Patent Publication Number: US-8987595-B2

Title: Electrical connector, an insert for an electrical connector and an electrical assembly

Description:
FIELD OF THE INVENTION 
     The present invention is directed to electrical connectors and electrical connector assemblies and more specifically, to a shear bolt connector with an insert. 
     BACKGROUND OF THE INVENTION 
     Utility transmission lines can include electrical connectors and/or electrical connector assemblies positioned overhead or buried underground. For example, known shear bolt connectors serve as underground splices of copper cables between 2/0 AWG to 75 kcmil and for applications up to 35 kV. Shear bolt connectors include a housing for receiving conductors and employ bolts that can be rotated to extend into the housing to physically contact and screw into the conductors to secure the conductors to the housing. 
     Untimely interruptions to electrical transmission can occur when conductors become separated or dislodged from the housing. This can be both time consuming and costly to any power provider. 
     Shear bolt connectors suffer from the drawback that the signals travelling through to the bolt are limited by the amount of contact between the conductor and the bolt. The amount of contact is limited by the threaded end of the bolt and the amount of deformability of the conductor. For example, the threaded end of the bolt limits the amount of contact by creating an uneven interface with the conductor (the conductor can be generally cylindrical and the bolt can have a planar or inconsistent threaded end). The amount of deformability of the conductor limits the amount of contact by limiting the ability of the bolt to penetrate into the conductor, thus limiting the amount of contact. With conductors having little deformability, such limitations increase a risk of the conductors being disconnected from the housing of the electrical connector. In addition, when the bolts directly deform the conductor, strands on the conductor can be severed, thereby reducing the ability to retain tension, especially when the bolts are repeatedly loosened and tightened. 
     An electrical connector, a conductive insert, and an electrical connector assembly, not suffering from one or more of the above drawbacks would be desirable in the art. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In an exemplary embodiment, an electrical connector includes a conductive housing and a conductive insert positioned within the conductive housing, and a bolt position within the conductive housing. The conductive housing includes a configuration for receiving a conductor and being in electrical communication with the conductor through the insert. The bolt is positioned within the housing and positioned to urge the conductive insert against the conductor when the bolt is adjusted. 
     In another exemplary embodiment, a conductive insert for an electrical connector includes engagement features capable of deformably engaging a conductor and a bolt recess positioned on a side opposite the engaging features. The conductive insert includes a curved geometry. 
     In another exemplary embodiment, a connector assembly includes an electrical connector comprising a conductive housing and a conductive insert positioned within the conductive housing, the conductive insert having engagement features and a conductor positioned within the conductive insert. The conductive insert is deformably engaged to the conductor by a bolt positioned within the conductive housing. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an exemplary electrical connector assembly installed between two conductors according to an embodiment of the present invention. 
         FIG. 2  is a cutaway section of an exemplary electrical connector according to an embodiment of the present invention. 
         FIG. 3  is a perspective view of another exemplary electrical connector according to an embodiment of the invention. 
         FIG. 4  is a partial perspective view of an exemplary insert for an electrical connector according to an embodiment of the present invention. 
         FIG. 5  is a partial perspective view of another exemplary insert for an electrical connector according to an embodiment of the invention. 
         FIG. 6  is a partial perspective view of yet another exemplary insert for an electrical connector according to an embodiment of the present invention. 
         FIG. 7  is a partial perspective view of an exemplary insert for an electrical connector according to an embodiment of the present invention. 
         FIG. 8  is a partial perspective view of an exemplary insert for an electrical connector according to an embodiment of the present invention. 
         FIG. 9  is a perspective view of an exemplary insert for an electrical connector according to the disclosure. 
         FIG. 10  is a perspective view of an exemplary insert for an electrical connector according to an embodiment of the present invention. 
