Electrical Connector

Abstract

A connector for making one or more electrical connections to a threaded male or female connection for power distribution applications such as power transformer connections especially in locations in which considerable moisture or water is likely to be present. A conductive connector is designed to mate at one end with the transformer connection within the transformer tank. A body, preferably tubular in shape, is suitably molded or cast about the connector and should be composed of a suitable water impervious resin such as epoxy or the like. The molded body terminates at one end in a bushing section for each transformer connection. The molded body at the other end terminates in a tubular cylindrical wall for each connector. Each cylindrical wall terminates in a peripheral raised rim from which a connector tang centrally protrudes. The raised rim mates with a shoulder on the inside of a waterproof, elastic, tubular sleeve to fully insulate the terminal connection against exposure.

Description

BACKGROUND OF THE INVENTION

In general usage, electrical connections from power system transformers terminate in an internally or externally threaded stud extending normally from the body of the transformer within the transformer tank. In the usual condition, the electrical connection or connections are effected by an intermediate connector which is in turn affixed to suitable cables. The intermediate connector may take the form of a conductive sleeve with the cable soldered or otherwise entered into the opposite end. Another approach has been to mount a terminal member with either a threaded bore or clearance opening on the stud. In the latter case, a clamping screw or the like would be used.

In either of the cases noted, problems have arisen relative to firmness of the connection. Other problems arise relative to the assembly and possible disassembly of the connection. Of course a necessary condition is that a tight and firm electrical connection is made and that the connection be waterproofed and suitably insulatable from moisture.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide a new and improved terminal connector for electrically connecting one or more cables to a threaded terminal connection.

It is a further object of the invention to provide a new high power carrying connector which is readily assembled onto the power source connection and may then be fully waterproofed and insulated.

It is a further object of the invention to provide an improved mating connector which may have a water impervious, insulating jacket molded thereon, the jacket serving to waterproof and insulate the connector and mate with the sleeve to waterproof and insulate the connection to one or more cables.

The invention shown and claimed herein employs the principle of a conductive connector fitted on the mounting connection to a power transformer or the like. A water impervious, insulating body is molded onto the connector leaving only the ends exposed. One end comprises the connection to the transformer, the other one or more tangs for connection to suitable feeder cables. The molded body has a raised peripheral rim about each cable connecting tang to mate with an elastic waterproof sleeve and fully protect each tang connection from exterior conditions and periodic submersion.

The connector or connectors may each be of one piece construction thereby eliminating joints which are troublesome in high power condition.

With any of the approaches shown, a waterproof, insulating jacket is molded onto the terminal connector to produce bushing at one end and the ridged periphery at the other. An enlarged central body section is provided to permit a support flange of suitable metal such as stainless steel to be sealingly embedded in the connector.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross section through a single terminal connector, embodying the invention exploded away from the mounting;

FIG. 2 is an end view of the connector of FIG. 1;

FIG. 3 is a side view in elevation of the terminal of FIG. 1, with a waterproof sleeve secured thereon, the sleeve being broken away in part;

FIG. 4 is a front view in elevation of a multiple connector embodying my principle;

FIG. 5 is a side view in elevation of the connector of FIG. 4;

FIG. 6 is a plan view in elevation of the connector of FIGS. 4 and 5;

FIG. 7 is a front view in elevation of an alternate form of multiple connector; and

FIG. 8 is a side view in elevation of the connector of FIG. 7.

Turning to the drawings in detail, in FIG. 1 and 2, I show a first embodiment of my invention. There I show a sheet metal transformer tank 10 which has a circular opening 12 for passing therethrough a stud-ended connector 20. The cavity 12 may have an enlarged counterbore 14 large enough to receive a jam nut 15 for reasons which will be explained. The transformer connection may be made through a terminal lug 16 which may be any conventional lug design. The lug connects conductively to the transformer and provides one or more openings threaded or otherwise for connection thereto of a suitable connector stud 21.

For mounting a terminal connection on the stud, I provide a jacketed, one-piece conducting connector 20 of copper, or aluminum, or other suitably conductive material or alloy. Connector 20 includes a main body 22 extending therethrough from stud 21 to its furthermost extremity being a terminal member 24 angled from the main body 22. The main body 22 is cylindrical and has extending from its end wall 26, an exteriorly threaded stud 23 centrally disposed within the main body 22. At a right angle to the main body is the terminal member 24 which in cross section is intermediately circular in section 27 and is a circular segmental tang 28. On the flat side of the terminal member 24 are suitably threaded openings 32 each of which may receive a suitably cable lug attaching bolt 30. The connector 20 is jacketed within a water impervious insulating jacket 34 which may be molded or cast of suitable plastic resin such as epoxy to adhere to and cover the connector body. At the transformer mounting end, the jacket terminates in a tapered frusto-conic bushing 40.

The jacket 34 has embedded therein, a stainless steel annular flange 42 protruding from the jacket body concentric to the main body of the connector. The flange is spaced from the body to maintain a layer of insulating material therebetween. The flange is adapted to be adhered in a waterproof fashion to the transformer tank 10 by suitable means such as welding, brazing or suitable water-impervious sealing methods.

