Patent Description:
Insulation piercing electrical tap connectors may be used to attach sensing conductors, also known as tap wires, to a power cable. Some voltage detection devices (e.g., some Absence of Voltage Tester (AVT) products) may use dual independent electrical tap connections to each phase of a power cable to perform voltage detection. Voltage detection devices may be mounted inside of a control panel. Applications exist within various industries that may benefit from permanent installation of voltage detection devices.

<CIT> discloses various implementation of insulation piercing connectors. The insulation piercing connectors may be used to attach dual independent electrical connections to a power cable for voltage detection purposes. In some implementations, an insulation piercing connector may include a top half, a bottom half, and a blade seal positioned between the top half and bottom half. A threaded fastener engages threads in a hole in a post on the bottom half and then tightened to compress the insulation piercing connector around a power cable.

<CIT> is an interface module with first mating interfaces to mate with the same cable tap connector. Contact arrays for either of two interface modules are defined by use of the same first members having first contact sections and transverse body sections, joined to one of two groups of socket members. The connector may be modified by selection of different interface modules or different types of mating connectors. The contacts of each array may also be of different sizes.

<CIT> relates to improvements for electrical connecting devices. A metal cable holder defines a cylindrical cavity in the wall of which are diametrically opposed slots permitting the device to be fitted of an insulated conductor at all position along its length. The conductor lies in the slots in the cable holder in a position in which it extends across and through the cavity. A wiring hole in which a terminal screw can be tightened is used to retain a wire for electrically connecting devices. The screw is accommodated in an access hole in the insulting body.

<CIT> describes a device for the quick connection of two electrical cables with the aid of double tips. A junction is provided by inserting the supply cable into a lower part of the housing. The outgoing cable is fixed in the upper part of the housing with the help of a choke socket. The upper part of the housing and the lower part of the housing are aligned parallel to one another and the insulation of the wires of the supply cable and the wires of the outgoing cable are pierced simultaneously.

The present disclosure describes insulation piercing connectors.

The insulation piercing connector according to the invention to which the present European patent relates comprises the features of independent claim <NUM>.

A method of installing an insulation piercing connector according to the invention comprises the features of independent claim <NUM>.

Permanent installation of Absence of Voltage Tester (AVT) products in a cabinet may often be simplified by using electrical tap connectors for permanent connection of AVT tap wires. These AVT products may be used to sense the voltage of a variety of wires or power cables having a variety of different sizes. Additionally, more than one wire in each cabinet may need to be tested/sensed. Thus, the installation of multiple electrical tap connectors in a single cabinet creates an over-crowded and cramped space that can make the cabinet a more difficult workspace. For example, this may require an electrician or other personnel to manipulate the position, angle, or location of the multiple electrical tap connectors, tap wires, or phase wires (power cables) within the cabinet.

The disclosed insulation piercing connectors are designed for use in electrical cabinets, or other appropriate applications, and addresses this cramped cabinet environment by offering a smaller footprint and a configuration adapted to fit well within the cabinet environment. Additionally, the disclosed insulation piercing connectors are provided to address a wider range of wire gauge sizes so end-users may have a consistent design aesthetic and installation methodology regardless of wire size.

The disclosed insulation piercing connector solves or improves upon one or more of the above noted problems and disadvantages. The disclosed insulation piercing connector provides a system for sensing voltage in a compact configuration connectable in or out of a control panel. Embodiments of the present disclosure illustrate an insulation-piercing electrical tap connector that may provide a consistent design aesthetic and installation methodology for a wider range of wire gauge sizes.

These and other objects, features, and advantages of the present disclosure will become apparent to those having ordinary skill in the art upon reading this disclosure.

<FIG> show illustrations of an insulation piercing connector <NUM> according to an embodiment of the present disclosure. The insulation piercing connector <NUM> is configured to provide dual independent electrical tap connections between a voltage detection device (not shown) and a cable (e.g., a power cable or phase wire).

