U.S. patent number 3,922,058 [Application Number 05/457,108] was granted by the patent office on 1975-11-25 for electrical connector.
Invention is credited to Joseph D. Kinnear.
United States Patent |
3,922,058 |
Kinnear |
November 25, 1975 |
Electrical connector
Abstract
An electrical connector assembly in the form of a tubular
element having a generally cylindrical cross section formed from a
strap-like member with overlapped curvilinear end portions. The
overlapped end portions are tapped and threaded while the tubular
element is in a clamped, compressed condition and while so
compressed clamping screws are threaded into the openings. The
tubular element is formed of a high strength material, such as
stainless steel, and encloses a sleeve member formed of a
conducting material, such as copper, in which the bared end of a
conductor is inserted and securely clamped therein by tightening
the screws.
Inventors: |
Kinnear; Joseph D. (Warren,
MI) |
Family
ID: |
26956364 |
Appl.
No.: |
05/457,108 |
Filed: |
April 1, 1974 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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273691 |
Jul 21, 1972 |
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Current U.S.
Class: |
439/811 |
Current CPC
Class: |
H01R
4/363 (20130101) |
Current International
Class: |
H01R
4/36 (20060101); H01R 4/28 (20060101); H01R
007/14 () |
Field of
Search: |
;339/272 ;24/135N |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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218,745 |
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Apr 1942 |
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CH |
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1,214,761 |
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Apr 1966 |
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DT |
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80,963 |
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Sep 1951 |
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CS |
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Primary Examiner: Custer, Jr.; Granville Y.
Assistant Examiner: Bicks; Mark S.
Attorney, Agent or Firm: Barnes, Kisselle, Raisch &
Choate
Parent Case Text
This is a continuation of application Ser. No. 273,691, filed July
21, 1972, now abandoned.
Claims
I claim:
1. An electrical connector comprising a tubular element formed as a
metal strap having overlapped end portions, said overlapped end
portions defining generally concentric, circular segments which are
disposed in face-to-face contacting relation through an arcuate
extent at least about 120.degree., the center of curvature of said
circular segments corresponding generally to the central axis of
the tubular member, said overlapped portions being provided with a
radially extending opening therethrough disposed centrally between
the ends thereof, said opening having a thread extending
continuously through said overlapped portions, a metal clamping
screw threaded through said opening and adapted when tightened to
clamp a stranded electrical conductor within the tubular element,
said threaded opening having a diameter at least as large as the
radius of curvature of the contacting faces of said overlapped end
portions so that the axial extent of the threads on diametrically
opposite sides of the threaded opening in a direction
circumferentially of said overlapped ends is substantially greater
than the radial thickness of said overlapped end portions whereby,
when a stranded conductor sized to substantially completely fill
said tubular element is inserted therein and the screw is
tightened, said two overlapped end portions are tensioned
circumferentially in opposite directions along the arcuate path of
said circular segments when the leading end of the screw bottoms on
the conductor and thereby tightly interengage said diametrically
opposite sides of said threaded opening substantially throughout
their axial extent with the juxtaposed threads of the screw.
2. An electrical connector as called for in claim 1 wherein said
tubular element is formed of a resilient metal and is prestressed
by circumferential contraction prior to forming the threaded
opening therein such that the outer overlapping end portion exerts
radial pressure in one circumferential direction against the thread
at one side of the screw and the inner overlapping end portion
exerts radial pressure in the opposite circumferential direction
against the thread at the circumferentially opposite side of the
screw.
3. An electrical connector as called for in claim 2 wherein the
outer overlapping end portion has a radially outwardly bent portion
adjacent the free end of the inner overlapping end portion, the
free end of the inner overlapped portion being disposed directly
adjacent said radially outwardly bent portion and serving to limit
the extent to which the tubular element can be circumferentially
contracted and thereby control said radial pressures exerted by
said overlapping portions against opposite sides of the screw
thread.
4. An electrical connector as called for in claim 3 wherein the
inner overlapped end portion cooperates with the inner periphery of
the remaining portion of said strap to define a generally
cylindrical socket for the end of the stranded electrical
conductor.
5. An electrical connector as called for in claim 1 including an
axially extending sleeve having a close fit in said tubular
element, said sleeve being formed of a highly electrically
conductive material and having an opening therein registering with
the inner end of said screw and through which the screw is adapted
to extend, and a separate metal saddle member removably disposed
within said sleeve and being formed of a readily deformable metal,
said saddle extending axially within said sleeve and registering
axially and circumferentially with the inner end of said screw.
