WO1996013877A1

WO1996013877A1 - Electrical wire connector

Info

Publication number: WO1996013877A1
Application number: PCT/US1995/011744
Authority: WO
Inventors: Hitesh Cherry; Michael A. Kandros; Daniel V. Nardone
Original assignee: The Whitaker Corporation
Priority date: 1994-10-31
Filing date: 1995-09-12
Publication date: 1996-05-09

Abstract

A wire conector (50) is disclosed having a C-shaped clamping member (52) an a mating wedge (54). The clamping member includes two oppositely formed rolled edges (58, 59) that form two opposing concave channels (60) for receiving a power cable (62) and the wedge for locking the cable tightly in place. A flange (74) extends from the wedge and has mounting holes (96) formed therein. A jumper cable (76) having a terminated end (78) is electrically connected to a surface (92) of the flange by means of two bolts (80) extending through holes in the terminal and the holes in the flange and two nuts (82) tightened in place. The wedge includes two opposite edges (64, 66), one having a concave surface (88) that engages the power cable and the other having a convex surface (90) that engages one of the convex channels (60) of the clamping member (52).

Description

ELECTRICAL WIRE CONNECTOR The present invention relates to wire connectors for electrical distribution systems of the type having an outer C-shaped clamping member and a wedge for interconnecting two or more wires.

In the power distribution industry wire connectors are widely used to interconnect electrical equipment to power conductors without physically breaking or rerouting the power conductor. The wire connector usually consists of two parts, a C-shaped clamping member and a wedge. Such wire connectors are disclosed in United States Patent numbers 3,280,856 and 3,349,167 both of which are incorporated herein by reference. A typical wire connector is shown in Figures 1 and 2 in a typical application. As shown, a wire connector 10 includes a C-shaped clamping member 12 and a wedge 14. The clamping member 12 has a web 16 and two oppositely formed rolled edges 18 that diverge from left to right, as viewed in Figure 1. The rolled edges 18 form opposing channels for receiving a power cable 20, or wire, and a tap lug 22 with the wedge 14 therebetween. The use of the term "power cable" herein is intended to include all electrical conductors for interconnecting electrical equipment to electrical power sources, either positive or negative polarity or ground, including cables, wires, and similar structures, of both stranded and solid construction. - The tap lug 22 has a cylindrical shank 24 that is disposed within one of the channels and a flange 26 having mounting holes therein. The wedge has opposite edges that diverge similarly to the rolled edges 18 and are concave to better seat the cylindrical shaped power cable 20 and shank 24. When installing the wire connector, the clamping member 12 is placed with one rolled edge over the power cable and the shank 24 of the tap lug 22 in the opposite channel. The wedge is then inserted into the larger end of the clamping member and forced into tight engagement with the cable 20 and shank 24. This operation is performed either with a hand tool or a power assisted tool. The power source for the power assisted tool can be hydraulic, electric, or solid propellant, as is well known in the industry. A jumper cable 28, or wire, having a long tongue terminal 30 terminated to one end thereof is electrically connected to the flange 26 by means of a pair of bolts 32 and nuts 34. The other end of the jumper cable is connected to an electrical device 36, such as a transformer or a lightning arrester. This electrical connection may be made to an exterior terminal, such as shown at 38 in Figure 1, or it may be made inside the outer case of the device 36. The tap lug 22 is a convenient way of electrically connecting the terminal 30 to the wire connector 10. However, when this tap lug is not available, the connection can be made by placing a short jumper wire, not shown, in the wire clamp in place of the shank 24, terminating the free end of the jumper wire with a terminal similar to the terminal 30 and then bolting the two terminals together. Use of the jumper wire instead of the tap lug is illustrated in the above referenced '856 and '167 patents. In either case, there are three electrical interfaces between the jumper 28 and the power cable 20. These electrical interfaces are between the terminal 30 and the flange 26, the shank 24 and one side of the wedge 14, and the other side of the wedge and the power cable 20. And in both cases an extra part must be used, either the tap lug 22 or a short terminated wire. The extra part increases the cost of the connection and the three electrical interfaces result in increased electrical resistance and power loss. Additionally, as shown in Figures 3 and 4, the diameter of the shank 24 will affect the range of sizes of the power cable 20 that can be accommodated by the wire connector 10. In the case where the current requirements are relatively small, the diameter of the shank 24 is also relatively small, as shown in Figure 3. In this case the power cable 20 has a size range schematically indicated by the solid circle 39 and the dashed circle 40. However, where the current requirements are larger, a larger diameter shank 24 must be used thereby effectively changing the acceptable range of sizes of the power cable 20, as schematically shown by the smaller solid circle 39 and the correspondingly smaller dashed circle 40 in Figure 4. This occurs because the larger diameter shank 24 shifts the wedge 14 upwardly, as viewed in Figure 4, leaving a smaller space for the power cable 20, therefore, the range of sizes that can be accommodated by the wire connector is shifted a corresponding amount toward the smaller diameters. This sometimes results in confusion as to the proper combination of cable and shank sizes and may contribute to equipment failure due to improper selection. What is needed is a wire connector that will interconnect the terminal 30 of the jumper cable 28 directly to the wire connector without the need for the tap lug 22 or the terminated short jumper, thereby eliminating one of the parts and one of the electrical interfaces. Additionally, a specific wire connector should consistently accommodate a known range of sizes of the power cable 20 to eliminate confusion as to proper combinations of sizes.

