Patent ID: 12212092

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 toFIGS.1A-16C.

Referring now to the drawings, a power cable connector assembly10according to embodiments of the present invention is shown inFIGS.1A-1B. As shown inFIG.1A, the power cable connector assembly10may include a power cable20and a power cable connector100. In some embodiments, the assembly10may further include a heat shrink tube30. As discussed in further detail below, in some embodiments, the heat shrink tube30may extend over at least a portion of an outer sleeve22of the power cable20and extend within at least a portion of the power cable connector100to create a seal, thereby protecting the interconnection between the power cable20and the power cable connector100.

FIG.1Bis an exploded view of the power cable connector100ofFIG.1A. As shown inFIG.1B, in some embodiments, the connector100may include a main body102, a back cover104and an insulator130. The main body102has a bore (or interior cavity)103therethrough. In some embodiments, the main body102may have a generally cylindrical shape. The main body102is configured to be removably secured to the insulator130and the back cover104. For example, in some embodiments, the main body102may comprise a first threaded section102athat corresponds to a threaded section104aof the back cover104and a second threaded section102bthat corresponds to a threaded section138of the insulator130(see also, e.g.,FIG.3A,FIG.5A,FIG.9B,FIG.11B).

The connector100further includes a first seal110aand a second seal110b. The first seal110ais configured and sized to form an interference fit within the main body102. In some embodiments, the main body102may comprise a clamp ring (or a plurality of spring fingers)102cconfigured to engage the first seal110a(see, e.g.,FIGS.10A-10C). The second seal110bis configured and sized to form an interference fit with the insulator130(see, e.g.,FIGS.8A-8B). As discussed in further detail below, different first and second seals110a,110bmay be used with the connector100to accommodate different sized conductor power cables22.

Each seal110a,110bcomprises two apertures111. The apertures111are sized to form an interference fit with a specific-sized conductor power cable22and corresponding seals110a,110bmay be used for different sized power cables22. For example, in some embodiments, seals110a,110bwith apertures111having a size of about 6 mm2would be used to accommodate conductors24having a similar size. However, if the conductors24have a size of about 25 mm2, then the seals110a,110bwith 6 mm2apertures111would be replaced with different seals110a,110bhaving a size of about 25 mm2to accommodate the conductors24having a similar size. Thus, the power cable connectors100of the present invention allow for the connection of multiple different sizes of conductor power cables20.

In some embodiments, the first and second seals110a,110bmay be color-coded to help installers match the appropriately sized seals110a,110bwith a specific-sized conductor power cable22. In some embodiments, the power cable connector100of the present invention may be used to accommodate power cables20with conductors24having a size between 6 mm2and about 25 mm2.

The connector100of the present invention further includes a pair of female connector pins106(i.e., positive and negative polarity). The female connector pins106correspond to the size of the inner conductors26of the power cable22. The female connector pins106are configured to be inserted into the insulator130. In some embodiments, interior channels132aof the insulator130are configured such that the female connector pins106may only be inserted one way (see, e.g.,FIGS.5A-5BandFIGS.7A-7B).

The connector100further includes an end cap112. The end cap112is configured to receive a portion of the insulator130(see, e.g.,FIGS.5A-5C). As discussed in further detail below, the end cap112may be secured to the insulator130via a locking nut140(see, e.g.,FIGS.6A-6E). In some embodiments, the locking nut140may be configured to implement a “bayonet” locking mechanism. A third seal114may reside between the insulator130and the end cap112. In some embodiments, the third seal114may be an O-ring.

In some embodiments, the power cable connector100of the present invention may further include a strain relief boot116. The strain relief boot116may be secured to the back cover104with a clamp120and a couple screws122and nuts124(see, e.g.,FIGS.13A-13B). Other known methods of securing the strain relief boot116to the back cover104may be used.

Referring toFIGS.2A-13B, a method of installing a power cable connector assembly10according to embodiments of the present invention is illustrated.