6. An electrical connector as called for in claim 5 wherein said
metal saddle comprises a sheet metal strip having one end disposed
within said tubular element adjacent one end thereof and its
opposite end projecting outwardly from the opposite end of the
tubular element, the inner end of said saddle defining an end wall
in the tubular element for limiting the extent to which a conductor
can be inserted therein and the outer end engaging said opposite
end of said tubular member to limit the extent to which the saddle
can be inserted into said tubular element.
7. An electrical connector as called for in claim 6 wherein said
saddle is sized to be frictionally retained within the tubular
element.
Description
This invention relates to an electrical connector of the screw
actuated pressure type for use as a terminal, a splice or a tap. As
distinguished from electrical connectors of the compression type
where the connector is swaged over a stranded conductor through the
use of precision dies that exert as much as forty tons of pressure,
the present invention involves an electrical connector wherein the
compression pressure between the stranded conductor and the
connector is obtained by tightening a screw.
More specifically, the present invention is an improvement over
electrical connectors of the type employing in their assembly
overlapping straps or castings or forgings through which one or
more screws are driven for clamping the conductor to the connector
assembly.
It is an object of this invention to provide an electrical
connector of the screw actuated type designed to exert tremendous
clamping pressure between the connector and the stranded conductor
while eliminating the tendency for the threads in the tapped hole
in the connector to strip.
More specifically, the present invention has for its object the
provision of an electrical connector capable of producing a
permanently high strength connection with a stranded conductor
which involves the use of simple stampings utilizing a minimum of
material.
Another object of the present invention resides in the provision of
a connector in the form of a spirally wound connector member having
overlapped ends through which one or more tapped openings are
provided for receiving clamping screws designed to exert pressure
against the end of a stranded conductor inserted into the spirally
wound member.
In connection with the preferred form of the present invention,
another object is to provide an electrical connector assembly
employing materials which are good electrical conductors for
contact with the stranded conductor and employing other materials
(such as stainless steel) which have substantially higher strength
characteristics and lower ductility than electrical conductors for
those components of the connector assembly which are subjected to
considerable stress in establishing the high pressure, high
strength connection between the connector assembly and the stranded
conductor.
Generally speaking, the preferred form of electrical connector of
the present invention includes an assembly of an outer tubular
element of circular spiral shape having overlapping end portions
provided with tapped holes for receiving clamping screws. A sleeve
of a conductive material (such as copper) is enclosed within the
spirally wound element. The sleeve is provided with openings
registering with the clamping screws. Within the sleeve there is
arranged a saddle underlying the inner ends of the screws and
adapted to overlie the conductor strands adjacent the inner ends of
the screws for applying clamping pressure to the conductor strands
without crushing or breaking them.
Other features of the present invention will become apparent from
the accompanying description and drawings, in which:
FIG. 1 is a perspective view of a stranded conductor cable having
the connector of the present invention attached thereto;
FIG. 2 is a sectional view along line 2--2 in FIG. 1;
FIG. 3 is a sectional view along line 3--3 in FIG. 2 and showing
one of the clamping screws in the tightened position and the other
in the initially assembled condition;
FIG. 4 is a diagrammatic view illustrating one advantage obtained
by using curvilinear overlapping end portions in the connector
assembly of the present invention;
FIG. 5 is an end view of a four conductor cable utilizing the
electrical connector of the present invention;
FIGS. 6 and 7 are perspective views illustrating modified forms of
electrical connectors according to the present invention;
FIG. 8 is a perspective view of one component of an electrical
connector of the present invention for joining three stranded
conductors;
FIG. 9 is an exploded perspective view showing the electrical
connector of the present invention employed for connecting a
conductor to an electrical storage battery;
FIG. 10 is a sectional view along line 10--10 in FIG. 9;
FIG. 11 is a fragmentary view showing a modified form of the
battery connector illustrated in FIG. 9.
Referring first to FIGS. 1 through 3, there is illustrated a cable
10 which comprises a stranded conductor 12 enclosed within an
insulating sheath 14. One end of cable 10 has sheath 14 stripped
therefrom with the bared ends of the conductor inserted within and
clamped to one form of connector assembly 16 of the present
invention. Connector assembly 16 includes an outer tubular element
18 in the form of a strap which is spirally wound in circular
fashion with overlapping ends 20,22. The inner periphery of tubular
element 18 is preferably shaped to present a generally circular
cylinder by providing a bend therein as at 24 so that the inner
overlapped end portion 22 is formed to the radius of the tubular
element 18 and the abrupt bend 24 offsets the outer overlapping end
portion 20 radially outwardly. With this arrangement there results
only a slight gap 26 in the inner periphery of the generally
cylindrical socket 28 defined by member 18. Within socket 28 there
is arranged a sleeve 30 formed of a good electrically conducting
material (such as copper). The outer diameter of sleeve 30 has a
close fit with cylindrical socket 28 and the inner diameter of
sleeve 30 is adapted to receive the bared end 32 of cable 10. One
end of sleeve 30 is flattened as at 34 to form a terminal lug for
connecting cable 10 to another conductor, such as a bus bar or a
terminal stud (not illustrated).