An electrical wire connector is disclosed for electrically connecting and mechanically securing two wires together. The wire connector includes a C-shaped clamp member having a web and two rolled over edges on opposite sides of said web. The two rolled over edges diverge toward a first end of the clamp member and form inwardly facing concave channels. A wedge is provided having first and second opposite edges diverging toward a first end of the wedge that are conformably received in a closed position between the two rolled over edges of the clamp member. The first opposite edge has a concave portion and the second opposite edge has a convex portion and are arranged so that when the wedge is in its closed position the convex portion engages one of the concave channels and the concave portion forms a wire receiving cavity with the other of the concave channels for securing to a first wire. An attachment is provided and arranged to secure a terminated end of a second wire to the wedge. Embodiments of the present invention will be described with reference to the accompanying drawings, in which:

FIGURE 1 is a schematic representation of a known wire connector showing how it is used; FIGURE 2 is an isometric view of the wire connector shown in Figure 1;

FIGURE 3 is a cross-sectional view taken along the lines 3-3 of Figure 1, showing a wire connector with an associated terminal lug; FIGURE 4 is similar to Figure 3 showing a larger sized terminal lug;

FIGURE 5 is a schematic representation of a wire connector incorporating the teachings of the present invention; FIGURE 6 is an isometric view of the wire connector shown in Figure 5;

FIGURES 7 and 8 are front and side views, respectively, of the wedge shown in Figure 6;

FIGURES 9 and 10 are front and side views, respectively, of a second embodiment of the wedge shown in Figure 6; and

FIGURE 11 is a side view of a third embodiment of the wedge shown in Figure 6.

There is shown in Figures 5 and 6 a wire connector 50 having a C-shaped clamping member 52 and a wedge 54. The clamping member 52 has a web 56 and two oppositely formed rolled edges 58 and 59 that diverge from left to right, as viewed in Figure 5. The rolled edges 58 and 59 form opposing concave channels 60, as best seen in Figure 6, for receiving a power cable 62 and the wedge 54 therebetween. The wedge 54 is relatively flat and elongated having two opposite edges 64 and 66 that diverge from a smaller end 68 toward a larger end 70 so that when assembled to the clamping member 52, in its fully inserted closed position as shown in Figure 5, the edge 64 is adjacent and substantially parallel to the rolled edge 58 and the edge 66 is adjacent and substantially parallel to the rolled edge 59. The wire connector 50 has a longitudinal axis 72 that extends through the wedge 54 equidistant from the edges 64 and 66, as shown in Figure 5. A flange 74 extends from the larger end 70 of the wedge 54. A jumper cable 76, or wire, having a long tongue terminal 78 terminated to one end thereof is electrically attached to the flange 74 by means of a pair of bolts 80 and nuts 82. The other end of the jumper cable is connected to an electrical device 84, such as a transformer or a lightning arrester. This electrical connection may be made to an exterior terminal, such as shown at 86 in Figure 5, or it may be made inside the outer case of the device 84.

