Conductor connection system

Details Conductor connection system Conductor connection system

1999-05-05

2001-07-17

Donovan, Lincoln (Department: 2839)

Electrical connectors

Metallic connector or contact also having securing part...

C174S08400S

Reexamination Certificate

active

06261137

ABSTRACT:

TECHNICAL FIELD
The invention relates to a conductor connection system.
BACKGROUND
A conductor connection system joins two conductors, which may be wires, cables, or contacts. Typical connectors of such a system include one or two channels into which the conductors are inserted.
A conventional single channel connector consists of a metal tube having a central bore. To connect two conductors, an end of a first conductor is inserted into one end of the metal tube and that end of the tube is crimped around the first conductor to secure the conductor. The same procedure is used to secure a second conductor in the connector.
Connectors of different bore diameters are provided for connection to conductors of different outer diameters. The bore diameter of the connector must be larger than the outer diameter of the conductor so that the conductor will fit in the connector, but must be small enough to provide a good fit between the crimped connector and the conductor.
A conventional two channel connector has the two channels arranged in parallel and separated by a metal wall. Each channel has an opening running along its length. To connect two conductors, an end of a first conductor is inserted into one of the channels so that the conductor extends along the entire length of the channel. That channel is then crimped around the conductor to secure the conductor. The same procedure is used to secure a second conductor in the other channel. This results in the two conductors being parallel to each other for at least the length of the channels.
To accommodate different conductor diameters, two channel systems are available in different sizes. The sizes vary based on the diameter of the closed channel. A conventional two channel connector can be configured to connect two different sized conductors by fabricating the connector so that the channels have different closed diameters.
Specialized tools, such as installation tools and crimping dies, are used to crimp the connectors around the conductors. The tools are sized to match their corresponding connectors so that each connector size typically requires a corresponding set of tools.
SUMMARY
In one general aspect, a conductor connector includes a generally tubular connector body having a non-uniform wall thickness and defining a central bore extending from a first end of the body. At least one groove is defined along an exterior surface of the body by a pair of side edges and a base edge.
Embodiments may include one or more of the following features. For example, the conductor connector may include a second groove positioned opposite the first groove. A third groove may be positioned adjacent to the first groove and a fourth groove may be positioned adjacent to the second groove. A wall thickness above and below the groove may be greater than the thickness in regions adjacent to the groove. The side edges may be parallel. An angle formed between the side edges and the base edge may be a right angle or an obtuse angle, such as an angle of approximately 106 degrees.
The conductor connector may further include a first conductor inserted into the central bore from one end of the body and a second conductor inserted into the central bore from a second end of the body. The connector may be crimped to retain the first conductor and the second conductor. The connector may be sized to secure conductors ranging in size from a first size having a first cross-sectional area to a second size having a second cross-sectional area 40% or more larger than that of the first size. For example, a connector may secure conductors having diameters ranging from 0.128 inches to 0.258 inches, for a cross-sectional area difference of 306%.
The connector also may include a terminal contact portion attached to the generally tubular connector body at a second end that is opposite the first end of the body. When the connector is so configured, a single conductor is inserted into the bore from the first end.
In another general aspect, a first conductor is terminated or spliced to a second conductor by providing a connector, a first conductor, and a second conductor. The connector includes a generally tubular connector body having a non-uniform wall thickness, defining a central bore extending from a first end of the body, and having at least one groove defined along an exterior surface of the body by a pair of side edges and a base edge. The first conductor is inserted into the central bore from one end of the body and the second conductor is inserted into the central bore from the second end of the body. The connector is crimped to the conductors.
The connector provides considerable advantages, such as permitting a particular connector to be used with conductors having a range of different sizes. This flexibility reduces the number of connectors and supporting tools (e.g., installing tools and crimping dies) needed to provide splicing and termination connections for a given set of conductor sizes, such as conductors ranging in size from #8 Solid AWG to 1033 MCM Stranded. Moreover, the connector has one or more grooves that provide stress relief to prevent damage to the conductors. A considerable benefit also results from the ability to fabricate the connector through the use of aluminum extrusion, rather than cold heading and tube draw dies.
Other features and advantages will be apparent from the following description, including the drawings, and from the claims.


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Kearney Taps, Terminals, and Splices Catalog; Section 141, 142, 143 Aug. 1996.

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