As seen in <FIG>, the insulation piercing connector <NUM> is shown in an exemplary assembled configuration that is ready for receipt by a customer. The insulation piercing connector <NUM> includes a top housing <NUM>, a bottom housing <NUM>, an outer insulator <NUM>, nuts <NUM>, and bolts <NUM>. The nuts <NUM> may be hex nuts, or any other suitable fastener. The bolts <NUM> may be screws, carriage bolts, or any other suitable fastener. In the embodiment, a top portion of the bottom housing <NUM> includes first concave portions <NUM> forming concave-down semi-circles on opposite faces of the bottom housing <NUM>. Second concave portions <NUM> are located on a bottom portion of the top housing <NUM>, forming concave-up semi-circles on opposite faces of the top housing <NUM>. The first concave portions <NUM> and the second concave portions <NUM> define a central aperture <NUM> through the insulation piercing connector <NUM> for receiving a cable. In an embodiment, the insulation piercing connector <NUM> may include first concave portions <NUM> and second concave portions <NUM> on both a front face and a rear face of the insulation piercing connector <NUM> that are opposite each other. In an alternate embodiment, the insulation piercing connector <NUM> may include first concave portions <NUM> and second concave portions <NUM> on only one of a front face or a rear face of the insulation piercing connector <NUM>.

In the embodiment, the outer insulator <NUM> may be made of rubber or other elastomer material. In an alternate embodiment, the outer insulator <NUM> may be made of any other suitable non-conductive material. The top housing <NUM> and the bottom housing <NUM> may be constructed of the same or similar polymers/plastics. In an alternate embodiment, the top housing <NUM> and the bottom housing <NUM> may be constructed from different materials, where the different materials may be non-conducting materials. In one example, top housing <NUM> and bottom housing <NUM> may be made of a glass-filled nylon polymer.

<FIG> show exploded views of the insulation piercing connector <NUM> during various states of assembly. <FIG> shows the insulation piercing connector <NUM> in an exploded view to show components spaced apart, such as before any assembly may have occurred. In addition to the features described above in <FIG>, the insulation piercing connector <NUM> additionally includes a tap wire housing <NUM>, terminal adjustment screws <NUM>, terminal housings <NUM>, stamped contacts <NUM>, spring washers <NUM>, flat washers <NUM>, inner insulators <NUM>, and support plate <NUM>. The inner insulators <NUM> may be made of rubber or other elastomer material, or alternatively, any suitable non-conducting material. The terminal adjustment screws <NUM> may be any screw, bolt, or other type of fastener. Additionally, although depicted as spring washers <NUM> and flat washers <NUM>, spring washers <NUM> and flat washers <NUM> may be any type of suitable washer according to other embodiments.

According to an exemplary method of assembly, the stamped contacts <NUM> may move upward through the bottom of the top housing <NUM> within channels (not shown) formed inside the top housing <NUM>. The terminal housings <NUM> may move downward into the top of top housing <NUM> to meet shoulders of the stamped contacts <NUM>. The terminal adjustment screws <NUM> may secure the terminal housings <NUM> with the stamped contacts <NUM> when positioned in top housing <NUM>.

<FIG> shows the terminal adjustment screws <NUM>, the terminal housings <NUM>, and the stamped contacts <NUM> assembled together to form a three-piece insulation piercing assembly. In the example embodiment, the insulation piercing assembly is depicted outside of the top housing <NUM> for ease of understanding and viewing, however, the insulation piercing assembly of the insulation piercing connector <NUM> is configured to be housed within the top housing <NUM> when in the assembled state. Accordingly, while the stamped contacts <NUM> are within the top housing <NUM>, to assemble the insulation piercing assembly the terminal housings <NUM> are moved downward onto the stamped contacts <NUM>. Next, the terminal adjustment screws <NUM> are positioned into the terminal housings <NUM>. Once assembled, the insulation piercing assembly includes a space <NUM> (as shown in <FIG>) between an inner-most wall of the terminal housing <NUM> and the stamped contacts <NUM> where tap wires <NUM> are inserted to form an electrical connection between the stamped contacts <NUM> and the voltage sensing device (not shown). The stamped contacts <NUM> may be made from a metal alloy.

Also shown in <FIG>, the outer insulator <NUM> includes a top portion <NUM> having an opening <NUM> through which the tap wires <NUM> are received. In an alternate embodiment, top portion <NUM> may include more than or less than one opening <NUM>. The outer insulator <NUM> additionally includes a first window <NUM> on a first side of the outer insulator <NUM>, and a second window (not shown) mirrored on a second side of the outer insulator <NUM>. The first window <NUM> and the second window are openings on the outer insulator <NUM>. According to some embodiments, the outer insulator <NUM> may not include one, or both, of the first window <NUM> or the second window.

The exemplary tap wire housing <NUM> additionally includes a first window <NUM> on a first side of the tap wire housing <NUM> and a second window (not shown) mirrored on a second side of the tap wire housing <NUM>. The first window <NUM> and the second window are openings on the tap wire housing <NUM>. According to some embodiments, the tap wire housing <NUM> may not include one, or both, of the first window <NUM> or the second window.

