The second end comprises a pivot post extending from the second end. The second member is rotatably connected to the first member on the pivot post. The second member is adapted to press the first conductor into the teeth of the metal plate. 
     In accordance with another aspect of the invention, an electrical connector is provided comprising a first connection section adapted to connect to a first electrical conductor; and a second connection section adapted to connect to a second electrical conductor. The first and second connection sections comprise a first member, a second member pivotably connected to the first member, and a compression member for compressing the second member towards the first member. The second member is adapted to compress the first conductor against the first member. The first member is adapted to connect to the second electrical conductor without the second member contacting the second conductor. 
    
    
     
       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 top plane view of one embodiment of the invention shown attached to first and second conductors; 
         FIG. 2  is a side view of the electrical connector and electrical conductors shown in  FIG. 1 ; 
         FIG. 3  is a cross sectional view taken along line  3 - 3  of  FIG. 1 ; 
         FIG. 4  is a cross sectional view taken along line  4 - 4  of  FIG. 2 ; 
         FIG. 5  is a plane top view of an alternate embodiment of the invention; 
         FIG. 6  is an exploded cross sectional view taken along line  6 - 6  of  FIG. 5 ; 
         FIG. 7  is a perspective view of another alternate embodiment of the invention; 
         FIG. 8  is a perspective view of another alternate embodiment of the invention; 
         FIG. 9  is a plane top view of the electrical connector and electrical conductors shown in  FIG. 8 ; 
         FIG. 10  is a cross sectional view taken along line  10 - 10  in  FIG. 9 ; 
         FIG. 11  is a side view of the electrical connector and electrical conductors shown in  FIG. 8 ; 
         FIG. 12  is a cross sectional view taken along line  12 - 12  in  FIG. 11 ; 
         FIG. 13  is a plane top view of another alternate embodiment of the invention; 
         FIG. 14  is an exploded cross sectional view of the electrical connector and electrical conductors shown in  FIG. 13 ; 
         FIG. 15  is a perspective view of another alternate embodiment of the invention; 
         FIG. 16  is a plane top view of another alternate embodiment of the invention; 
         FIG. 17  is an exploded cross sectional view taken along line  17 - 17  in  FIG. 16 ; 
         FIG. 18  is a cross sectional view similar to  FIG. 17 , but showing the members assembled; 
         FIG. 19  is an enlarged view of a section of  FIG. 18 ; 
         FIG. 20  is a perspective view of another embodiment of the invention; 
         FIG. 21  is a perspective view of one of the metal plates used in the connector shown in  FIG. 7 ; 
         FIG. 22  is a perspective view of one of the metal plates used in the connector shown in  FIG. 15 ; and 
         FIG. 23  is a perspective view of one of the metal plates used in the connector shown in  FIG. 20 . 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Referring to  FIGS. 1 and 2 , there is shown an electrical connector  10  incorporating features of the invention. Although the invention will be described with reference to the example embodiments shown in the drawings, it should be understood that the invention can be embodied in many alternate forms of embodiments and concepts of electrical contacts. In addition, any suitable size, shape or type of elements or materials could be used. 
     The connector  10  is configured to connect tap conductors  14  to a main conductor  12 . The main conductor  12  could be a cable in a power distribution system for example. The main conductor  12  includes an electrically conductive core  16  (such as wound conductor strands for example) and outer electrical insulation  18 . The tap conductors  14  each also include an electrically conductive core  16  (such as wound conductor strands for example) and outer electrical insulation  18 . 
     The connector  10  generally comprises a first member or jaw  20 , a second member or jaw  22 , and a compression connector  24 . Referring also to  FIGS. 3-6 , the first member  20  comprises a first end  26 , an opposite second end  28 , and a hole  30  between the two ends  26 ,  28 . A top side of the first end  26  has insulation piercing teeth  32  arrange in a channel. The teeth  32  form a first connection section. The middle section has a post  31  extending from the top side. The hole  30  extends through the post  31 . The second end  28  has conductor receiving holes  34  extending into a bottom side of the second end  28 . Threaded holes  36  intersect with the holes  34 . The threaded holes  36  extend into two opposed lateral sides of the second end  28 . A top side of the second end  28  has two upward extending, laterally spaced pivot posts  44 . Each post  44  has a pivot pin receiving area in its top side. 