     
    
    
     Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Provided is an electrical connector assembly, an electrical connector, and a conductive insert. Embodiments of the present disclosure provide increased retention for electrical connectors in comparison to similar electrical connectors devoid of the conductive insert, provide increased conductivity between conductors in comparison to similar electrical connectors devoid of the conductive insert, provide versatility with various size conductors, distribute force over a conductor thereby reducing or eliminating severing of conductor strands, and combinations thereof. 
       FIG. 1  shows an electrical connector assembly  100  including an electrical connector  102 , a first conductor  104 , and a second conductor  106 . The electrical connector assembly  100  is for any suitable application. For example, in one embodiment, the electrical connector assembly  100  is a utility connector for being positioned overhead. In another embodiment, the electrical connector assembly  100  is a utility connector for being positioned underground. 
     The electrical connector  102  electrically connects the first conductor  104  to the second conductor  106 . The first conductor  104  and the second conductor  106  are electrically conductive conductors, such as stranded cables, capable of transmitting electrical power and/or signals. In one embodiment, the first conductor  104  and the second conductor  106  include the same material, for example, copper or aluminum. In another embodiment, the first conductor  104  and the second conductor  106  include differing materials, for example, the first conductor  104  being copper and the second conductor  106  being aluminum. In one embodiment, the first conductor  104  and the second conductor  106  are the same size and/or shape. In another embodiment, the first conductor  104  and the second conductor  106  have differing sizes and/or shapes, for example, the first conductor  104  having a thickness that is greater or smaller than the second conductor  106 . 
     Referring to  FIG. 2 , the electrical connector  102  includes a conductive housing  108  and a conductive insert  110  positioned within the conductive housing  108  to receive and retain the first conductor  104  (see  FIG. 1 ) and/or the second conductor  106  (see  FIG. 1 ). The conductive housing  108  is in electrical communication with the first conductor  104  and the second conductor  106  through the conductive insert  110 . 
     The conductive housing  108  includes any suitable material. In one embodiment, for example, as in an overhead application, the conductive housing  108  includes aluminum. In another embodiment, for example, as in an underground application, the conductive housing  108  includes copper. 
     The conductive housing  108  is any suitable geometry. As shown in  FIG. 1 , in one embodiment, the conductive housing  108  is frusto-conical. In another embodiment, as shown in  FIG. 3 , the conductive housing  108  is a substantially planar portion  302  of the electrical connector  102  with the conductive inserts  110  having a corresponding geometry. In yet another embodiment, the conductive housing  108  is cylindrical, rectangular, cuboid, hex-shaped, or any other suitable geometry with the conductive insert  110  having a corresponding geometry. 
     Referring again to  FIG. 1 , the conductive housing  108  includes any suitable features for securing the conductive insert  110  in a predetermined position. For example, in one embodiment, the conductive housing  108  includes an adhesive (not shown) applied between the conductive housing  108  and the conductive insert  110  to retain the conductive insert  110  in place during positioning of the first conductor  104  (see  FIG. 1 ) and/or the second conductor  106  (see  FIG. 1 ). In one embodiment, the adhesive is a temporary adhesive that is only present during assembly and does not affect electrical conductivity during operation of the electrical connector assembly  100 . In one embodiment, the conductive housing  108  includes suitable alignment or securing features (not shown) for aligning and securing the conductive insert  110  within the conductive housing  108 . Suitable alignment or securing features include, but are not limited to, threading, snaps, clips, protrusions, keying, recesses, fasteners, other suitable alignment features, or combinations thereof. 
     In one embodiment, the conductive housing  108  includes one or more bolts  112  positioned within the conductive housing  108 . The one or more bolts  112  extend from outside of the conductive housing  108  through the conductive housing  108  to contact the conductive insert  110  (see  FIG. 2 ). The bolts  112  are positioned so that when adjusted by being rotated they urge the conductive insert  110  against the first conductor  104  and/or the second conductor  106 . By urging the bolts  112  toward the conductive insert  110 , the conductive insert  110  engages the first conductor  104  or the second conductor  106  and the electrical connection between the first conductor  104  or the second conductor  106  and the conductive housing  108  is formed or increased, thereby forming or increasing the electrical connection between the first conductor  104  and the second conductor  106 . 