FIGS.2A-2Cillustrate the power cable20being prepared to attach the power cable connector100described above. As shown inFIG.2A, an outer sleeve22(e.g., a nylon braid) of the power cable20is pulled back a length (L1) to expose the separate conductors24within the power cable20. In some embodiments, the outer sleeve22is pulled back at least a length (L1) of about 145 mm. As discussed above, and shown inFIG.2B, in some embodiments, a heat shrink tube30may be used to help provide an additional seal with the power cable20. In some embodiments, the heat shrink tube30may be slid onto the power cable20until the conductors24extend out from the heat shrink tube30a length (L1A) of about 80 mm. In some embodiments, the heat shrink tube30may have a length (L1B) of about 95 mm and the tube30may overlap the outer sleeve22of the power cable20a length (L1C) of about 30 mm. After the heat shrink tube30is positioned on the power cable20, heat may then be applied to secure the tube30in place on the power cable20. As shown inFIG.2C, the conductors24are then stripped back a length (L2) to expose the inner conductors26. In some embodiments, the conductors24are stripped back a sufficient length (L2) to allow the inner conductors26to be coupled with a respective female conductor pin106of the power cable conductor100(see, e.g.,FIGS.4A-4B). For example, in some embodiments, the conductors24may be stripped back a length (L2) of about 10 mm.

FIGS.3A-3Billustrate parts of the power cable connector100being slid onto the prepared power cable20in the following order: (1) the strain relief boot116; (2) the back cover104; (3) the first seal110a; (4) the main body102; and (5) the second seal110b. As discussed above, and shown inFIGS.3A-3B, the apertures111of the first and second seals110a,110bare sized to slide onto and form an interference fit with the conductors24. Different sized seals110a,110b(i.e., different sized apertures111of seals110a,110b) may be used to accommodate different sized conductors24. Note, in some embodiments, the seals110a,110bmay be the same color (i.e., color-coded) to help indicate to a technician determine during installation which seals110a,110bwill accommodate the same sized conductor24. In some embodiments, the parts (i.e.,116,104,110b,102, and110a) are slid onto the power cable20until a sufficient length (L3) of prepared power cable20extends outwardly from the main body102of the connector100. For example, in some embodiments, the parts (i.e.,116,104,110b,102, and110a) are slid onto the power cable20until the stripped conductors24,26extend outwardly from the main body102a length (L3) of about 25 mm.

FIGS.4A-4Billustrate the female conductor pins106of the connector100being coupled (or attached) to the inner conductors26of the conductor power cable20. Each pin106has a polarity (i.e., one negative and one positive) that corresponds to a similar polarity of the inner conductors26. The inner conductors26are received by a respective recess106ain the female conductor pins106until an outer edge of the pins106contact the outer jacket of the conductor24. Screws107are used to secure the conductors26within the recesses106aof the female conductor pins106. Different sized screws107may be used depending on the size of the conductors26being secured to the female conductor pins106. For example, a short version of the screws107may be used to tighten copper sections of the wires (i.e., the inner conductors26) having a size between about 16 mm2and about 25 mm2, whereas a longer version of the screws107may be used to tighten inner conductors26having a size between about 6 mm2and about 10 mm2. In some embodiments, the screws107may be tightened to about 5 Nm. In some embodiments, the screws107may have a TORX shape which allows the use of a dynamometric key preset at 5 Nm. The TORX shape of the screws107may help improve reliability and repeatability of the tightening force used to secure the inner conductors26to the female conductor pins106.

FIGS.5A-5CandFIGS.6A-6Fillustrate the assembly and securing of the end cap112to the insulator130. As shown inFIGS.5A-5C, in some embodiments, the insulator130has a body134and a pin section132extending axially from the body134. The body134of the insulator130may comprise one or more recesses136that extend along an outer surface of the body134. As discussed herein, in some embodiments, the body134of the insulator130may also comprise a threaded section138that corresponds to the second threaded section102bof the main body102of the connector100. The pin section132comprises two interior channels132aconfigured to receive the pair of female conductor pins106. In some embodiments, the interior channels132amay be configured to form an interference fit with the female conductor pins106.

Still referring toFIGS.5A-5C, in some embodiments, a third seal114may reside between the end cap112and the insulator130. As shown inFIGS.5A-5B, the third seal114has an aperture114acorresponding to the shape of the pin section132of the insulator130. InFIG.5C, the end cap112is slid onto the pin section132of the insulator130until the third seal114is secured therebetween. In some embodiments, the third seal114may be an O-ring. In some embodiments, at least a portion of the end cap112may be hex-shaped.

