Patent Publication Number: US-7896714-B2

Title: Submersible electrical set-screw connector

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority under 35 U.S.C. §119(e) to U.S. provisional patent application No. 61/131,877 filed Jun. 13, 2008 which is hereby incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     1. Field of the Invention 
     The invention relates to an electrical connector and, more particularly, to a submersible electrical set-screw connector. 
     2. Brief Description of Prior Developments 
     Submersible electrical set-screw connectors for making connections in power distribution networks are known in the art. U.S. Pat. No. 6,764,354 B2, which is hereby incorporated by reference in its entirety, discloses a submersible electrical set-screw connector. A similar insulated water-tight connector assembly including a set screw driver and plug is disclosed in U.S. Patent Publication No. 2006/0155280 A1 which is hereby incorporated by reference in its entirety. These conventional connectors provide set-screw assemblies having various configurations. 
     SUMMARY 
     The foregoing and other problems are overcome, and other advantages are realized, by the use of the exemplary embodiments of this invention. 
     In accordance with one aspect of the invention, a submersible electrical set-screw connector is disclosed. The submersible electrical set-screw connector includes a connector body section and a first sealing member. The connector body section includes a first opening and a second opening. The first opening is substantially perpendicular to the second opening. The first opening is adapted to receive a portion of an electrical conductor. The first sealing member is removably connected to the submersible electrical set-screw connector. The sealing member is adapted to receive the electrical conductor. The sealing member includes an outer cylindrical surface and an inner cylindrical surface. The outer cylindrical surface includes a first centerline axis. The inner cylindrical surface includes a second centerline axis. The first centerline axis is offset from the second centerline axis. 
     In accordance with another aspect of the invention, an electrical connector sealing member is disclosed. The electrical connector sealing member includes a main section having an outer diameter and an inner diameter. The main section is adapted to be disposed between a portion of an electrical connector and an electrical conductor. The main section includes a first wall thickness between the outer diameter and the inner diameter. The sealing member includes a second different wall thickness between the outer diameter and the inner diameter. The second wall thickness is more than two times larger than the first wall thickness. 
     In accordance with another aspect of the invention, a method of manufacturing an electrical connector sealing member is disclosed. A main section having an outer surface is provided. The outer surface includes a first diameter. The main section is adapted to be received by an electrical connector at the outer surface. An inner surface extending through the main section is provided. The inner surface includes a second diameter. The inner surface is adapted to receive an electrical conductor. A centerline axis of the inner surface is spaced from a centerline axis of the outer surface. The first diameter is approximately double the second diameter. 
    
    
     
       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 submersible electrical set-screw connector comprising features of the invention; 
         FIG. 2  is a cross section view of the submersible electrical set-screw connector shown in  FIG. 1 ; 
         FIG. 3  is a front view of a set-screw assembly used in the submersible electrical set-screw connector shown in  FIG. 1 ; 
         FIG. 4  is a cross section view of the set-screw assembly shown in  FIG. 3 ; 
         FIG. 5  is a perspective view of a clamp for use with the connector shown in  FIG. 1 ; 
         FIGS. 6A-6C  are end views of sealing members for use with the connector shown in  FIG. 1 ; 
         FIG. 7  is a cross sectional view of the connector shown in  FIG. 1 , similar to  FIG. 2 , but showing connection of a different size conductor to the connector; and 
         FIG. 8  is a cross sectional view of the connector shown in  FIG. 1 , similar to  FIGS. 2 and 7 , but showing connection of another different size conductor to the connector. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , there is shown a perspective view of a submersible electrical set-screw connector  10  incorporating features of the invention, intended to be used to connect multiple electrical conductors  12  (only one of which is shown) to each other. 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. 
     Referring also to  FIGS. 2-4 , the connector  10  generally comprises a body  14 , a cover  16 , set screw assemblies  18 , adapters  20 , and sealing members  22 . In an alternate embodiment the adapters  20  might not be provided. The connector might also include sealing plugs (not shown) to cover unused holes in the cover  16 . The body, or connector body section,  14  is comprised of electrically conductive material, such as aluminum for example. The body  14  has holes (or openings)  24  for receiving the electrically conductive cores  15  of the conductors  12 . The body  14  also has holes (or openings)  26  for receiving the set screw assemblies  18 . The holes  24  are substantially perpendicular to the holes  26 . However, alternate embodiments may comprise any suitable configuration. The cover  16  is preferably overmolded onto the body  14 . The cover is comprised of an electrically insulating material such as a polymer material. The cover  16  has tubes  27  with holes (or openings)  28  for receiving ends of the conductors  12  and the sealing members  22 . The sealing members  22  may be removably connected to the connector  10  at the holes  28 . Referring also to  FIG. 5 , each tube  27  preferably has a clamp  50  on it to clamp the tube  27  and the sealing member  22  onto the outer diameter of the conductor  12 . The cover  16  also has holes (or openings)  30  for receiving the set screw assemblies  18 . The holes  28  are substantially perpendicular to the holes  30 . However, alternate embodiments may comprise any suitable configuration. 