As shown in FIG. 2, the extent of overlap of the ends 20,22 is
preferably at least about 120.degree.. These overlapping end
portions are provided with two tapped openings 36,38 for receiving
clamping screws 40,42, respectively. Screws 40,42 preferably have a
relatively large diameter in relation to the inner diameter of
copper sleeve 30. As shown in FIGS. 2 and 3, sleeve 30 is provided
with a pair of openings 44,46 for accommodating the inner ends of
screws 40,42.
In the preferred embodiment of the invention tubular element 18 is
formed of a high strength, acid resistant material (such as
stainless steel) having some degree of resilience. As originally
formed and in the free state of element 18 the end portions 20,22
of member 18 are overlapped to a lesser extent than shown in FIG.
2. Thereafter, element 18 is clamped in suitable manner to increase
the overlap to the extent shown in FIG. 2. In the clamped condition
openings 36,38 are drilled and tapped and screws 40,42 are threaded
thereinto. The clamping pressure is then removed from element 18 so
that the overlapping end portions 20,22 tend to spring or shift
circumferentially apart to the positions they assumed prior to
clamping. End portion 20 has a tendency to shift circumferentially
in a clockwise direction and end portion 22 has a tendency to shift
in a counterclockwise direction as viewed in FIG. 2. Thus, the
tension exerted by the overlapping portions 20,22 against
diametrically opposite sides of screws 40,42 result in the screws
being tightly gripped in the threaded openings. This not only
serves to retain the screws within the threaded openings so that
they do not become loosened and lost during shipment, but also
results in a lock washer effect without requiring a separate lock
washer. The radial pressure exerted by the overlapping portions
20,22 against diametrically opposite sides of the screws can be
varied from zero or a very slight amount to a very high value,
depending upon the clamping pressure exerted against the lateral
sides of member 18 when the holes therein are drilled and
tapped.
In some instances, particularly in the case of fine wire strands,
it is inadvisable to have the inner ends of socket head screws
40,42 bear directly upon the wire strands because of the
possibility of shearing or crushing of the wire strands.
Accordingly, it is preferred to employ a saddle 48 within sleeve 30
to prevent such shearing, cutting or crushing of the stranded wire.
As shown in FIG. 6, saddle 48 has a longitudinally extending strap
portion 50 which preferably is of slightly arcuate cross section in
a generally transverse direction to conform to the inner diameter
of sleeve 30. At one end strap 50 is flared radially outwardly as
at 52 and at the opposite end strap 50 is formed with an end
portion 54 which extends transversely across sleeve 30 with a
return bent end portion 56 adapted to frictionally engage the
portion of sleeve 30 diametrically opposite the portion engaged
with strap 50. The outwardly flared end 52 of saddle 48 forms a
stop for limiting the extent to which the saddle can be inserted
into sleeve 30 and the transversely bent portion 54 forms a stop
against which the free end of the bared portion 32 of the cable is
adapted to abut. Saddle 48 is dimensioned to have a rather tight
fit in sleeve 30 so that once it is inserted therein it will be
retained by friction, thus enabling the entire assembly to be
shaped intact without the probability of individual components
becoming loosened and lost.