As best seen in Figures 7 and 8, the edge 64 has a concave surface 88 and the opposite edge 66 has a convex surface 90, both concave and convex surfaces diverging toward the larger end 70 and running substantially the entire length of the wedge 54. The flange 74 is rigidly attached to the larger end 70 of the wedge 54, as shown in Figures 7 and 8. The flange may either by welded to the wedge or formed integral with the wedge by any suitable method such as casting or forging so that the wedge and flange are of unitary construction. The flange 74 is elongated having a longitudinal axis that is perpendicular to the axis 72 and includes two major substantially flat surfaces 92 and 94 that are parallel. Two mounting holes 96 are formed through the flange and spaced to conform to the standard spacing of the holes in the terminal 78. The mounting holes 96 will accommodate a wide range of sizes of terminals for varied current requirements. The flange 74 is joined to the wedge adjacent the larger end 70, well below the concave surface 88, as viewed in Figure 7, so that it does not interfere with the power cable 62 in operation. The convex surface 90 extends from the smaller end 68 to the surface 92 of the flange and is long enough so that when the wire connector 50 is assembled to a power cable of minimum diameter, within the range of acceptable sizes, a space 98 separates the end of the clamping member 52 and the flange 74, as best seen in Figure 6. This assures that the wedge 54 will properly mate with the clamping member 52 for all sizes of power cables 62 within the range of sizes specified for the wire connector 50. When the wedge is properly mated to a clamping member 52, the convex surface 90 is in wedging engagement with a concave channel 60 while the cable 62 is wedged between the concave surface 88 and the other concave channel 60. Because the convex surface 90 is of known size and shape, the range of sizes of power cables that can be accommodated is also known and does not vary when the size of the terminal 78 changes due to varying current requirements of the device 84. A recess 100 and stiffening rib 102 may be optionally formed in each side of the wedge 54 for making the wedge lighter and easier to grip during use in the field. Note that the two mounting holes 96 have axes 104 that are substantially parallel to the axis 72, as shown in Figure 8.

A second embodiment of the wedge 54 is shown in Figures 9 and 10. There, a wedge 110 is shown having edges 64 and 66 that diverge from a smaller end 68 to a larger end 70, including a concave surface 88, a convex surface 90, and a longitudinal axis 72, similar to those identically numbered elements in the wedge 54. A flange 112 is rigidly attached to and extends from the larger end 70 of the wedge 110 well below the concave surface 88 as shown. The flange 112 is elongated having opposite major substantially flat surfaces 114 and 116 that are parallel. A pair of mounting holes 118 are formed through the flange 112 and are identically sized and spaced as the holes 96 of the flange 74, however, the holes 118 have axes 120 that are substantially perpendicular to the axis 72. The convex surface 90 of the wedge 110 extends from the smaller end 68 to a surface 122 of the flange 112 and is long enough so that when the wire connector 50 is assembled to a power cable of minimum diameter, a space separates the end of the clamping member 52 and the flange 112, in a manner similar to the operation of the wedge 54. This assures that the wedge 110 will properly mate with the clamping member 52.

A third embodiment of the wedge 54 is shown in Figure 11. There, a wedge 130 is shown having edges 64 and 66 that diverge from a smaller end 68 to a larger end 70, including a concave surface 88, a convex surface 90, and a longitudinal axis 72, similar to those identically numbered element in the wedge 110. However, instead of a flange 112, the wedge 130 has an extended portion 132, or shank that is long enough to accommodate mounting holes 118 therein in a manner similar to that of the flange 112. Otherwise, the wedge 130 operates in an identical manner to the wedge 54. An important advantage of the present invention is that the number of electrical interfaces between the terminal 78 and the power cable 62 is reduced from three to two thereby reducing power loss. Additionally, the need for a tap lug 22 is eliminated thereby reducing the number of parts needed to utilize the wire connector 50. And, the known size and shape of the convex surface 90 permits specifying a precise range of sizes for the power cables that can be accommodated by a specific wire connector 50, thereby eliminating a source of confusion and error.