     As shown in  FIG. 1 , in one embodiment, four of the bolts  112  are included. A first bolt  112   a  and a second bolt  112   b  are on a first portion  103  proximal to the first conductor  104  of the conductive housing  108 . A third bolt  112   c  and a fourth bolt  112   d  are on a second portion  105  of the conductive housing  108  proximal to the second conductor  106 . The first bolt  112   a  and the second bolt  112   b  correspond to a first conductive insert  110   a  (for example, see  FIG. 2 ) positioned within the conductive housing  108  proximal to the first conductor  104 . Similarly, the third bolt  112   c  and the fourth bolt  112   d  on the portion of the conductive housing  108  proximal to the second conductor  106  correspond to a second conductive insert  110   b  (for example, see  FIG. 2 ) positioned within the conductive housing  108  proximal to the second conductor  106 . As will be appreciated, fewer than four bolts  112  or more than four bolts  112  can be included. Likewise, the arrangement of the bolts  112  may be in any suitable orientation. 
     The conductive housing  108  retains the first conductor  104  and/or the second conductor  106  within the conductive housing  108  and/or the conductive inserts  110 . In one embodiment, the conductive housing  108  is arranged and disposed for the first conductor  104  and the second conductor  106  to be positioned to abut each other (not shown) or proximate with each other within the conductive housing  108 . Referring to  FIG. 2 , in another embodiment, the conductive housing  108  includes an interior wall  202  separating a first conductor region  204  and the first conductor  104  from a second conductor region  206  and the second conductor  106 . The first conductor region  204  and the second conductor region  206  of housing  108  each include an end portion  212  and an internal portion  214 . The corresponding end portions  212  are configured to receive the first conductor  104  or second conductor  106 , and during installation, the ends of the first conductor  104  and second conductor  106  are positioned within the corresponding internal portions  214 , and are positioned to be abutting and contacting the interior wall  202 . 
     The conductive insert  110  is configured to securely retain the first conductor  104  (see  FIG. 1 ) within the first conductor region  204  and/or the second conductor  106  (see  FIG. 1 ) within the second conductor region  206 . The retention of the first conductor  104  and/or the second conductor  106  is achieved by any suitable mechanism or features on the conductive insert  110  arranged and disposed for contacting the first conductor  104  and/or the second conductor  106 . As shown in  FIG. 2 , in one embodiment, the conductive insert  110  includes engagement features  208 , such as peaks or ridges, for securely engaging the first conductor  104  and/or the second conductor  106 . The engagement features  208  are positioned on an engagement surface  203  of the conductive insert  110 . During installation, the first conductor  104  and second conductor  106  are positioned within the conductive insert  110 , adjacent to the engagement surface  203 . In one embodiment, the engagement features  208  deformably engage the first conductor  104  and/or the second conductor  106  upon the conductive insert  110  being urged toward the first conductor  104  (see  FIG. 1 ) and/or the second conductor  106  (see  FIG. 1 ). In other embodiments, the first conductor  104  and/or the second conductor  106  are retained by a rough surface (not shown) on the conductive insert  110 , by axial grooves (not shown) on the conductive insert  110 , by threading (not shown) on the conductive insert  110 , by independent protrusions (not shown) on the conductive insert  110 , or combinations thereof. 
     The engagement features  208  are arranged on the conductive insert  110  in any suitable manner. For example, referring to  FIG. 2 , in one embodiment, the engagement features  208  are arranged in a consistent periodic arrangement with each of the engagement features  208  extending in a substantially vertical orientation, the orientation essentially perpendicular to the longitudinal axis of the conductive insert  110 . 