When it is desired to connect cable 10 to connector 16 the bared
end 32 of the cable is inserted within sleeve 30 with the strap
portion 50 of the saddle overlying the wire strands
circumferentially adjacent the inner ends of screws 40,42. After
the bared end of the wire is fully inserted within sleeve 30 to the
position shown in FIG. 3, screws 40,42 may be tightened as by a
conventional Allen wrench 58. In FIG. 3 screw 40 is shown in the
tightened clamping position while screw 42 is shown in the free
condition. The section of FIG. 2 is taken through screw 42 and,
thus, FIG. 2 illustrates the condition of the connector before the
screw is tightened. When screw 42 is tightened so as to advance it
to the broken line position 60, the strap portion 50 of saddle 48
will have a depression formed therein similar to the distorted
depression 62 formed in the strap portion under the inner end of
clamping screw 40. Between these two depressions the strap will
remain generally flat as indicated at 63. As can be seen in FIG. 3,
tightening of screws 40,42 exerts tremendous pressure against the
bared end of the stranded conductor -- particularly those portions
thereof radially aligned with the inner ends of screws 40,42. While
saddle 48 prevents the wire strands from being crushed or sheared
by the ends of the screws, nevertheless the wire strands
(particularly those adjacent the inner ends of the screws) are
substantially distorted in an axial direction so as to
substantially increase the resistance against pulling the cable out
of the connector by tensioning the cable. Saddle 48 provides an
additional function as illustrated in FIG. 3; namely, that of
confining the wire strands within the sleeve 30 so that all of the
wire strands are effectively compressed together within the
connector when the screws are tightened.
It will be appreciated in the embodiment illustrated in FIGS. 1
through 3, since the tubular element 18, screws 40,42, and
preferably saddle 48 are formed of a ferrous material (such as
stainless steel) which is substantially stronger than copper or
other good electrically conductive materials and since the
conductor strands 12 are compressed into intimate contact with
sleeve 30 which is formed of copper or the like, the connector
assembly provides a low resistance connection between the cable and
sleeve 30 while utilizing the high strength characteristics of
those components (namely, screws 40,42, saddle 48 and element 18)
which are subjected to high mechanical stresses. When screws 40,42
are tightened strap portion 50 would have to fail in tension to
pull the cable out of the connector.
The tight spiral design of element 18 possesses several distinct
advantages over electrical connectors of the type, for example,
shown in U.S. Pat. No. 2,907,978 which shows a generally
rectangularly shaped connector with flat overlapping strap portions
through which a clamping screw is threaded. One of these advantages
is illustrated in FIG. 4 and resides in the fact that when the
overlapped portions through which the screws extend are of
curvilinear shape a substantially greater amount of thread area
results than is the case where the overlapping portions are simply
flat strap ends. For example, as shown in FIG. 4, the portions of
the threaded openings displaced circumferentially from the axes of
screws 40,42 have an axial extent corresponding to the length a.
The axial extent of these threads gradually diminishes to a minimum
value at each side of the screw aligned with the axis of the
connector, which length is designated in FIG. 4 as b. The length b
corresponds to the double thickness of the strap from which element
18 is formed. Thus, if the overlapping portions of the connector
were formed as flat straps the maximum thread depth would
correspond to the dimension b which, as shown diagrammatically in
FIG. 4, is substantially less than the maximum axial extent a when
the overlapped ends are of curvilinear shape.
For example, in a connector of the present invention where the
strap from which element 18 is formed is fourteen gauge metal
having a nominal thickness of 0.075 inch and the screws 40,42 have
a half inch diameter, if the inner diameter d of element 18 is
about three-fourths inch, then the axial extent a of the thread of
the curvilinear overlapped portions is over 20 percent greater than
the axial extent b, which would be the case if the overlapped
portions were simply flat straps. In addition, it will be noted
that since threaded openings 36,38 are formed in curvilinear
surfaces they are actually of oval shape and, therefore, have a
slightly greater circumference than a circular opening formed in a
flat surface. Thus, by forming the overlapped end portions 20,22 of
curvilinear shape the engaging thread area between the screws and
the threaded openings is very substantially increased over similar
openings formed in flat overlapping straps. Obviously when the
amount of engaged thread area is substantially increased and the
overlapping ferrous end portions 20,22 are under spring tension,
the tendency for the threads to strip is eliminated.
In addition, since the overlapping end portions 20,22 were coiled
and clamped when tapped, they exert a radial pressure on the screw
resulting from the coil or spiral attempting to unwind in
proportion to the clamping pressure employed when the holes are
drilled and tapped. Furthermore, when the strands of the cable end
32 are fully compressed so that the screws "bottom", continued
rotation of the screws results in the application of substantial
pressure at the section C of the inner overlapped portion 22 and
the section D of the outer overlapped portion 20. These are exactly
the sections where the threads have their maximum axial extent. If
continued force is applied to the screws the inner member 22 cannot
rise away from the saddle 48 because it underlies the outer member
20. Therefore very substantial energy is stored within the threads
of the inner member 22. Since the free end of the outer member 20
is permitted to rise slightly, continued rotation of the screws
after they have bottomed will cause the free end of the outer
member 20 to rise slightly, thus resulting in the action of a split
lock nut and thereby effectively locking this stored up energy in
the connector. Furthermore, the tight circular coil of element 18
has a relatively close fit with sleeve 30 which in turn closely
embraces the bared end of the conductor. Thus there is very little
slack in the connector which would result in distortion of the
connector rather than clamping the conductor when the screws are
tightened.
