Patent Publication Number: US-11658436-B2

Title: Power cable connectors and assemblies

Description:
RELATED APPLICATION(S) 
     The present application claims priority from and the benefit of U.S. Provisional Application Ser. No. 63/047,213, filed Jul. 1, 2020, the disclosure of which is hereby incorporated herein in its entirety. 
    
    
     FIELD 
     The present application is directed generally toward telecommunications equipment, and more particularly, power cable connectors and power cable connector assemblies. 
     BACKGROUND 
     Power cables for telecommunications equipment are available in a variety of sizes. A majority of the time larger diameter power trunk cables are used at the bottom of an antenna tower and the smaller diameter power jumper cables are used at the top of the antenna tower. The larger diameter cables have less electrical resistance, but are heavier and more expensive because of the amount of copper used. Typically, a terminal block is used when transitioning from larger diameter cables to smaller diameter cables. However, different terminal blocks are needed for different sized cables making installation difficult and labor intensive for a technician, thereby increasing costs. There may be a need for power cable connectors that allow for the connection of multiple different sizes of conductor power cables, while also reducing installation time and reducing costs. 
     SUMMARY 
     A first aspect of the present invention is directed to a power cable connector. The power cable connector may include a generally cylindrical main body having a bore therethrough, a back cover configured to be removably secured to an end of the main body, a first seal sized to fit within at least a portion of the bore of the main body, a pair of female conductor pins configured to be coupled to the inner conductors of a power cable, an insulator having a pair of inner channels sized to receive the pair of female conductor pins, wherein the insulator is configured to be removably secured to an opposing end of the main body, a second seal sized to fit within at least a portion of the insulator, an end cap, a third seal residing between the insulator and the end cap, and a locking nut configured to secure the end cap to the insulator. 
     Another aspect of the present invention is directed to a power cable connector assembly. The assembly may include a power cable having two separate conductors and a power cable connector. The connector may include a generally cylindrical main body having a bore therethrough, a back cover configured to be removably secured to an end of the main body, a first seal sized to fit within at least a portion of the bore of the main body, a pair of female conductor pins configured to be coupled to the inner conductors of a power cable, an insulator having a pair of inner channels sized to receive the pair of female conductor pins, wherein the insulator is configured to be removably secured to an opposing end of the main body, a second seal sized to fit within at least a portion of the insulator, an end cap, a third seal residing between the insulator and the end cap, and a locking nut configured to secure the end cap to the insulator, wherein the power cable connector is secured to the power cable. 
     Another aspect of the present invention is directed to a method of assembling a power cable connector assembly. The method may include the following steps: (a) providing a power cable having two separate conductors; (b) providing a power cable connector including a main body, a back cover, a first, second seal and third seal, a pair of female conductor pins, an insulator, an end cap, a locking nut, and a strain relief boot; (c) pulling back an outer sleeve of the power cable to expose the two separate conductors; (d) striping both conductors to expose the inner conductors; (e) sliding onto the power cable the following parts of the power cable connector, in order, the strain relief boot, the back cover, the first seal, the main body and the second seal; (f) attaching the each inner conductor to a respective female conductor pin; (g) inserting the third seal and the end cap onto the insulator and securing the insulator and the end cap together with the locking nut; (h) inserting the female conductor pins into the insulator; (i) sliding the second seal into insulator; (j) sliding and rotating the main body onto the insulator; (k) sliding the first seal into the main body; (l) sliding and rotating the back cover onto the main body; (m) sliding at least a portion of the strain relief boot into the back cover; and (n) installing a clamp to secure the strain relief boot to the back cover. 
     It is noted that aspects of the invention described with respect to one embodiment, may be incorporated in a different embodiment although not specifically described relative thereto. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination. Applicant reserves the right to change any originally filed claim and/or file any new claim accordingly, including the right to be able to amend any originally filed claim to depend from and/or incorporate any feature of any other claim or claims although not originally claimed in that manner. These and other objects and/or aspects of the present invention are explained in detail in the specification set forth below. Further features, advantages and details of the present invention will be appreciated by those of ordinary skill in the art from a reading of the figures and the detailed description of the preferred embodiments that follow, such description being merely illustrative of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG.  1 A  is a perspective view of a connector assembly according to embodiments of the present invention. 
         FIG.  1 B  is an exploded view of the connector assembly of  FIG.  1 A . 