Claims

CLAIMS:

1. An electrical wire connector for electrically connecting two wires together comprising:

(a) a C-shaped clamp member (52) having a web (56) and two rolled over edges (58,59) on opposite sides of said web (56) , said two rolled over edges diverging toward a first end of said clamp member and forming inwardly facing concave channels (60) ;

(b) a wedge (54,110,130) having first and second opposite edges (64,68) diverging toward a first end (70) of said wedge (54,110,130) to be conformably received in a closed position between said two rolled over edges (58, 59) of said clamp member (52) , said first opposite edge (64) having a concave portion (88) and said second opposite edge (66) having a convex portion (90) and arranged so that when said wedge (54,110,130) is in said closed position said convex portion (90) engages one of said concave channels (60) and said concave portion (88) forms a wire receiving cavity with said other of said concave channels (60) for securing to a first wire (62) ; and

(c) an attachment arranged to secure a terminated end (78) of a second wire (76) to said wedge (54,110,130) .

2. The wire connector according to claim 1, wherein said attachment includes a hole (96,118) in said wedge and a bolt (80) for extending through said hole and said terminated end (78) of said second wire (76) and a nut (82) threaded onto said bolt for tightly securing said terminated end (78) to said wedge (54) .

3. The wire connector according to claim 1, wherein said attachment includes a flange (74,112,132) extending from said wedge (54,110,130) , a hole (96,118) in said flange and a bolt (80) for extending through said hole (96,118) and said terminated end (78) of said second wire (76) and a nut (82) threaded onto said bolt (80) for tightly securing said terminated end to said flange.

4. The wire connector according to claim 3, wherein said hole (118) has an axis (120) that is substantially perpendicular to the longitudinal axis of said first wire (62) when said wedge (110) is in said closed position.

5. The wire connector according to claim 3, wherein said hole (96) has an axis and said wedge (54) has a longitudinal axis (72) that is substantially equidistant between said first and second opposite edges and substantially parallel to said axis of said hole (96) .

6. An electrical wire connector for electrically connecting two wires together comprising a C-shaped clamp member (52) having a web (56) and two rolled over edges (58,59) on opposite sides of said web (56), said two rolled over edges (58,59) diverging toward a first end of said clamp member (53) and forming inwardly facing concave channels (60); a wedge (54,110,130) having first and second opposite edges (64,66) diverging toward a first end (70) of said wedge (54,110,130) to be conformably received in a closed position between said two rolled over edges (58,59) of said clamp member, characterized in that: said first opposite edge (64) having a concave portion (88) and said second opposite edge (66) having a convex portion (90) and arranged so that when said wedge (54,110,130) is in said closed position said convex portion (90) engages one of said concave channels (60) and said concave portion (88) forms a wire receiving cavity with said other of said concave channels (60) for securing to a first wire (62) ; and an attachment arranged to secure a terminated end (78) of a second wire (76) to said wedge (54,110,130).

7. The wire connector according to claim 6, wherein said attachment includes a hole (96,118) in said wedge and a bolt (80) for extending through said hole and said terminated end (78) of said second wire (76) and a nut (82) threaded onto said bolt for tightly securing said terminated end (78) to said wedge (54) .

8. The wire connector according to claim 6, wherein said attachment (96,118) includes a flange (74,112,132) extending from said wedge (54,110,130), a hole in said flange and a bolt 80) for extending through said hole (96,118) and said terminated end (78) of said second wire (76) and a nut (82) threaded onto said bolt (80) for tightly securing said terminated end to said flange.

9. The wire connector according to claim 8, wherein said hole (118) has an axis (120) that is substantially perpendicular to the longitudinal axis of said first wire (62) when said wedge (110) is in said closed position.

10. The wire connector according to claim 8 wherein said hole (69) has an axis and said wedge(54) has a longitudinal axis (72) that is substantially equidistant between said first and second opposite edges and substantially parallel to said axis of said hole (96) .