     In this embodiment, as best seen in  FIG. 4 , the first member  20  comprises metal plates  38 ,  40  and an overmolded body  42  of plastic material. The plates  38  have the teeth  32  at one end and intersect the holes  34  at an opposite end. The teeth  32  of the first plate  38  are generally spaced and parallel to the teeth  32  of the second plate  38 . The plates  40  form fastener plates with the threads for the holes  36 . The holes  34  are generally orthogonal to the holes  36 , and are located between one of the conductor plates  38  and one of the fastener plates  40  at each lateral side. However, in an alternate embodiment any suitable arrangement of members could be used to form the first member  20 . 
     The second member  22  is preferably a one piece member, such as made of metal for example. The second member  22  comprises a first end  46 , a second end  48  and a hole  50  in a middle section. The first end  46  has a bottom side with a conductor contact surface  52 . The second end  48  has pivot posts  54  which extend laterally outward from opposite sides of the second end  48 . The hole  50  has a general oval shape when viewed from above, but a funnel shape when viewed in cross section as seen in  FIGS. 3 and 6 . 
     The compression connector  24  comprises a bolt  56  and a fastener  58 . The bolt  56  has a head  57  located on the bottom side of the first member  20 . The bolt  58  extends through the hole  30 . The fastener  58  is screwed onto the bolt  56 . The fastener  58  has a flat washer  60  and an O-ring friction member  62 . The bolt  56  extends through the hole  50 . A portion of the post  31  having the hole  30  extends into the hole  50 . The flat washer  60  contacts the top surface of the second member  22  at lateral sides of the top of the hole  50 . 
     The pivot posts  54  are located in respective ones of the receiving pivot slots of the pivot posts  44 . The pivot posts  44 ,  54  form a rotating pivot which is spaced from the compression connector  24  and the second connection section formed at the fasteners  64 . 
     The main conductor  12  is captured between the surface  52  and the channel having the teeth  32 . When the nut  58  is tightened on the bolt  56 , the main conductor  12  is pressed into the teeth  32  of the plates  38  by the second member  22 . The teeth  32  pierce through the insulation  18  and make electrical contact with the conductor core  16  of the main conductor  12 . Thus, the plates  38  are electrically connected to the main conductor  12 . The hole  50  provides sufficient spacing for the post  31  to allow pivotal movement of the second member  22  on the first member  20  as the fastener  58  is being tightened on the bolt  56 . 
     The connector  10  includes threaded fasteners  64 , such as bolts. The fasteners  64  are threaded into the holes  36 . Ends of the tap conductors  14 , having their insulation  18  removed at those ends, are inserted into the holes  34 . The fasteners  64  contact the ends of the tap conductors  14  and press the ends against the outward facing lateral sides of the metal plates  38 . Thus, this forms a mechanical gripping of the ends of the conductors  14  in the holes  34 , and electrical connection of the tap conductors  14  to the main conductor  12  via the plates  38 . 
     Referring also to  FIG. 7 , an alternate embodiment of the electrical connector is shown. In the embodiment shown in  FIGS. 1-6 , the second end  28  and tap conductor receiving holes  34  where arranged in an array of four 2-by-2 holes. In this embodiment, the electrical connector has a first member  20 ′, the second member  22  and the connector  24 . The first member  20 ′ is identical to the first member  20 , but it has a second end  28 ′ which has four tap conductor receiving holes arranged in an array as a series in line with each other. The threaded holes  36 ′ for the fasteners  64  all extend into a same side of the second end  28 ′. The first end of the plates  38 ′ have the teeth  32  (see  FIG. 3 ), and the opposite second ends of the plates  38 ′ have bent sections for the fasteners  64  to press the conductors  14  against.  FIG. 21  shows an example of one of the plates  38 ′. 
     Referring also to  FIGS. 8-14  another alternate embodiment of the invention is shown. In this embodiment the electrical connector  66  has the same second member  22  and fastener  24 , but a different first member  68 . The first member  68  has the first end  26  and post  31  with the hole  30  in the middle section. 