         FIG.  2 A  through  FIG.  13 B  illustrate an exemplary method of assembling a connector assembly according to embodiments of the present invention. 
         FIGS.  14 A- 14 C  illustrate an exemplary method of disassembling a connector assembly according to embodiments of the present invention. 
         FIG.  15 A  is a perspective view of a coupler according to embodiments of the present invention that may be used with the connector assembly of  FIG.  1 A . 
         FIG.  15 B  is a side view of the coupler of  FIG.  15 A . 
         FIG.  15 C  is an end view of the coupler of  FIG.  15 A . 
         FIG.  15 D  is an exploded view of the coupler of  FIG.  15 A  illustrating the coupler key and corresponding keyed hole in an infrastructure flange. 
         FIG.  15 E  illustrates exemplary dimensions of the keyed holed in the infrastructure flange. 
         FIGS.  16 A- 16 C  are views of an exemplary infrastructure flange having multiple couplers of  FIG.  15 A  secured thereto, wherein one of the couplers has the connector assembly of  FIG.  1 A  secured thereto. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. Like numbers refer to like elements throughout and different embodiments of like elements can be designated using a different number of superscript indicator apostrophes (e.g.,  10 ′,  10 ″,  10 ′″). 
     In the figures, certain layers, components, or features may be exaggerated for clarity, and broken lines illustrate optional features or operations unless specified otherwise. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. 
     It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention. The sequence of operations (or steps) is not limited to the order presented in the claims or figures unless specifically indicated otherwise. 
     Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising”, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.” 
     Pursuant to embodiments of the present invention, a power cable connector is provided that allows for the connection of multiple different sizes of conductor power cables. Power cable connector assemblies, methods of assembling a power cable connector, and couplers are also provided herein. Embodiments of the present invention will now be discussed in greater detail with reference to  FIGS.  1 A- 16 C . 
     Referring now to the drawings, a power cable connector assembly  10  according to embodiments of the present invention is shown in  FIGS.  1 A- 1 B . As shown in  FIG.  1 A , the power cable connector assembly  10  may include a power cable  20  and a power cable connector  100 . In some embodiments, the assembly  10  may further include a heat shrink tube  30 . As discussed in further detail below, in some embodiments, the heat shrink tube  30  may extend over at least a portion of an outer sleeve  22  of the power cable  20  and extend within at least a portion of the power cable connector  100  to create a seal, thereby protecting the interconnection between the power cable  20  and the power cable connector  100 . 
       FIG.  1 B  is an exploded view of the power cable connector  100  of  FIG.  1 A . As shown in  FIG.  1 B , in some embodiments, the connector  100  may include a main body  102 , a back cover  104  and an insulator  130 . The main body  102  has a bore (or interior cavity)  103  therethrough. In some embodiments, the main body  102  may have a generally cylindrical shape. The main body  102  is configured to be removably secured to the insulator  130  and the back cover  104 . For example, in some embodiments, the main body  102  may comprise a first threaded section  102   a  that corresponds to a threaded section  104   a  of the back cover  104  and a second threaded section  102   b  that corresponds to a threaded section  138  of the insulator  130  (see also, e.g.,  FIG.  3 A ,  FIG.  5 A ,  FIG.  9 B ,  FIG.  11 B ). 
     The connector  100  further includes a first seal  110   a  and a second seal  110   b . The first seal  110   a  is configured and sized to form an interference fit within the main body  102 . In some embodiments, the main body  102  may comprise a clamp ring (or a plurality of spring fingers)  102   c  configured to engage the first seal  110   a  (see, e.g.,  FIGS.  10 A- 10 C ). The second seal  110   b  is configured and sized to form an interference fit with the insulator  130  (see, e.g.,  FIGS.  8 A- 8 B ). As discussed in further detail below, different first and second seals  110   a ,  110   b  may be used with the connector  100  to accommodate different sized conductor power cables  22 . 
     Each seal  110   a ,  110   b  comprises two apertures  111 . The apertures  111  are sized to form an interference fit with a specific-sized conductor power cable  22  and corresponding seals  110   a ,  110   b  may be used for different sized power cables  22 . For example, in some embodiments, seals  110   a ,  110   b  with apertures  111  having a size of about 6 mm 2  would be used to accommodate conductors  24  having a similar size. However, if the conductors  24  have a size of about 25 mm 2 , then the seals  110   a ,  110   b  with 6 mm 2  apertures  111  would be replaced with different seals  110   a ,  110   b  having a size of about 25 mm 2  to accommodate the conductors  24  having a similar size. Thus, the power cable connectors  100  of the present invention allow for the connection of multiple different sizes of conductor power cables  20 . 