The tap wire housing <NUM> also includes a top portion <NUM> having two apertures <NUM>. In an alternate embodiment, the top portion <NUM> may include more than or less than two apertures <NUM>. The two apertures <NUM> and the opening <NUM> may be for the insertion of wires or cables through the example insulation piercing connector <NUM>.

Exemplary top housing <NUM> includes seated portions <NUM> where the terminal adjustment screws <NUM> and terminal housings <NUM> of the insulation piercing assembly abut and rest on when placed into the top housing <NUM>. The seated portions <NUM> may be recess features within the top housing <NUM>. The stamped contacts <NUM> extend upward through channels within the body of the top housing <NUM> to have the shoulders of the stamped contacts <NUM> reach the seated portions <NUM> to interact with the terminal housings <NUM> and terminal adjustment screws <NUM> when the terminal housings <NUM> are placed into the top housing <NUM>. The top housing <NUM> additionally includes openings <NUM> and corresponding cylindrical extensions <NUM>, and the bottom housing <NUM> includes openings <NUM> for receiving the cylindrical extensions <NUM>. The bolts <NUM> are provided to be inserted and extend through the openings <NUM> when the insulation piercing connector <NUM> is further assembled. Although not expressly depicted, cylindrical extensions <NUM> may optionally internally include threads to engage with the threaded portion of bolts <NUM>.

Support plate <NUM> includes cut outs <NUM> for allowing the bolts <NUM> to extend through. The cut outs <NUM> are depicted in <FIG> as having a square shape because the bolts <NUM> may optionally include square shanks. However, the cut outs <NUM> may be any shape for allowing the bolts <NUM> to extend through. The support plate <NUM> may be made from metal stamping.

<FIG> shows the insulation piercing connector <NUM> in an assembly state where the insulation piercing assembly is positioned to be housed within the top housing <NUM>. In <FIG>, the stamped contacts <NUM> are only partially visible as the stamped contacts <NUM> are housed within the top housing <NUM>. The terminal adjustment screws <NUM> may contact the stamped contacts <NUM> and adjust the relative position of the terminal housings <NUM>. According to an installation example, during installation an electrician may apply a torque using a tool, such as a screwdriver, on the terminal adjustment screws <NUM>. This torque may thereby apply pressure on tap wires <NUM> (shown in <FIG>) being compressed between one face or wall of the terminal housing <NUM> and one face of the stamped contact <NUM> (within spaces <NUM>), until a specified torque value is achieved.

Additionally, <FIG> illustrates a directional arrow <NUM> representing the movement of the inner insulators <NUM> upward towards the inside of the top housing <NUM> to partially or fully surround the tines/blades of the stamped contacts <NUM>. The dashed lines <NUM> represent the interconnection of elements <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> with respect to the other features of insulation piercing connector <NUM>.

<FIG> illustrate views looking up into a bottom-side of the top housing <NUM>. The top housing <NUM> includes a top portion <NUM> and a bottom portion <NUM>, as well as a front face <NUM> and a back face (not shown) that is opposite to the front face <NUM>. The top housing <NUM> further includes cylindrical extensions <NUM> and a second concave portion <NUM> on both the front face <NUM> and the back face (not shown). <FIG> shows the uncovered tines or blades of stamped contacts <NUM>, where the directional arrow <NUM> indicates the direction of movement of the inner insulators <NUM> for them to be installed within the top housing <NUM>. <FIG> shows, in the example embodiment, the inner insulators <NUM> in an installed state where the inner insulators are positioned to cover over the blades of the stamped contacts <NUM>. The inner insulators <NUM> may be U-shaped and include an opening at the top to surround the stamped contacts <NUM>. In an alternate embodiment, the inner insulators <NUM> may take on one of a variety of different shapes including semi-circular, rectangular, etc. In an alternate embodiment, the stamped contacts <NUM> and the inner insulators <NUM> may be positioned into the top housing <NUM> from the top or sides of the top housing <NUM>.