Referring toFIGS.6A-6F, in some embodiments, the end cap112may be secured to the insulator130via a locking nut140. The locking nut140has an annular body142and comprises one or more protrusions144extending radially inward from the annular body142. As discussed above, the insulator130may comprise one or more recesses136. In some embodiments, the end cap112also may comprise one or more recesses112a. As discussed below, the recesses136,112amay be configured to receive (and guide) the protrusions144of the locking nut140as the locking nut140is inserted onto the insulator130and end cap112.

After the insulator130, the third seal114, and the end cap112are combined together, the locking nut140may be used to secure the end cap112to the insulator130. As shown inFIG.6A, each protrusion144of the locking nut140may be aligned with a respective recess136of the insulator130. As shown inFIG.6B, the locking nut140is slid onto the insulator130with the protrusions144sliding within the recesses136of the insulator130(i.e., guiding the locking nut140) until the protrusions144reach the opposing edge of the insulator130and third seal114. As shown inFIG.6C, the locking nut140is then rotated along the third seal114until each protrusion144of the locking nut140is aligned with a respective recess112aof the end cap112. As shown inFIG.6D, the locking nut140is then slid onto the end cap112with the protrusions144sliding within the recesses112aof the end cap112(i.e., continuing to guide the locking nut140). As shown inFIG.6E, the locking nut140is then rotated as the protrusions144continue to slide within the recesses112aof the end cap112until the protrusions144reach the end of the recesses112a, thereby locking the locking nut140in place on the end cap112and securing the end cap112to the insulator130.FIG.6Fshows the end cap112secured to the insulator130by the locking nut140and ready to be combined to the power cable connector assembly10.

In some embodiments, the locking nut140may further comprise a plurality of ribs146. The ribs146may help to enhance a technician's grip on the locking nut140, for example, when the technician is rotating the locking nut140on the end cap112.

FIGS.7A-7Bshow the female conductor pins106being inserted into the insulator130. The female conductor pins106are inserted until at least a portion is received within the interior channels132aof the pin section132of the insulator130(see also, e.g.,FIG.10C). As discussed herein, in some embodiments, the insulator130may form an interference fit with the female conductor pins106. As shown inFIGS.7A-7B, the insulator130surrounds the connection between the female conductor pins106and the inner conductors26. As discussed herein, in some embodiments, the interior channels132aof the insulator130are configured such that the female connector pins106may only be inserted one way.

Referring now toFIGS.8A-13B, the steps for securing together the remaining parts of the connector100are illustrated. First, as shown inFIGS.8A-8B, the second seal110bis slid until as least a portion of the seal110bis received within the body134of the insulator130(see also, e.g.,FIG.10C). Next, the main body102is slid over the second seal110band engages a portion of the insulator130(FIGS.9A-9B). As shown inFIG.9B, the main body102is rotated such that the second threaded section102bengages the corresponding threaded section138of the insulator130, thereby securing the main body102to the insulator130.

Next, as shown inFIGS.10A-10C, the first seal110ais slid into the main body102of the connector until the seal110acontacts an inner annular flange102fof the main body102(FIG.10C). In some embodiments, the main body102may comprise a clamp ring (or a plurality of spring fingers)102cthat surrounds the seal110a. Next, as shown inFIGS.11A-11B, the back cover104is slid to engage a portion of the main body102. The back cover104is then rotated such that the threaded section104aof the back cover104engages the corresponding first threaded section102aof the main body102, thereby securing the back cover104to the main body102. In some embodiments, as the back cover104is rotated onto the main body102, the flexible clamp ring102cis compressed against the first seal110ato create an even tighter seal between the connector100and the conductors26.