     In some embodiments, the first and second seals  110   a ,  110   b  may be color-coded to help installers match the appropriately sized seals  110   a ,  110   b  with a specific-sized conductor power cable  22 . In some embodiments, the power cable connector  100  of the present invention may be used to accommodate power cables  20  with conductors  24  having a size between 6 mm 2  and about 25 mm 2 . 
     The connector  100  of the present invention further includes a pair of female connector pins  106  (i.e., positive and negative polarity). The female connector pins  106  correspond to the size of the inner conductors  26  of the power cable  22 . The female connector pins  106  are configured to be inserted into the insulator  130 . In some embodiments, interior channels  132   a  of the insulator  130  are configured such that the female connector pins  106  may only be inserted one way (see, e.g.,  FIGS.  5 A- 5 B  and  FIGS.  7 A- 7 B ). 
     The connector  100  further includes an end cap  112 . The end cap  112  is configured to receive a portion of the insulator  130  (see, e.g.,  FIGS.  5 A- 5 C ). As discussed in further detail below, the end cap  112  may be secured to the insulator  130  via a locking nut  140  (see, e.g.,  FIGS.  6 A- 6 E ). In some embodiments, the locking nut  140  may be configured to implement a “bayonet” locking mechanism. A third seal  114  may reside between the insulator  130  and the end cap  112 . In some embodiments, the third seal  114  may be an O-ring. 
     In some embodiments, the power cable connector  100  of the present invention may further include a strain relief boot  116 . The strain relief boot  116  may be secured to the back cover  104  with a clamp  120  and a couple screws  122  and nuts  124  (see, e.g.,  FIGS.  13 A- 13 B ). Other known methods of securing the strain relief boot  116  to the back cover  104  may be used. 
     Referring to  FIGS.  2 A- 13 B , a method of installing a power cable connector assembly  10  according to embodiments of the present invention is illustrated. 
       FIGS.  2 A- 2 C  illustrate the power cable  20  being prepared to attach the power cable connector  100  described above. As shown in  FIG.  2 A , an outer sleeve  22  (e.g., a nylon braid) of the power cable  20  is pulled back a length (L 1 ) to expose the separate conductors  24  within the power cable  20 . In some embodiments, the outer sleeve  22  is pulled back at least a length (L 1 ) of about 145 mm. As discussed above, and shown in  FIG.  2 B , in some embodiments, a heat shrink tube  30  may be used to help provide an additional seal with the power cable  20 . In some embodiments, the heat shrink tube  30  may be slid onto the power cable  20  until the conductors  24  extend out from the heat shrink tube  30  a length (L 1A ) of about 80 mm. In some embodiments, the heat shrink tube  30  may have a length (L 1B ) of about 95 mm and the tube  30  may overlap the outer sleeve  22  of the power cable  20  a length (L 1C ) of about 30 mm. After the heat shrink tube  30  is positioned on the power cable  20 , heat may then be applied to secure the tube  30  in place on the power cable  20 . As shown in  FIG.  2 C , the conductors  24  are then stripped back a length (L 2 ) to expose the inner conductors  26 . In some embodiments, the conductors  24  are stripped back a sufficient length (L 2 ) to allow the inner conductors  26  to be coupled with a respective female conductor pin  106  of the power cable conductor  100  (see, e.g.,  FIGS.  4 A- 4 B ). For example, in some embodiments, the conductors  24  may be stripped back a length (L 2 ) of about 10 mm. 
       FIGS.  3 A- 3 B  illustrate parts of the power cable connector  100  being slid onto the prepared power cable  20  in the following order: (1) the strain relief boot  116 ; (2) the back cover  104 ; (3) the first seal  110   a ; (4) the main body  102 ; and (5) the second seal  110   b . As discussed above, and shown in  FIGS.  3 A- 3 B , the apertures  111  of the first and second seals  110   a ,  110   b  are sized to slide onto and form an interference fit with the conductors  24 . Different sized seals  110   a ,  110   b  (i.e., different sized apertures  111  of seals  110   a ,  110   b ) may be used to accommodate different sized conductors  24 . Note, in some embodiments, the seals  110   a ,  110   b  may be the same color (i.e., color-coded) to help indicate to a technician determine during installation which seals  110   a ,  110   b  will accommodate the same sized conductor  24 . In some embodiments, the parts (i.e.,  116 ,  104 ,  110   b ,  102 , and  110   a ) are slid onto the power cable  20  until a sufficient length (L 3 ) of prepared power cable  20  extends outwardly from the main body  102  of the connector  100 . For example, in some embodiments, the parts (i.e.,  116 ,  104 ,  110   b ,  102 , and  110   a ) are slid onto the power cable  20  until the stripped conductors  24 ,  26  extend outwardly from the main body  102  a length (L 3 ) of about 25 mm. 