     Each of the set screw assemblies  18  generally comprise a screw body  32  and a screw head  34 . Similar set screw assemblies are described in U.S. patent application Ser. No. 12/103,200 filed Apr. 15, 2008 which is hereby incorporated by reference in its entirety. The screw body, or body part,  32  is preferably comprised of metal and comprises a first end  36  for contacting the conductor  12  or the adapter  20 , a threaded shaft (or threaded section)  38  and a second end  40 . The second end  40  has a general hexagon shape with a channel  42  therein. The channel  42  extends in a direction substantially transverse to a central axis  39  of the threaded section  38 . 
     The screw head  34  is preferably comprised of an electrically insulating material, such as a molded plastic or polymer material. The screw head  34  is preferably overmolded onto the second end  40  of the screw body  32 . During overmolding, material forming the screw head  34  extends into the channel  42  to form locking section  44  and surrounds a portion of an outer surface of the second end  40 . This interlocks the screw head  34  onto the screw body  32  as a non-removable connection forms the screw body  32  and the screw head  34  into a one-piece member. In an alternate embodiment the connection might be removable, such as if the screw head is connected to the screw body after the screw head is formed. 
     The screw head, or head part,  34  generally comprises the locking section  44  located in the channel  42  and a top hexagon section  48 . A separate or integrally formed sealing ring section  46  is provided. The locking section  44  is integrally formed with the screw head  34  during the overmolding. The top hexagon section  48  is aligned with the hexagon shape of the second end  40  of the screw body  32  such that the material of the screw head  34  at the top hexagon section  48  has a substantially uniform thickness. During overmolding, the screw body  32  is precisely located in one of six positions in the molding device to align the hexagon shapes. The uniform thickness of the material at the top hexagon section  48  provides the benefit of better strength of the section  48  and helps to prevent cracks from developing. The hexagon shape is provided for a hexagon shaped tool or a wrench to screw the set screw assembly  18  into the body  14  and cover  16 . In alternate embodiments, other shapes could be provided. 
     When the set screw assembly  18  is inserted into one of the holes  30 ,  26 , the threaded shaft  38  can thread into the threaded hole  26 . The sealing ring section  46  can make a sealing engagement with the cover  16  at the hole  30 . 
     While the submersible electrical set-screw connector  10  has been described in connection with the set screw assembly  18 , one skilled in the art will appreciate that the invention is not necessarily so limited and that any suitable set screw assembly may be provided. 
     Referring now also to  FIG. 6 , in a preferred embodiment of the invention the cover  16  can be used with multiple different types of the sealing members.  FIG. 6  shows three types of the sealing members  22 ,  22 ′,  22 ″ which can be sold individually or as part of a kit with the connector  10 . More or less than three types of sealing members could be provided. The sealing members  22 ,  22 ′,  22 ″ may comprise a main sections  51 ,  53 ,  55  having a same outer shape with a same constant outer diameter  72  which is sized and shaped to fit inside one of the holes  28 . The outer shape may be a cylindrical shape forming an outer cylindrical surface, wherein the sealing members  22 ,  22 ′,  22 ″, are received by the holes  28  at the outer cylindrical surface. A flange (or flange section)  73  may also be provided on the sealing members  22 ,  22 ′,  22 ″. 
     According to one embodiment of the invention, the sealing members may be one piece members formed from a resilient material such as an elastomer or polymer material, for example. However, in alternate embodiments, any suitable type of material may be provided. 