<FIG> show the insulation piercing connector <NUM> further including tap wires <NUM> and the power cable or phase wire <NUM> during various stages of assembly, according to some embodiments. In <FIG>, tap wires <NUM> are inserted through the opening <NUM> of the outer insulator <NUM> and subsequently moved through apertures <NUM> of the tap wire housing <NUM>, toward the central aperture <NUM>. According to the embodiments relating to <FIG>, the tap wires <NUM> are inserted vertically downwards through the insulation piercing connector <NUM>. An exterior sleeve or outer insulating casing of the tap wires <NUM> may be stripped off to expose the inner conductor <NUM> of the tap wires <NUM>, as shown by the exposed ends of the tap wires <NUM> shown in <FIG>. In an alternate embodiment, the tap wires <NUM> may have been manufactured to include the exposed ends showing the inner conductor <NUM>. In <FIG>, the inner conductor <NUM> at the exposed ends of the tap wires <NUM> are inserted into the spaces <NUM> between the wall of the terminal housings <NUM> and the face of the stamped contacts <NUM>.

According to the embodiments illustrated by <FIG>, the phase wire <NUM> is positioned in the central aperture <NUM>. The phase wire <NUM> may be positioned perpendicular to the tap wires <NUM>, or according to an alternate embodiment, the phase wire <NUM> may be placed in the central aperture <NUM> at a later point in assembly of the insulation piercing connector <NUM>.

<FIG> and <FIG> show the tap wire housing <NUM> and the top housing <NUM> as receiving tap wires <NUM> prior to tap wire housing <NUM> being installed onto top housing <NUM>. During the assembly process, the tap wire housing <NUM> may be assembled onto top housing <NUM> prior to the inclusion of tap wires <NUM>. Therefore, the tap wire housing <NUM> may have a transparent, opaque or semi-transparent quality, and the tap wire housing <NUM> may be made from polycarbonate materials, or any other suitable polymer or non-conducting material. This quality may aid an electrician's assembly of the insulation piercing connector <NUM> by allowing the electrician to see when tap wires <NUM> are appropriately situated within tap wire housing <NUM> and top housing <NUM>. In an alternate embodiment, the tap wire housing <NUM> and top housing <NUM> may receive the tap wires <NUM> prior to the attachment of the tap wire housing <NUM> onto top housing <NUM>.

According to the insulation piercing connector <NUM> shown in <FIG>, the tap wire housing <NUM> is positioned onto top housing <NUM> with tap wires <NUM> properly installed within the insulation piercing connector <NUM>. According to some embodiments, the top housing <NUM> may have a cantilever snap-fit feature <NUM> that engages into one or more recesses on the tap wire housing <NUM> (e.g., the first window <NUM> and/or the second window). In an alternate embodiment, the tap wire housing <NUM> may form a connection with top housing <NUM> via any appropriate securing mechanism.

<FIG> shows the exemplary insulation piercing connector <NUM> with the outer insulator <NUM> positioned over the tap wire housing <NUM>. After verification of a proper tap wire installation, an electrician may move the outer insulator <NUM> downward towards the tap wire housing <NUM> until the outer insulator <NUM> completely encompasses and/or obscures the tap wire housing <NUM>. The outer insulator <NUM> may friction-fit with the tap wire housing <NUM>. In an alternate embodiment, the tap wire housing <NUM> may form a connection with the outer insulator <NUM> via any appropriate securing mechanism. Once the outer insulator <NUM> is fully fitted onto tap wire housing <NUM>, a cable tie may be placed on the top portion <NUM> of outer insulator <NUM> to secure the tap wires <NUM> in place.

The outer insulator <NUM> may provide a variety of advantages to the present disclosure, two of which may include (<NUM>) ensuring electrical isolation of internal energized metal from the exterior of the insulation piercing connector <NUM>, and (<NUM>) providing supplemental cable routing and retention capability for securing installed tap wires <NUM> when cable ties (or other cable management devices) are installed just below the opening <NUM>. In an example, installation and securement of tap wires <NUM> may be completed before assembly of the insulation piercing connector <NUM> to phase wire <NUM>.

<FIG> shows insulation piercing connector <NUM> with phase wire <NUM> resting on first concave portions <NUM> and ready for connection. In the current embodiment, the bolts <NUM> and support plate <NUM> (not shown) are positioned into recesses (not shown) within the bottom housing <NUM>. The threaded portion of the bolts <NUM> follows dashed lines <NUM> into the cylindrical extensions <NUM> of top housing <NUM>. The nuts <NUM>, spring washers <NUM>, and flat washers <NUM> may follow the path of the dashed lines <NUM> to be threaded onto the carriage bolts <NUM> as they appear through openings <NUM>. Torque may be applied to the nuts <NUM> until a specified torque is achieved which ensures proper termination of the insulation piercing connector <NUM> onto the phase wire <NUM>. An example of proper termination and a final assembly state for the insulation piercing connector <NUM> may be seen in <FIG>. Although including two bolts <NUM> is optional, there are several advantages to having two bolts <NUM> in the example insulation piercing connector <NUM> disclosed. One such advantage may include that as torque is applied to both sides of the insulation piercing connector <NUM> the housing (both top housing <NUM> and bottom housing <NUM>) are less apt to relax over time from a polymeric perspective. Additionally, the support plate <NUM> may reinforce the bottom housing <NUM> against any plastic relaxation, which may provide a solid connection over time.