The main body of the connector is formed with a right angle elbow 44 to the rear of which (FIG. 1 the connector diameter is increased gradually in portion 27 leading to its end wall 45 leading from which the terminal segmental tang 28 protrudes. The jacket covers this elbow and the circular section 27 with a thick layer of molded, waterproof, insulation 46 and terminates co-planarly with the connector end wall 45. The jacket 34 has a raised annular peripheral rib 50 beginning at the connector end wall 45. The rib is flared diametrically outwardly in a direction toward the elbow section and ends in an inwardly directed planar shoulder 52 which blends into the jacket.

In FIGS. 1-3, I have shown a single connection and in FIGS. 4-8 I have shown multiple connector structures. The multiple connector structure 120 shown in FIGS. 4-6 includes three individual connector members 122, 124 and 126 similar generally to connector 20 of FIGS. 1. The three connectors 122, 124 and 126 are fitted in spaced apart relationship within a molded or cast jacket 130. The jacket may be of suitable water-impervious material such as epoxy. The jacket has a main common section which tapers from its major oval section 132 of largest dimension into a tapered bushing section 134. The bushing section terminates in a flat end wall 136 from which protrudes the three separate conducting studs commonly indicated by the reference numeral 138 of connector members 122, 124, and 126. The studs are shown with an internally threaded cavity 140 into which may be connected a suitable bolt (not shown) to connect the stud to a transformer terminal lug in any known manner.

The connector members extend separately spaced apart within jacket 130 and each terminates in its respective terminal 152, 154 and 156. The terminals are shaped as described in the earlier embodiment and each has about its circular portion 158 respective jacket arms 162, 164 and 166. These jacket arms are integrally formed with the jacket of the jacket material.

Each such jacket arm terminates in a peripheral rib 50 as described for the earlier embodiment, with each such peripheral rib tapering outwardly from its outermost edge 51 to a radial disposed shoulder 52.

The major oval section 132 has molded therein a flange of stainless steel of the like. The flange is insulatedly spaced from the connector members and is firmly embedded in the jacket in waterproof bond with the jacket. The flange is designed to be suitably adhered or bonded to a suitably shaped transformer tank opening not shown in a sealing relation therewith with the conducting studs 138 within the tank and terminal tangs 152, 154 and 156 outside the tank.

In this showing, the two outer connector members 122 and 126 are angled at a suitable elbow 169 to space the stud end of the connector members closer together than the terminal ends.

In FIGS. 7 and 8, I show a minor variation on the showing of FIGS. 4-6 with right angled connector members 172, 174 and 176 in a main jacket 180. The outer connector members 172 and 176 are angled inwardly toward the central member in addition to the right angled elbow of each member. Each member is preferably of one piece construction and each is spaced from the others. The construction is otherwise similar to that described for FIGS. 4-6.

With any of these approaches a tubular waterproof, elastic sleeve or sheath 190 as shown in FIG. 3 is mounted on the embodiment of FIG. 1 sealingly fitted over the tang jacket 46. The use of sleeves of suitable synthetic rubber or plastic of this type is known in the art. The sleeve includes an interior annularly ridged entry area 192. This entry area leads to an annular shoulder 194 forming one edge of an annular groove 196 from which the sleeve tapers to a lesser diameter tube 198 for the major extent of the tube length. The tube terminates at its far end 199 in sealing relation with a cable sheath 200 therein, the conductor 202 sheath 200 being connected to terminal 24. The connector jacket shoulder 52 mates with the sleeve shoulder 194 to seal the jacket to sleeve joint in a watertight, waterproof manner.

The sleeve may be of the type shown generally in U.S. Pat. No. 3,480,905 issued to J. A. Toedtman on Nov. 25, 1969 for "Electrical Connector Manifold" and assigned to the assignee of this invention.

By the construction shown, the flange 42 is sealed to tank 10 (as shown in FIG. 3) and with the connector jacket and seal to the cable sheath being waterproof and water impervious, a thorough insulating waterproof shield is formed about the connector.

In the multiple connector structures, similar sleeves are mounted on each of the three terminals 152, 154 and 156 and sealingly mate with the respective jacket arms 162, 164, and 166 at the respective sealing ribs 50 in a manner similar to that shown in FIG. 3.

While there has been shown what is at present thought to be the preferred embodiment of the invention, it is understood that changes may be made therein and it is intended to cover in the appended claims all such modifications which fall within the true spirit and scope of the invention.

Claims

I claim:

1. A power connector structure for making electrical connections to stud ended power distributing members, in which there is a structure wall disposed outwardly of said members and having openings for said members, the invention comprising: a plurality of terminal members of high current carrying capacity, each including a first portion for mating with said members inwardly of said wall for carrying current from the distributing members, and a terminal portion of said body extending from the first portion, means common to all said terminal members for insulatingly covering each first body portion and each terminal portion with a one-piece jacket of water-impervious material, a planar shielding wall extending from said jacket for waterproof mounting to said structure wall, an individual integral arm extending from the jacket for covering each terminal portion; a terminal tang end of each of terminal members protruding from said terminal portion for connection to individual sheathed cables, a peripheral rib circumscribing an end of the jacket of each jacket terminal portion to provide a sealing surface for receiving thereabout one end of a tubular insulating sheath to sealingly mate each jacket to said sheath and thereby to waterproofingly cover said terminal ends.

2. A connector as claimed in claim 1, wherein said one-piece jacket comprises a jacket of epoxy material molded onto said terminal member.

3. A connector as claimed in claim 1, wherein said rib comprises a peripheral shoulder normal to said body terminal portion, and a wall tapering from said shoulder and terminating at the end of said terminal portion for mating said shoulder with an internal annular depression in the sheath wall.