As a final step, and as shown inFIGS.12A-13B, the strain relief boot116and clamp120are secured to the connector100.FIGS.12A-12Billustrate the strain relief boot116being slid until at least a portion of the boot116is inserted within the back cover104. As shown inFIG.12B, at least a portion of the strain relief boot116still overlaps the heat shrink tube30. After the strain relief boot116is positioned, the clamp120may be secured to the connector100. As shown inFIGS.13A-13B, the clamp120may be secured to the connector100via a pair of screws122and nuts124. Similar to screws107used to secure the inner conductors26to the female conductor pins106described herein, the pair of screws122may have a TORX shape to allow the use of a dynamometric key to tighten them at a pre-determined strength. As shown inFIG.13A, in some embodiments, the back cover104of the connector100may comprise a pair of flanges104fconfigured to receive the screws122and secure the clamp120to the back cover104. Other known methods may be used to secure the clamp120to the connector100.

FIGS.14A-14Cillustrate disassembling a power cable connector assembly10according to embodiments of the present invention.

The power cable connector assembly10described herein may be used with direct current (DC) power conductors. In some embodiments, the assembly10may be used with 30-amp conductors. In some embodiments, the power cable connector assembly10of the present invention may be used with single-core conductor cables or dual-core conductor cables. The power cable connector assembly10of the present invention may be used instead of the terminal blocks described above.

Referring now toFIGS.15A-15E, a coupler200that may be used with the power cable connector assembly10described herein is illustrated. As shown inFIGS.15A-15E, the coupler200has a generally cylindrical main body202. In some embodiments, the main body202of the coupler200may comprise a threaded portion220(see, e.g.,FIG.15D). A pair of mating sections204,206extend axially in opposing directions from the main body202. The end of each mating section204,206comprises an aperture207that generally corresponds to the shape of the pin section132of the insulator130of the power cable connector assembly10. The aperture207allows the pin section132to be received within an interior cavity208of each mating section204,206.

The coupler200further includes a pair of conductor pins210(i.e., one positive and one negative) that extend through the main body202. Opposing ends of the conductor pins210reside within the respective interior cavity208of the mating sections204,206. To attach the coupler200to a power cable connector assembly10described herein, first the locking nut140is loosened and the end cap112is removed. Next, the pin section132of the assembly10is inserted through aperture207and into the interior cavity208of mating section206. As the pin section132is being inserted into the interior cavity208, each conductor pin210is received by a respective interior channel132aof the pin section132. The pin section132is inserted into the mating section206until the third seal114contacts an annular shoulder202aof the main body202of the coupler200.

In some embodiments, the coupler200may be configured to be secured to an infrastructure flange230. In some embodiments, the infrastructure flange230is fixed to the mast of a base station tower (not shown). As shown inFIGS.15D-15E, in some embodiments, the threaded portion220of the main body202of the coupler200may comprise two flat surfaces209a,209bimplementing a “key” configured to match a keyed hole (or shape)230ain the infrastructure flange230(see, e.g.,FIGS.16A-16C). The two opposite surfaces209a,209bmirror surfaces of the keyed hole230ain the infrastructure flange230(see, e.g.,FIG.15D). The coupler200fits into the flange230by penetrating the shaped or keyed hole230aavailable on the flange230. In some embodiments, different couplers200may each have a different “key” that corresponds to respective keyed holes230ain the infrastructure flange230.

The “key” (i.e., flat surfaces209a,209bof the threaded portion220) of the coupler200allows a one-way only insertion of the coupler200into the infrastructure flange230(i.e., via keyed hole230a), prevents rotation of the coupler200during tightening of HEX nut203, and allows a repetitive and self-oriented assembling of multiple couplers200in the same infrastructure flange230showing all the positive and negative polarities in the same orientation.

As shown inFIG.15D, the coupler200may be secured to the assembly10in a similar manner with the end cap112, i.e., by rotating the locking nut(s)140as the protrusions144slide within recesses206ain the mating section206. A second power cable connector assembly10′ may then be secured to the coupler200in a similar manner using the opposing mating section204.

FIG.15Eillustrates an exemplary keyed hole in the infrastructure flange230having opposite faces239a,239bthat match the flat surfaces209a,209bof threaded portion220of the coupler200described herein.

FIGS.16A-16Cillustrate an infrastructure flange230having four couplers200assembled on the flange230via keyed holes230aaccording to embodiments of the present invention.FIGS.16B-16Cillustrate a power cable connector assembly10secured to one of the couplers200.

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.