Note: Descriptions are shown in the official language in which they were submitted.
ELECTRICAL CONNECTOR
This invention relates to an electrical connector for
electrically and mechanically connecting two conductors
together. More particularly, the connector is of the type
including a C-shaped member and toggle blocks which
compress the conductors into parallel channels in the
C-shaped member.
Electrical connectors of the type having a C-shaped
body member having converging channels and a complementary
wedge member have been known from at least as early as -
April 21, 1931 when U.S. Patent 1,801,277 issued to W. G.Kelley on an application filed May 18, 1926. Subsequent
thereto a large number of patents disclosing different and
improved embodiments have issued, including more recently
U.S. Patents 4,415,222 and 4,600,264. In each of the
disclosures, the basic Kelley concept was followed; i.e.,
two conductors are electrically and mechanically connected
by being pressed into and against interior curved surfaces
or channels provided in a C-shaped body member by a wedge
being driven longitudinally into the body member between
the conductors.
It is now proposed to provide an electrical connector
wherein the conductors are forced into parallel channels
in a C-shaped body member by a pair of toggle blocks beiny
pressed into the body member in a direction normal to the
longitudinal axis.
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According to the invention, an electrical connector
is provid0d which includes an elongated, C-shaped body
member having parallel, inwardly fa~ing,
conductor-receiving channels along each longitudinal side
and a pair of to-ggle blocks pivotally engaging each other
along one side which have a combined width greater than
the space between conductors positioned in the channels so
that upon forcing the toggle blocks into the body member,
the conductors are mechanically gripped and electrically
interconnected.
Figure 1 is an exploded, perspective view of the
electrical connector of the present invention showing the
components thereof;
Figures 2 and 3 are sectional views taken normal to
the connector axis illustrating the connection of
electrical conductors therein;
Figure 4 is a perspective view of a tool used in
conjunction with the electrical connector;
Figure 5 is an exploded, perspective view of another
embodiment of the electrical connector of the present
; invention showing the components thereof;
Figures 6 and 7 are perspective views showing a tool
and the connecting of two conductors in the electrical
: connector of Figure 5;
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Figure 8 is an exploded, perspective view of still
another embodiment of the electrical connector of the
present invention showing the components thereof;
Figure 9 is a parspective view of an assembled
5 electrical connector of Figure 8 preparatory to
electrically connecting a pair of conductors; and
Figures 10 and 11 are perspective views of opposing
sides of the electrical connector of Figure 7 subsequent
to electrically connecting the pair of conductors.
With reference to Figure 1, the components of
electrical connector 10 include C-shaped bo~y member 12
and a pair of toggle blocks 14,16~ Preferably, body
member 12 and toggle blocks 14,16 are made from 6061-T-6
aluminum.
C-shaped body member 12 is preferably extruded with
the longitudinal edges rolled over to define channel
portions ~8 and to provide parallel, interior curved
channels 20~ Channels 20 face each other across surface
22 of wall 24 which join channel portions 18. Channels 20
are dimensioned to conformably receive a range of
conductor sizes; e.g~, from 795 26/7 ACSR to 536-37 AAC.
Wall 24 of body member 12 is thickest along a
longitudinally extending middle portion 26 relative to
parallel side portions 28 which are between and joins
middle portion 26 and channel portions 18. As shown, the
thickness of side portions 28 decreases outwardly from
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middle portion 26. The outward thinning of side portion
28 facilitates outward flexing of channel portions 18.
Pin 30 is mounted in wall 24 in the center of body member
12 and projects outwardly from wall surface 22.
Toggle block 14 includes an exterior curved or convex
pivoting surface 32 extending along one longitudinal side
and an outwardly facing, conductor-receiving channel 34
extending along the opposite longitudinal side. Hole 36
is provided in block 14 adjacent surface 32 and
intermediate the ends.
Toggle block 16 includes an int~rior curved or
concave pivoting surface 38 extending along one
longitudinal side and an interior curved, or outwardly
facing, conductor receiving channel 40 extending along the
opposite longitudinal side.
Channels 34,40 on toggle blocks 14,16 respectively
are dimensioned to cooperate with channels 20 in body
member 12 in confining and compressing conductors
therebetween.
As indicated in the drawings, pivoting surfaces 32,38
on blocks 14,16 respectively conformably engage each other
in the same manner as a ball and socXet joint.