       FIGS.  4 A- 4 B  illustrate the female conductor pins  106  of the connector  100  being coupled (or attached) to the inner conductors  26  of the conductor power cable  20 . Each pin  106  has a polarity (i.e., one negative and one positive) that corresponds to a similar polarity of the inner conductors  26 . The inner conductors  26  are received by a respective recess  106   a  in the female conductor pins  106  until an outer edge of the pins  106  contact the outer jacket of the conductor  24 . Screws  107  are used to secure the conductors  26  within the recesses  106   a  of the female conductor pins  106 . Different sized screws  107  may be used depending on the size of the conductors  26  being secured to the female conductor pins  106 . For example, a short version of the screws  107  may be used to tighten copper sections of the wires (i.e., the inner conductors  26 ) having a size between about 16 mm 2  and about 25 mm 2 , whereas a longer version of the screws  107  may be used to tighten inner conductors  26  having a size between about 6 mm 2  and about 10 mm 2 . In some embodiments, the screws  107  may be tightened to about 5 Nm. In some embodiments, the screws  107  may have a TORX shape which allows the use of a dynamometric key preset at 5 Nm. The TORX shape of the screws  107  may help improve reliability and repeatability of the tightening force used to secure the inner conductors  26  to the female conductor pins  106 . 
       FIGS.  5 A- 5 C  and  FIGS.  6 A- 6 F  illustrate the assembly and securing of the end cap  112  to the insulator  130 . As shown in  FIGS.  5 A- 5 C , in some embodiments, the insulator  130  has a body  134  and a pin section  132  extending axially from the body  134 . The body  134  of the insulator  130  may comprise one or more recesses  136  that extend along an outer surface of the body  134 . As discussed herein, in some embodiments, the body  134  of the insulator  130  may also comprise a threaded section  138  that corresponds to the second threaded section  102   b  of the main body  102  of the connector  100 . The pin section  132  comprises two interior channels  132   a  configured to receive the pair of female conductor pins  106 . In some embodiments, the interior channels  132   a  may be configured to form an interference fit with the female conductor pins  106 . 
     Still referring to  FIGS.  5 A- 5 C , in some embodiments, a third seal  114  may reside between the end cap  112  and the insulator  130 . As shown in  FIGS.  5 A- 5 B , the third seal  114  has an aperture  114   a  corresponding to the shape of the pin section  132  of the insulator  130 . In  FIG.  5 C , the end cap  112  is slid onto the pin section  132  of the insulator  130  until the third seal  114  is secured therebetween. In some embodiments, the third seal  114  may be an O-ring. In some embodiments, at least a portion of the end cap  112  may be hex-shaped. 
     Referring to  FIGS.  6 A- 6 F , in some embodiments, the end cap  112  may be secured to the insulator  130  via a locking nut  140 . The locking nut  140  has an annular body  142  and comprises one or more protrusions  144  extending radially inward from the annular body  142 . As discussed above, the insulator  130  may comprise one or more recesses  136 . In some embodiments, the end cap  112  also may comprise one or more recesses  112   a . As discussed below, the recesses  136 ,  112   a  may be configured to receive (and guide) the protrusions  144  of the locking nut  140  as the locking nut  140  is inserted onto the insulator  130  and end cap  112 . 