<FIG> is a cross-sectional view taken along line <NUM>-<NUM> of the insulation piercing connector <NUM> shown in <FIG>. The inner insulators <NUM> respectively cover the teeth/blades of stamped contacts <NUM> prior to the insulation piercing connector <NUM> being compressed around phase wire <NUM>. The inner insulators <NUM> prevent voltage leakage prior to compression of the top housing <NUM> with the bottom housing <NUM>.

Once compressed, however, the teeth/blades of stamped contacts <NUM> may penetrate through the inner insulators <NUM> due to the compression force and may be exposed to the outer insulating layer of the phase wire <NUM>. When further compression occurs, the two stamped contacts <NUM> penetrates the outer insulating layer of the phase wire <NUM> and contacts the conductor core of the phase wire <NUM> (which may be solid or stranded), thereby providing dual independent electrical connections to phase wire <NUM> via the two stamped contacts <NUM>. The inner insulators <NUM> at this point prevent voltage leakage at the connection points between the stamped contacts <NUM> and the phase wire <NUM>. In an alternate embodiment, a greater or fewer number of stamped contacts <NUM> and inner insulators <NUM> may be included depending on the intended configuration and purpose.

In an alternate embodiment, a pin in sleeve contact or a DB style connector may be utilized to replace the stamped contacts <NUM> shown in <FIG>. Additionally, the embodiments disclosed may include a circuit board for providing an electrical coupling between the stamped contacts <NUM> and the tap wires <NUM>.

<FIG> shows an insulation piercing connector <NUM> according to an alternative embodiment of the present disclosure. The insulation piercing connector <NUM> is similar to the insulation piercing connector <NUM>. The insulation piercing connector <NUM> includes an outer insulator <NUM>, a top housing <NUM> and a bottom housing <NUM>. However, insulation piercing connector <NUM> may be made into a variety of different sizes to fit a variety of different power cables or phase wires. In an example, the axes <NUM> of the main fasteners or bolts moves inward or outward as alternate embodiment sizes get smaller or larger, respectively. Additionally, the diameter <NUM> of the opening may get smaller or larger as alternate embodiment sizes get smaller or larger, respectively, to accommodate different ranges of wire gauge sizes of the power cable or phase wire being tested by the insulation piercing connector <NUM>.

<FIG> shows an exploded view of an insulation piercing connector <NUM> according to another embodiment of the present disclosure. This alternative design of the insulation piercing connector <NUM> provides a consistent design aesthetic and installation methodology for a wider range of wire gauge sizes of phase wires that will be tested.

The insulation piercing connector <NUM> includes an outer insulator <NUM> for covering over a tap wire housing <NUM>, where the attachment mechanism between the outer insulator <NUM> and the tap wire housing <NUM> is described in more detail with reference to <FIG>. The outer insulator <NUM> provides electrical isolation from the interior of the insulation piercing connector <NUM>, and provide a shape for enabling cable routing and retention features for securing installed tap wires using, for example, cable ties or other cable management devices.

The insulation piercing connector <NUM> further includes a top housing <NUM> and a bottom housing <NUM>. The top housing <NUM> includes a bottom portion formed in a concave portion, and the bottom housing <NUM> includes a top portion formed in a concave portion. The top housing <NUM> and the bottom housing <NUM> are configured to come together in an assembled state to receive the phase wire <NUM> to fit within a cylindrical recess formed by the respective concave portions of the top housing <NUM> and the bottom housing <NUM>. For example, <FIG> shows the insulation piercing connector <NUM> in the assembled state where the top housing <NUM> and the bottom housing <NUM> have come together to receive the phase wire <NUM> to fit within the cylindrical recess formed by the respective concave portions of the top housing <NUM> and the bottom housing <NUM>.