Toggle blocks 14,16 are sized so that their combined
width is greater than the space between conductors
positioned in respective channels 20 in body member 12.
The excess width is such that upon pushing blocks 14r16
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into that space, the conductors are compressed and
mechanically gripped and, by reason of the conductivity of
body member 12 and toggle blocks 14,16 are electrically
interconnected.
Blocks 14,16 are preferably made by well known
casting techniques.
Pin 30 is preferably made from a malleable material
such as aluminum.
In use, bared sections of conductors 42,44 are
positioned in respective channels 20 in body member 12 as
shown in Figure 2. Toggle blocks 14,16 are added as
shown; i.e., channels 34,40 are abutting conductors 42,44
respectively, pivoting surfaces 32,38 are in engagement
with each other and pin 30 extends through hole 36 in
block 14. Toggle blocks 14,16 are then pressed in towards
surface 22 of wall 24 of body ~ember 12. As blocks 14,16
move down into the space between conductors 42,44 as shown
in Figure 3, conductors 42,44 are compressed between
respective channels 20 and channels 34,40 to complete the
mechanical gripping and electrically interconnection. Pin
30 may be mushroomed over toggle blocks 14,16 as shown to
secure the blocks 14,16 in body member 12 although this is
not necessary since toggle blocks 14,16 are pushed over
center and are locked in position. To the extent required
by the dimensions of conductors 42,44 channel portions 22
are resiliently spread apart which insures continued
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compressive forces on conductors 42,4~ even in the event
of conductor creep, a well known phenomenon experienced by
aluminum cables and wires.
During the compression of conductors 42,44, the
individual strands rub against each other and oxides and
dirt are wiped therefrom to enhance the electrical
connection. Further, the connection is gas tight, which
reduces the incident of corrosion.
Plier-type tool 46 shown in Figure 4 illustrates a
suitable means for pressing toggle blocks 14,16 into the-
position shown in Figures 3 and also for mushrooming pin30. Tool 46 includes two members 48,50 with each having
handle 52 at one end (only a segment thereof being shown)
and jaws 54,56 respectively at the other end. Members
48,50 are pivotally pinned together so that by closing
handles 52, jaws 54,56 move in towards each other. Jaw 54
has a flat surface 58 which abuts surface 60 on wall 24
of body member 12. Jaw 56 is T-shaped and includes notch
62 therein. The depth of notch 62 is such that the free
end of pin 30 abuts the floor thereof ~ust before toggle
blocks 14,1~ are completely pressed into body member 12.
During the final travel, pin 30 is mushroomed as shown in
Figure 3 to secure blocks 14,16.
The second embodiment of the electrical connector of
the present invention, indicated by reference numeral 110
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includes C-shaped body member 112, toggle blocks 114 and
hinge pin 116.
With respect to member 112, it is identical to member
12 except for the absence of pin 30. The several
structural features of member 112 are accordingly
referenced with like numerals.
With respect to toggle blocks 114, hinge sections 13Q
are provided on one longitudinal side and outwardly facing
channels 132 are provided on the opposing side. Blocks
114 are identical with channels 132 being dimensioned tQ
cooperate with channels 20 in body member 1~2. In this
respect, channel 132 on one block 114 and a respective
channel 20 may be of a different arcuate dimension
relative to channel 132 on the other block 114 and other
channel 20.
Hinge sections 130 include a pair of spaced apart
ears 134 projecting outwardly from side surface 136.
Pin-receiving holes 138 are provided in each ear 134.
Toggle blocks 114 are sized so that their combined
width is greater than the space between conductors
positioned in respective channels 20 in body member 112.
The excess width is such that upon pushing blocks 114 into
that space, the conductors are compressed and mechanically
gripped and, by reason of the conductivity of body member
112, toggle blocks 114 and pin 116 are electrically
interconnected.
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Blocks 114 are preferably made by well known casting
techniques.
Pin 116 includes shaft 140 which is dimensioned to be
snugly received in holes 138 in ears 134. Pin 116 may
include an upset or head on one end as shown but such is
not necessary.
Toygle blocks 114 are pivotally joined together by
interfingering ears 134 on respective blocks 114, as shown
in Figure 1, and sliding sha~t 140 of pin 116 through
aligned holes 138.