     After the insulator  130 , the third seal  114 , and the end cap  112  are combined together, the locking nut  140  may be used to secure the end cap  112  to the insulator  130 . As shown in  FIG.  6 A , each protrusion  144  of the locking nut  140  may be aligned with a respective recess  136  of the insulator  130 . As shown in  FIG.  6 B , the locking nut  140  is slid onto the insulator  130  with the protrusions  144  sliding within the recesses  136  of the insulator  130  (i.e., guiding the locking nut  140 ) until the protrusions  144  reach the opposing edge of the insulator  130  and third seal  114 . As shown in  FIG.  6 C , the locking nut  140  is then rotated along the third seal  114  until each protrusion  144  of the locking nut  140  is aligned with a respective recess  112   a  of the end cap  112 . As shown in  FIG.  6 D , the locking nut  140  is then slid onto the end cap  112  with the protrusions  144  sliding within the recesses  112   a  of the end cap  112  (i.e., continuing to guide the locking nut  140 ). As shown in  FIG.  6 E , the locking nut  140  is then rotated as the protrusions  144  continue to slide within the recesses  112   a  of the end cap  112  until the protrusions  144  reach the end of the recesses  112   a , thereby locking the locking nut  140  in place on the end cap  112  and securing the end cap  112  to the insulator  130 .  FIG.  6 F  shows the end cap  112  secured to the insulator  130  by the locking nut  140  and ready to be combined to the power cable connector assembly  10 . 
     In some embodiments, the locking nut  140  may further comprise a plurality of ribs  146 . The ribs  146  may help to enhance a technician&#39;s grip on the locking nut  140 , for example, when the technician is rotating the locking nut  140  on the end cap  112 . 
       FIGS.  7 A- 7 B  show the female conductor pins  106  being inserted into the insulator  130 . The female conductor pins  106  are inserted until at least a portion is received within the interior channels  132   a  of the pin section  132  of the insulator  130  (see also, e.g.,  FIG.  10 C ). As discussed herein, in some embodiments, the insulator  130  may form an interference fit with the female conductor pins  106 . As shown in  FIGS.  7 A- 7 B , the insulator  130  surrounds the connection between the female conductor pins  106  and the inner conductors  26 . As discussed herein, in some embodiments, the interior channels  132   a  of the insulator  130  are configured such that the female connector pins  106  may only be inserted one way. 
     Referring now to  FIGS.  8 A- 13 B , the steps for securing together the remaining parts of the connector  100  are illustrated. First, as shown in  FIGS.  8 A- 8 B , the second seal  110   b  is slid until as least a portion of the seal  110   b  is received within the body  134  of the insulator  130  (see also, e.g.,  FIG.  10 C ). Next, the main body  102  is slid over the second seal  110   b  and engages a portion of the insulator  130  ( FIGS.  9 A- 9 B ). As shown in  FIG.  9 B , the main body  102  is rotated such that the second threaded section  102   b  engages the corresponding threaded section  138  of the insulator  130 , thereby securing the main body  102  to the insulator  130 . 
     Next, as shown in  FIGS.  10 A- 10 C , the first seal  110   a  is slid into the main body  102  of the connector until the seal  110   a  contacts an inner annular flange  102   f  of the main body  102  ( FIG.  10 C ). In some embodiments, the main body  102  may comprise a clamp ring (or a plurality of spring fingers)  102   c  that surrounds the seal  110   a . Next, as shown in  FIGS.  11 A- 11 B , the back cover  104  is slid to engage a portion of the main body  102 . The back cover  104  is then rotated such that the threaded section  104   a  of the back cover  104  engages the corresponding first threaded section  102   a  of the main body  102 , thereby securing the back cover  104  to the main body  102 . In some embodiments, as the back cover  104  is rotated onto the main body  102 , the flexible clamp ring  102   c  is compressed against the first seal  110   a  to create an even tighter seal between the connector  100  and the conductors  26 . 
     As a final step, and as shown in  FIGS.  12 A- 13 B , the strain relief boot  116  and clamp  120  are secured to the connector  100 .  FIGS.  12 A- 12 B  illustrate the strain relief boot  116  being slid until at least a portion of the boot  116  is inserted within the back cover  104 . As shown in  FIG.  12 B , at least a portion of the strain relief boot  116  still overlaps the heat shrink tube  30 . After the strain relief boot  116  is positioned, the clamp  120  may be secured to the connector  100 . As shown in  FIGS.  13 A- 13 B , the clamp  120  may be secured to the connector  100  via a pair of screws  122  and nuts  124 . Similar to screws  107  used to secure the inner conductors  26  to the female conductor pins  106  described herein, the pair of screws  122  may have a TORX shape to allow the use of a dynamometric key to tighten them at a pre-determined strength. As shown in  FIG.  13 A , in some embodiments, the back cover  104  of the connector  100  may comprise a pair of flanges  104   f  configured to receive the screws  122  and secure the clamp  120  to the back cover  104 . Other known methods may be used to secure the clamp  120  to the connector  100 . 