     Referring to  FIG. 4 , in another embodiment, the engagement features  208  are arranged in a consistent periodic arrangement and each of the engagement features  208  extend at an angle  402 , relative to the longitudinal axis of the conductive insert  110 , other than vertical, for example, directed toward the end portion  212  (see  FIG. 2 ) of a corresponding conductive housing  108  or the internal portion  214  (see  FIG. 2 ) of the corresponding conductive housing  108 . 
     Referring to  FIG. 5 , in one embodiment, the engagement features  208  are separated by substantially planar portions  302  between each of the engagement features  208  on the engagement surface  203 . 
     Referring to  FIG. 6 , in yet another embodiment, the engagement features  208  are arranged in a non-periodic arrangement and/or include engagement features  208  of differing heights, shapes, orientations, or combinations thereof. 
     The conductive insert  110  includes any other features capable of engaging the conductive housing  108  and/or retaining the first conductor  104  and/or the second conductor  106 . For example, referring to  FIG. 6 , in one embodiment, the conductive insert  110  includes an increasing thickness, the increasing thickness being formed by a first maximum thickness  602  in a first region  604  being less than a second maximum thickness  606  in a second region  608 , or by being otherwise generally tapered, partially tapered, or sloped (independent of the slope formed by the engagement features  208 ). The first region  604  corresponds to the end portion  212  (see  FIG. 2 ) of the conductive housing  108  or the internal portion  214  (see  FIG. 2 ) of the conductive housing  108 , with the second region  608  corresponding to the respective alternative of the end portion  212  (see  FIG. 2 ) of the conductive housing  108  or the internal portion  214  (see  FIG. 2 ) of the conductive housing  108 . In contrast, as shown in  FIG. 2 , in one embodiment, the conductive insert  110  includes a substantially consistent thickness throughout. 
     Referring to  FIG. 7 , in one embodiment, an exterior abutment surface  703  of the conductive insert  110  is arranged and disposed to conform to the shape of and to contact the conductive housing  108 . In one embodiment, the conductive insert  110  is arranged and disposed to be positioned in a single predetermined orientation within the conductive housing  108  (see  FIG. 2 ). In one embodiment, the conductive insert  110  includes alignment features for being in the predetermined orientation within the conductive housing  108 . For example, in one embodiment, the conductive insert  110  includes threading, snaps, clips, protrusions, keying, recesses, fasteners, other suitable alignment features corresponding to the conductive housing  108 , or combinations thereof. 
     Additionally or alternatively, in one embodiment, the conductive insert  110  includes a bolt recess  702  capable of providing alignment and distributing force from one of the bolts  112  (see  FIG. 2 ) along the conductive insert  110 . Upon the bolt  112  being adjusted inwardly toward the first conductor region  204  (see  FIG. 2 ) and/or the second conductor region  206 , the bolt recess  702  is engaged by the bolt  112 . The bolt recess  702  has a geometry corresponding to the bolt  112 . In one embodiment, the bolt recess  702  includes a bottom  704  configured to receive and engage the bottom of bolt  112 . In one embodiment, the bolt recess  702  includes threading (not shown). As shown in  FIG. 8 , in one embodiment, the bolt recess  702  is a cylindrical recess that is slightly larger in diameter than the bolts  112 . In this embodiment, when the bolt  112  is inwardly adjusted, the bolt  112  engages and applies force to the bottom  704  of the bolt recess  702 . 
     Referring to  FIG. 8 , in one embodiment, the conductive insert  110  includes two bolt recesses  702  and a generally curved geometry. 
     Referring to  FIG. 9 , in one embodiment, the conductive insert  110  includes a generally cylindrical geometry with one or more engagement regions  809  having the engagement features  208  and a non-engagement region  804  devoid of the engagement features  208 . 
     Referring to  FIG. 10 , in one embodiment, the conductive insert  110  includes engagement features  208  extending throughout the engagement surface  203  to receive the first conductor  104  and/or the second conductor  106  (see  FIG. 1 ). 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.