As shown in <FIG>, the insulation piercing connector <NUM> includes various fastener and connection components to bring the insulation piercing connector <NUM> into the final assembled state. To secure the tap wire housing <NUM> to the top housing <NUM>, two screws <NUM> (e.g., self-tapping screws) are inserted down through openings on the tap wire housing <NUM> and secured into threaded receiving holes in the top housing <NUM>. To secure the top housing <NUM> to the bottom housing <NUM>, two bolts <NUM> (e.g., hex drive cap bolts) are inserted down through openings on the top housing with the use of spring washers <NUM> and flat washers <NUM>, and through openings on the bottom housing <NUM>, before hex nuts <NUM> are fastened to the threaded ends of the hex drive cap bolt at the bottom-side of the bottom housing <NUM>.

The insulation piercing connector <NUM> also includes an insulation piercing assembly comprised of terminal adjustment screws <NUM>, terminal housings <NUM>, and stamped contacts <NUM>. The insulation piercing assembly of the insulation piercing connector <NUM> operates in the same manner as described for the insulation piercing assembly included in the insulation piercing connector <NUM>. The insulation piercing connector <NUM> also includes an inner insulator <NUM> that covers within the top housing <NUM>, at least partially, the end of the stamped contacts <NUM> including the piercing tines when the insulation piercing connector <NUM> is in the assembled state.

<FIG> shows an enlarged view of the top housing <NUM> and an illustration of how the insulation piercing assembly fits within the top housing <NUM> in the assembled state. In the assembled state, a top end of the stamped contacts <NUM> is shown to include shoulders that rest on top of the terminal housings <NUM>. An exposed conductor portion of the tap wires <NUM> is inserted to fit within a space <NUM> between the stamped contacts <NUM> and the inner surface of the terminal housings <NUM>. The terminal adjustment screws <NUM> are adjusted (e.g., rotated/screwed) to control the size of the space <NUM> to accommodate the tap wires <NUM> held by the insulation piercing assembly, to either secure the tap wires <NUM> or release the tap wires <NUM> from the insulation piercing assembly. During an installation process of the tap wires <NUM> into the insulation piercing connector <NUM>, a user applies torque on the terminal adjustment screws <NUM> until a specified torque value is applied, thereby applying pressure on the tap wire <NUM> that rests within the space <NUM> by compressing the space <NUM> between the stamped contacts <NUM> and the inner surface of the terminal housings <NUM>. The installation of the tap wires <NUM> into the insulation piercing assembly of the insulation piercing connector <NUM> may be completed prior to, or after, field installation of the insulation piercing connector <NUM> to the phase wire <NUM>.

<FIG> also shows how the screws <NUM> are secured into the threaded openings of the top housing <NUM>. <FIG> also shows how the bolt <NUM> is inserted down into the opening of the top housing <NUM> to be received by a corresponding opening of the bottom housing <NUM>.

<FIG> shows the insulation piercing connector <NUM> in a partially assembled state, where the tap wire housing <NUM> is secured to the top housing <NUM>. <FIG> also shows the tap wires <NUM> inserted down through the insulation piercing connector <NUM>. In particular, the outer insulator includes a top portion <NUM>, where the top portion <NUM> includes a top opening <NUM> through which the tap wires <NUM> are received. In this partially assembled state, the tap wire housing <NUM> is secured to the top housing <NUM> by the screws <NUM> (not shown).

<FIG> shows the insulation piercing connector <NUM> in a further partially assembled state where the outer insulator <NUM> is fit over the tap wire housing <NUM>. The outer insulator <NUM> is secured to the tap wire housing <NUM> via a snap-fit mechanism where the outer insulator <NUM> includes four socket openings <NUM> for each receiving their own respective socket protrusion <NUM> formed on the tap wire housing <NUM>. The insulation piercing connector <NUM> is shown to include four socket openings <NUM> on the outer insulator <NUM> and four socket protrusions <NUM> on the tap wire housing <NUM>, however any number of one or more socket openings <NUM> and one or more socket protrusions <NUM> may be used according to other embodiments.

As shown in <FIG>, the outer insulator <NUM> is provided to fit over the tap wire housing <NUM> such that the socket openings <NUM> come down and snap-fit over the socket protrusions <NUM> of the tap wire housing <NUM>. <FIG> shows an assembled state where the outer insulator <NUM> has been snap-fit onto the tap wire housing <NUM>. <FIG> also shows an enlarged view over area A that includes a specific illustration of how the socket protrusion <NUM> fits inside the socket opening <NUM> to accomplish the snap-fit attachment mechanism. <FIG> shows another enlarged view of the socket protrusion <NUM> in an attached state where the socket protrusion <NUM> engages the socket opening <NUM> by being snap-fit into the socket opening <NUM>. <FIG> shows an enlarged view of a detached state where the socket protrusion <NUM> has been detached from the socket opening <NUM>. The outer insulator <NUM>, including the socket opening <NUM>, may be made from a plastic or other elastomer material that allows the socket opening <NUM> to deform for allowing the socket protrusion <NUM> to fit into, and out of, the socket opening <NUM> during the attachment and detachment process.