       FIGS.  14 A- 14 C  illustrate disassembling a power cable connector assembly  10  according to embodiments of the present invention. 
     The power cable connector assembly  10  described herein may be used with direct current (DC) power conductors. In some embodiments, the assembly  10  may be used with 30-amp conductors. In some embodiments, the power cable connector assembly  10  of the present invention may be used with single-core conductor cables or dual-core conductor cables. The power cable connector assembly  10  of the present invention may be used instead of the terminal blocks described above. 
     Referring now to  FIGS.  15 A- 15 E , a coupler  200  that may be used with the power cable connector assembly  10  described herein is illustrated. As shown in  FIGS.  15 A- 15 E , the coupler  200  has a generally cylindrical main body  202 . In some embodiments, the main body  202  of the coupler  200  may comprise a threaded portion  220  (see, e.g.,  FIG.  15 D ). A pair of mating sections  204 ,  206  extend axially in opposing directions from the main body  202 . The end of each mating section  204 ,  206  comprises an aperture  207  that generally corresponds to the shape of the pin section  132  of the insulator  130  of the power cable connector assembly  10 . The aperture  207  allows the pin section  132  to be received within an interior cavity  208  of each mating section  204 ,  206 . 
     The coupler  200  further includes a pair of conductor pins  210  (i.e., one positive and one negative) that extend through the main body  202 . Opposing ends of the conductor pins  210  reside within the respective interior cavity  208  of the mating sections  204 ,  206 . To attach the coupler  200  to a power cable connector assembly  10  described herein, first the locking nut  140  is loosened and the end cap  112  is removed. Next, the pin section  132  of the assembly  10  is inserted through aperture  207  and into the interior cavity  208  of mating section  206 . As the pin section  132  is being inserted into the interior cavity  208 , each conductor pin  210  is received by a respective interior channel  132   a  of the pin section  132 . The pin section  132  is inserted into the mating section  206  until the third seal  114  contacts an annular shoulder  202   a  of the main body  202  of the coupler  200 . 
     In some embodiments, the coupler  200  may be configured to be secured to an infrastructure flange  230 . In some embodiments, the infrastructure flange  230  is fixed to the mast of a base station tower (not shown). As shown in  FIGS.  15 D- 15 E , in some embodiments, the threaded portion  220  of the main body  202  of the coupler  200  may comprise two flat surfaces  209   a ,  209   b  implementing a “key” configured to match a keyed hole (or shape)  230   a  in the infrastructure flange  230  (see, e.g.,  FIGS.  16 A- 16 C ). The two opposite surfaces  209   a ,  209   b  mirror surfaces of the keyed hole  230   a  in the infrastructure flange  230  (see, e.g.,  FIG.  15 D ). The coupler  200  fits into the flange  230  by penetrating the shaped or keyed hole  230   a  available on the flange  230 . In some embodiments, different couplers  200  may each have a different “key” that corresponds to respective keyed holes  230   a  in the infrastructure flange  230 . 
     The “key” (i.e., flat surfaces  209   a ,  209   b  of the threaded portion  220 ) of the coupler  200  allows a one-way only insertion of the coupler  200  into the infrastructure flange  230  (i.e., via keyed hole  230   a ), prevents rotation of the coupler  200  during tightening of HEX nut  203 , and allows a repetitive and self-oriented assembling of multiple couplers  200  in the same infrastructure flange  230  showing all the positive and negative polarities in the same orientation. 
     As shown in  FIG.  15 D , the coupler  200  may be secured to the assembly  10  in a similar manner with the end cap  112 , i.e., by rotating the locking nut(s)  140  as the protrusions  144  slide within recesses  206   a  in the mating section  206 . A second power cable connector assembly  10 ′ may then be secured to the coupler  200  in a similar manner using the opposing mating section  204 . 
       FIG.  15 E  illustrates an exemplary keyed hole in the infrastructure flange  230  having opposite faces  239   a ,  239   b  that match the flat surfaces  209   a ,  209   b  of threaded portion  220  of the coupler  200  described herein. 
       FIGS.  16 A- 16 C  illustrate an infrastructure flange  230  having four couplers  200  assembled on the flange  230  via keyed holes  230   a  according to embodiments of the present invention.  FIGS.  16 B- 16 C  illustrate a power cable connector assembly  10  secured to one of the couplers  200 . 
     The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.