     The first member  68  has two metal plates  72  and the overmolded plastic housing or body  74 . Each metal plate  72  has a first end with the teeth  32  at the first end  26  and a second end having two sets of teeth  76 . The teeth  76  are sized and shaped to pierce through the insulation  18  of the tap conductors  14  to electrically and mechanically connect with the conductive cores  16  of the tap conductors  14 . The body  74  has slots  78  extending inward from the lateral and top sides of the body  74 . The metal plates  72  are located in the slots  78 . Thus, the tap conductors  14  can be inserted into the slots  78  from a top side of the body  74 , into the teeth  76 , and extend out lateral sides of the body. Caps  80  can be used to cover the top sides of the slots  78 . The caps are shown connected to the second end  70 ′ of the first member by living hinges. However, the caps  80  could be separate members. The caps  80  can be used to push the tap conductors  14  into the teeth  76 . In this embodiment the caps  80  have snap-lock latches  82  which can engage latch teeth  84  in the slots  78  to retain the caps  80 . The latch teeth  84  extend downward for a distance to allow the attachment of the caps  80  to be range taking for different size conductors  14 . For example,  FIGS. 8-14  show different size diameter conductors  14 . The arrangement of the teeth  76  is also range taking to enable use with the different size diameter conductors  14 . Thus, the teeth  76  are provided for piercing through insulation  18  for connection to the tap conductors  14 . This allows connection with the tap conductors  14  without having to first remove the insulation  18  from the ends of the conductors  14  as is done in the first and second embodiments described above. 
     Referring also to  FIG. 15 , an alternate embodiment of the electrical connector  100  is shown. The electrical connector  100  includes a first member  102 , the second member  22  and the connector  24 . The first member  102  is identical to the first member  68  except for its second end. In the embodiment shown in  FIGS. 8-14 , the second end  70  and tap conductor receiving slots  78  where arranged in an array of 2-by-2 slots. In this embodiment, the second end  70 ′ has four tap conductor receiving slots arranged in an array as a series in line with each other. The second end  70 ′ is arranged as two spaced block sections to save material. The tap conductors  14  can all exit a same side of the second end  70 ′. The second ends of the metal plates  72 ′, thus, have a bent or “L” shape as opposed to the straight shape of the second ends of the metal plates  72 . However, each metal plate  72 ′ has the teeth  76  (see  FIG. 14  for the tap conductors  14 ).  FIG. 22  shows an example of one of the plates  72 ′. 
     Referring also to  FIGS. 16-19  another alternate embodiment of the invention is shown. In this embodiment the electrical connector  86  has the same second member  22  and fastener  24 , but a different first member  88 . The first member  88  has the first end  26  and post  31  with the hole  30  in the middle section. The second end  90  of the first member  88  is configured with insulation displacement areas for connection to the tap conductors  14 . This allows connection with the tap conductors  14  without having to first remove the insulation  18  from the ends of the conductors as is done in the first embodiment described above. 
     The first member  88  has two metal plates  92  and the overmolded plastic housing or body  94 . Each plate  92  has a first end with the teeth  32  at the first end  26  and a second end having two sets of insulation displacement connections (IDC)  96 . The IDCs  96  are sized and shaped to slice through opposite side of the insulation  18  of the tap conductors  14  to electrically and mechanically connect with the conductive cores  16  of the tap conductors  14 . The body  94  has slots  98  extending inward from the lateral and top sides of the body  94 . The IDCs are located in the slots  98 . Thus, the tap conductors  14  can be inserted into the slots  98  from a top side of the body  94 , into the IDCs, and extend out lateral sides of the body. Caps  80  can be used to cover the top sides of the slots  98 . The caps  80  can be used to push the tap conductors  14  into the IDCs. In this embodiment the caps  80  have latches  82  which can engage latch teeth  84  in the slots  78  to retain the caps  80 . 
     Referring also to  FIG. 20 , an alternate embodiment of the connector is shown. In the embodiment shown in  FIGS. 16-19 , the second end  90  and tap conductor receiving slots  98  where arranged in an array of 2-by-2 slots. In this embodiment, the second end  90 ′ has four tap conductor receiving slots arranged in an array as a series in line with each other. The second end  90 ′ is arranged as two spaced block sections to save material.  FIG. 23  shows an example of one of the plates  92 ′ used in the connector. The tap conductors  14  can all exit a same side of the second end  90 ′. 
     Embodiments of the invention allow a common upper connector member, such as  22  for example, to be used with a variety of different lower connector members, such as  20 , or  20 ′ or  68  for example. Even though an embodiment of the invention can use two connector parts ( 20  and  22  for example) to clamp onto a first conductor, one of these connector parts ( 22  for example) is not used to connector to the second conductors  14 . The wire connections for the second conductors  14  are merely with the first connector part ( 20  for example). 
     It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. For example, features recited in the various dependent claims could be combined with each other in any suitable combination(s). In addition, features from different embodiments described above could be selectively combined into a new embodiment. Accordingly, the invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.