<FIG> shows a bottom-side view of the of the outer insulator <NUM> and the tap wire housing <NUM> in their attached state. From this bottom-side view, the snap-fitment of the socket protrusion <NUM> to fit within the socket opening <NUM> can be seen. The outer insulator <NUM> and/or the tap wire housing <NUM> may be formed using a straight-pull injection-molding process, or other manufacturing process that does not require complicated side action or other advanced manufacturing methods.

<FIG> shows the insulation piercing connector <NUM> in the assembled state where the tap wires <NUM> enter the insulation piercing connector <NUM> through the top opening <NUM> and runs internally through the insulation piercing connector <NUM> to attach to the insulation piercing assembly within the top housing <NUM>. Also in this assembled state, the phase wire <NUM> is securely fit into the cylindrical recess created by the concave portions of the top housing <NUM> and the bottom housing <NUM> coming together. Also in this assembled state, the stamped contacts <NUM> (not shown) pierce through an insulation covering of the phase wire <NUM> to make electrical contact with an inner conductor of the phase wire <NUM>. To achieve this assembled state, torque may be applied to the bolts <NUM> until a predetermined torque is achieved to ensure proposer termination of the insulation piercing connector <NUM> to the phase wire <NUM>.

<FIG> shows an exploded view of an insulation piercing connector <NUM> according to an example of the present disclosure useful for understanding the invention. The insulation piercing connector <NUM> is similar to the insulation piercing connector <NUM>, but having the outer insulator <NUM>, tap wire housing <NUM>, and related fastener components removed. This alternative design of the insulation piercing connector <NUM> may provide improved structural optimization (rigidity), reduced number of components within the product assembly, improved functionality in the form of improved di-electric performance, and a simplified installation methodology.

The insulation piercing connector <NUM> includes the top housing <NUM> and the bottom housing <NUM>, where the top housing <NUM> and the bottom housing <NUM> are attached using the bolts <NUM> (e.g., hex driven cap bolts), the spring washers <NUM>, and the flat washers <NUM>. The bolts <NUM> are inserted through openings <NUM> on the top housing <NUM>, and down through openings <NUM> on the bottom housing <NUM>. According to some embodiments, the threaded end of the bolts <NUM> are secured to inner threads within the openings <NUM> of the bottom housing <NUM>. According to other embodiments, nuts (not illustrated) are threaded onto the threaded ends of the bolts <NUM> at the bottom-side of the bottom housing <NUM> after the bolts have been inserted through both the openings <NUM> and the openings <NUM>. When the top housing <NUM> and the bottom housing <NUM> are attached together, they form a cylindrical recess for holding the phase wire <NUM>, as shown in <FIG> that illustrates the insulation piercing connector <NUM> in the assembled state. The top housing <NUM> includes a top portion <NUM> and a top opening <NUM> for receiving the tap wires <NUM>.

The insulation piercing assembly in the insulation piercing connector <NUM> uses a simpler design with fewer components when compared to the insulation piercing assembly used in the insulation piercing connector <NUM>. This simpler design will be described as the integrated contact assembly <NUM> of the insulation piercing connector <NUM>. The integrated contact assembly <NUM> includes a screw fastener <NUM> and an integrated housing and piercing contact (integrated HPC) that combines the housing <NUM> and the piercing contact <NUM> into a single-piece component. A more detailed description of the integrated contact assembly <NUM> is provided with respect to <FIG>. Related to the integrated contact assembly <NUM>, the insulation piercing connector <NUM> also includes an inner insulator <NUM>. The inner insulator <NUM> may be made from an elastomer material and be configured to fit within an inner housing of the top housing <NUM> to cover, at least partially, the piercing contact <NUM>.

<FIG> shows an insulation piercing connector <NUM> according to an alternative example useful for understanding the invention that includes the insulation piercing connector <NUM> using an alternative example of the insulation piercing assembly. According to the insulation piercing connector <NUM>, the insulation piercing assembly directly attaches the stamped contacts <NUM> to an exposed conductor <NUM> of the tap wires <NUM>. The stamped contacts <NUM> may be attached to the exposed conductor <NUM> using an adhesive, welding process, or other known attachment process.