     The sealing members  22 ,  22 ′,  22 ″ have different size inner diameter holes  52 ,  54 ,  56 . The inner diameter holes  52 ,  54 ,  56 , provide a cylindrical shape forming an inner cylindrical surface extending through the main section  51 ,  53 ,  55 . The different size holes  52 ,  54 ,  56  allow use of the connector  10  with different size conductors  12 ,  12 ′,  12 ″ (wherein the main section  51 ,  53 ,  55  receives the conductors  12 ,  12 ′,  12 ″ at the inner cylindrical surface) as shown in  FIGS. 2 ,  7  and  8 . In this embodiment the holes  52 ,  54 ,  56  each have a centerline axis  58 ,  60 ,  62  which are offset (or radially spaced) from the center axis  64  of the respective sealing member  22 ,  22 ′,  22 ″ by respectively different offsets  66 ,  68 ,  70 . However, in an alternate embodiment at least one of the sealing members could have the centerline axis of its conductor receiving hole aligned with its center axis. 
     Any suitable outer diameter and inner diameter may be provided for the sealing members. For example, in  FIGS. 2 and 6A , the outer diameter  72  (of the outer cylindrical surface  74 ) may be about forty percent larger than an inner diameter  75  of the hole  52  (and the inner cylindrical surface  80 ). Additionally, due to the offset configuration of the outer and inner diameters, various different wall thicknesses  86 ,  88  may be provided between the inner surface  80  and the outer surface  74 . For example, the wall thickness  86  may be about two times larger (or thicker) than the wall thickness  88 . However, any suitable wall thickness configuration may be provided. 
     For example, in  FIGS. 7 and 6B , the outer diameter  72  (of the outer cylindrical surface  76 ) may be about seventy five percent larger than an inner diameter  77  of the hole  54  (and the inner cylindrical surface  82 ). Additionally, due to the offset configuration of the outer and inner diameters, various different wall thicknesses  90 ,  92  may be provided between the inner surface  82  and the outer surface  76 . For example, the wall thickness  90  may be about three times larger (or thicker) than the wall thickness  92 . However, any suitable wall thickness configuration may be provided. 
     For example, in  FIGS. 8 and 6C , the outer diameter  72  (of the outer cylindrical surface  78 ) may be about double (or two times larger than) an inner diameter  79  of the hole  56  (and the inner cylindrical surface  84 ). Additionally, due to the offset configuration of the outer and inner diameters, various different wall thicknesses  94 ,  96  may be provided between the inner surface  84  and the outer surface  78 . For example, the wall thickness  94  may be about five times larger (or thicker) than the wall thickness  96 . However, any suitable wall thickness configuration may be provided. 
     According to one embodiment, the wall thicknesses  88 ,  92 ,  96  may be substantially the same thickness. However, any suitable configuration may be provided. 
     The connector  10  can preferably be placed on the ground with the conductors  12 ,  12 ′,  12 ″ also lying on the ground as they enter the connector  10 . The offset nature of the holes  52 ,  54 ,  56  allow the holes to be located close to the bottom of the connector for the purpose of allowing the conductors  12 ,  12 ′,  12 ″ to lay close to the ground as they enter the connector  10 . 
     As seen in  FIGS. 2 ,  7  and  8 , the connector  10  can also comprise different size adapters  20 ,  20 ′,  20 ″ for the different size conductors  12 ,  12 ′,  12 ″. However, in alternate embodiments more or less than three size adapters could be provided, or the connector might not have any adapters, such as if the set screw assemblies  18  are long enough for example. 
     When the clamps  50  are tightened around the outer perimeter of respective ones of the tubes  27 , the tubes  27  compress the sealing members  20 ,  22 ′,  22 ″ onto the outer insulation  13  of the conductors  12 ,  12 ′,  12 ″ to form a watertight seal with the conductors in the holes  28 . The sealing members  22 ,  22 ′,  22 ″ form removable bushings which can be provided as a kit for the installer/user to configure as he/she sees fit in view of the sizes of the conductors being connected together by the connector  10 . 
     According to another example of the invention, a method of manufacturing an electrical connector sealing member is disclosed. The method includes the following steps. Providing a main section having an outer surface, wherein the outer surface comprises a first diameter, wherein the main section is adapted to be received by an electrical connector at the outer surface. Providing an inner surface extending through the main section, wherein inner surface comprises a second diameter, wherein the inner surface is adapted to receive an electrical conductor, wherein a centerline axis of the inner surface is spaced from a centerline axis of the outer surface, and wherein the first diameter is approximately double the second diameter. It should be noted that any of the above steps may be performed alone or in combination with one or more of the steps. 
     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 invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.