This extremely effective locking action is of great importance in
electrical connectors. All electrical conductors physically expand
when electrical energy flows through their resistance. This
mechanical expansion and contraction through heat and cooling
cycles of varying loads is one of the primary causes for connector
failure due to bolts, screws or nuts working loose after a period
of operation. This problem of loosening of the connectors is
aggravated in the case of portable power equipment, such as lift
trucks, electric trains and other heavy moving equipment, because
of the mechanical vibration involved in the use of such
equipment.
Another advantage of the present invention is shown somewhat
diagrammatically in FIG. 5 which illustrates a four conductor cable
64 wherein each stranded conductor 66 is provided with a connector
such as shown at 16 in FIGS. 1 through 3. When the connectors 16
are arranged as illustrated with their overlapping ends facing
radially outwardly, it will be noted that a maximum spacing s
between each of the conductors 66 is obtained and that the adjacent
portions of the connectors 16 are of single metal thickness. This
arrangement is important in connection with three-phase current
where it is important to maintain maximum spacing between the
conductors. With the conductor of the present arrangement this
maximum spacing is obtained within a minimum of all cross sectional
area of cable 64 while still retaining the advantages of the
tubular curvilinear double thickness of material for the tapped
screw holes. In addition, the screws are located around the outer
periphery of the cable and are thus radially accessible.
The embodiment illustrated in FIG. 6 is very similar to that
illustrated in FIGS. 1 through 3 with the exception that sleeve 68
is a strap of semi-circular configuration as distinguished from the
completely circular configuration of sleeve 30 and is stamped from
flat stock so as to provide a flat attaching lug 70 integral with
one end thereof. In other respects the connector shown in FIG. 6 is
similar in construction and function to that shown in FIGS. 1
through 3.
In the embodiment illustrated in FIG. 7 the connector element 72 is
shaped similarly to the connector element 18. However, connector
element 72 is formed of a conductive material (such as copper)
rather than a ferrous material (such as stainless steel). Thus
connector element 72 can be formed from flat stock integrally with
an attachment lug 74. With the arrangement shown in FIG. 7 the need
for an inner sleeve, such as sleeve 68 or sleeve 30, is eliminated
but the advantages of the increased thread area because of the
curvilinear shape of the overlapped end portions of element 72 are
retained.
FIG. 8 illustrates a T-shaped sleeve member 76 having three legs
78. Sleeve member 76 is formed of a good electrically conductive
material (such as copper) and is employed with three connectors of
the type illustrated in FIGS. 1 through 3 and 6 for electrically
interconnecting three cables.
FIGS. 9 through 11 illustrate the connector of the present
invention used for connecting a battery cable 80 to a storage
battery strap 82. Strap 82 is a lead casting having sockets which
are permanently attached to the battery posts 84 by burning them
into place so as to puddle the lead. In the arrangement shown in
FIGS. 9 and 10, at one end strap 82 has an integrally cast
cylindrical socket member 86. In the process of casting strap 82 a
copper sleeve 88 (which has the same function as sleeve 30 in FIGS.
1 through 3) is lead coated to resist corrosion and is cast in
place within socket member 86. Sleeve 88 is received within a
stainless steel tubular element 18 and the battery cable 80 is
connected therewith utilizing a saddle 48 in the same manner as
described previously in connection with FIGS. 1 through 3. As a
matter of convenience sleeve 88 can be formed with diametrically
opposed openings 90 so that strap 82 can be inverted from the
position shown in FIG. 9 depending upon the post arrangement of the
battery and, thus, enable the screw 92 on element 18 to be
accessible from the top face of the battery regardless of the
orientation of strap 82.
The arrangement shown in FIG. 11 is substantially identical to that
shown in FIGS. 9 and 10 except that the socket member 94 is cast on
the battery strap 82 so that the axis of socket 94 is inclined at
an angle of about 45.degree. to the axis of strap 82. The
arrangement shown in FIG. 11 is utilized in connection with
batteries of particular design where accessibility to the battery
cable connection is facilitated by this angular disposition of the
connector.
The connector arrangements illustrated in FIGS. 9 through 11 can be
made entirely acid resistant by enclosing the entire connector
assembly in an acid resistant, heat shrinkable sleeve (not
illustrated).
* * * * *