<FIG> shows the insulation piercing connector <NUM> in a partially assembled state where the tap wires <NUM> have been inserted and connected to the integrated contact assembly <NUM>, and the phase wire <NUM> has been placed within the cylindrical recess being formed by the top housing <NUM> and the bottom housing <NUM>.

<FIG> shows the insulation piercing connector <NUM> in the assembled state where the tap wires <NUM> have been inserted and connected to the integrated contact assembly <NUM>, and where the piercing contacts <NUM> (not illustrated) are internally positioned to pierce the phase wire <NUM> that is now placed within the cylindrical recess formed by the top housing <NUM> and the bottom housing <NUM> coming together in the assembled state. Although <FIG> and <FIG> have been described as relating to the insulation piercing connector <NUM> using the integrated contact assembly <NUM>, <FIG> and <FIG> may also apply to the insulation piercing connector <NUM> using the insulation piercing assembly that directly attaches the stamped contacts <NUM> to the exposed conductor <NUM> of the tap wires <NUM>.

<FIG> shows a view of the integrated contact assembly <NUM> where the tap wire <NUM> is secured to the integrated contact assembly <NUM>, and the piercing contacts <NUM> are piercing the phase wire <NUM> to electrically connect to the conductor <NUM> of the phase wire <NUM>. As shown in <FIG>, the tap wire <NUM> is secured to the integrated contact assembly <NUM> by inserting the exposed conductor <NUM> into a space <NUM> of the housing <NUM>. The screw fastener <NUM> is inserted into a fastener opening <NUM> of the housing <NUM> and a torque is applied to the screw fastener <NUM> to bias the screw fastener <NUM> towards the piercing contacts <NUM>. This biasing of the screw fastener <NUM> moves the screw fastener <NUM> towards the piercing contacts and thereby decreases the space <NUM> in which the exposed conductor <NUM> resides. Eventually, the screw fastener will abut against the exposed conductor <NUM> and push the exposed conductor <NUM> to in turn abut against the piercing contacts <NUM>.

The single-piece design of the integrated HPC that combines the housing <NUM> and the piercing contact <NUM> reduces the number of unique components and the number of assembly steps to manufacture and field-use the insulation piercing connector <NUM>. Although the integrated HPC is shown in <FIG> to have the housing <NUM> shaped into a cylindrical shape, alternative embodiments within the scope of this disclosure provide the housing <NUM> in different shapes and opening configurations. For example, <FIG> show the integrated HPCs <NUM>, <NUM>, <NUM> including a housing portion with a cube shape.

In <FIG> the integrated HPC <NUM> includes a fastener opening <NUM> for receiving the screw fastener <NUM> on a first surface of the housing portion that is opposite the piercing contact portion. <FIG> also shows the integrated HPC <NUM> including a space <NUM> for receiving the exposed conductor <NUM> of the tap wires <NUM> on a second surface (top) of the housing portion that is adjacent to the piercing contact portion.

In <FIG> the integrated HPC <NUM> includes a fastener opening <NUM> for receiving the screw fastener <NUM> on the first surface of the housing portion that is opposite the piercing contact portion. <FIG> also shows the integrated HPC <NUM> including a space <NUM> for receiving the exposed conductor <NUM> of the tap wires <NUM> on a third surface (side) of the housing portion that is adjacent to the piercing contact portion.

Claim 1:
An insulation piercing connector (<NUM>, <NUM>, <NUM>), comprising:
an outer insulator (<NUM>, <NUM>, <NUM>) comprising an opening (<NUM>, <NUM>);
a tap wire housing (<NUM>, <NUM>) comprising at least one aperture (<NUM>);
a top housing (<NUM>, <NUM>, <NUM>),
wherein the tap wire housing and the top housing removably connect with each other;
a bottom housing (<NUM>, <NUM>, <NUM>),
wherein the top housing and the bottom housing form a central aperture (<NUM>) for holding a power cable (<NUM>); and
a contact (<NUM>, <NUM>) configured to be housed within the top housing in an assembled state, the contact configured to electrically couple a tap wire (<NUM>, <NUM>) to the power cable, wherein the opening (<NUM>, <NUM>), the at least one aperture (<NUM>), and the top housing (<NUM>, <NUM>, <NUM>) are arranged to receive the tap wire (<NUM>, <NUM>) therethrough to couple the tap wire with the contact within the top housing in the assembled state.