Figures 6 and 7 illustrate how conductors 42,44 are
electrically interconnected and mechanically gripped in
connector 110. Tool 146, which is used to force hlocks
114 into body member 112, includes tool head 148 mounted
on handle 150. U~shaped head 148 includes back arm 152
against which connector 110 is positioned. Front arm 154
: includes housing 156, bolt 158 threadedly mounted in
housing 156 and T-shaped bar 160, located between arms
152,154 and moved therebetween by bolt 158 to which it is
attached.
: Portions of conductors 42,44 with their insulation
jacket removed are placed in respective channels 20 in
: body member 112. Toggle blocks 114, joined together as
described above, are positioned in body member 112 with
respective channels 132 abutting conductors 42,44 and
hinge sections 130 projecting outwardly as shown in Figure
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6. With the back of connector 110 against back arm 152 of
tool 146, bar 160 is advanced against blocks 114 by
turning bolt 158 clockwise to force toggle blocks 114 in
between conductors 42,44 and against surface 22 of wall 24
as shown in Figure 6. In accommodating the width of
blocks 114, conductors 42,44 are compressed tightly
between respective channels 20 in body member 112 and
respective channels 132 in blocks 114 and are accordingly
electrically interconnected and mechanically gripped. To
the extend required by the dimensions of conductors 42,447
channel portions 18 are resiliently spread apart which
insures continued compressive forces on conductors ~2,44
even in the event of conductor creep, a well known
phenomenon experienced by aluminum cables and wires.
As shown in Figure 7, toggle blocks 114 are pushed
over center which locks them in position and insures
integrity of connector 110.
During the aforementioned compression of conductors
42,44, the individual strands rub against each other and
oxides and dirt are wiped therefrom to enhance the
electrical connection. Further, the connection is very
tight which reduces the incident of corrosion.
; Another feature of the present invention is that
connector 110 may be used repeatedly.
The third embodiment of the electrical connector of
the present invention, indicated by reference numeral 210,
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is shown in Figures 8-11. Connector 210 includes C-shaped
body~ member 212, toggle blocks 214, hinge pin 216, eye
bolt 218 and nut 220.
C-shaped body member 212 is identical to body member
112 except for the presence of hole 234 extending through
wall 24. Accordingly, the several structural features of
member 212 are referenced with the same numerals as used
with members 12 and 112.
With respect to toggle blocks 214, hinge sections 2 3 6
are provided on one longitudinal side and outwardly facing
channels 238 are provided on the opposing sides. Blocks
214 are identical with channels 238 dimensioned to
cooperate with channels 20 in body member 212.
Hinge sections 23 6 include three, spaced apart ears
240 projecting outwardly from side surface 2A2 with ears
240a being wider than ears 240b and 240c. Pin receiving
holes 244 extend through each ear 240. Notches 246 in
side surfaces 242 of blocks 214 adjacent ears 240b,
cooperatively form a passage for bolt 218 when blocks 214
are joined together.
Toggle blocks 214 are sized so that their combined
width is greater than the space between conductors
positioned in respective channels 20 in body member 212.
The excess width is such that upon pushing blocks 214 into
space, the conductors are compressed and mechanically
gripped, and by reason of the conductivity of body member
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212 and toggle blocks 214, are electrically
interconnected.
Blocks 214 may be made by well known casting
techniques or by extrusion coupled with machining.
Pin 216 includes shaft 248 which is dimensioned to be
snugly received in holes 244 in ears 240 and hole 250 in
eye bolt 218. Pin 216 may include an upset or head on one
end of shaft 248 as shown but such is not necessary.
Eye bolt 218 includes the aforementioned hole 250 and
threaded shaft 252 which receives nut 220.
Toggle blocks 214 are pivotally joined together by
interfingering ears 240 on respective blocks 214 and
sliding shaft 248 of pin 216 through aligned holes 244.
Bolt 218 is positioned so that shaft 248 of pin 216 passes
through hole 250 and threaded shaft 252 passes through
notches 246 and extends outwardly from blocks 214.
Figure 9 illustrates a step in electrically
~: connecting and mechanically gripping conductors 42,44.
Bared sections of conductors 42,44 are placed in
respective channels 20 of C-shaped body member 212 and
toggle blocks 214, joined as described above, ara
positioned so that respective channels 238 abut against
respective conductors 42, 44 and threaded shaft 252 o~ bolt
218 passes through hole 234 in wall 24 of member 212. As
shown, blocks~214 angle out of member 212 due to their
combined width being greater than the space between
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conductors 42,44 in channels 20 of member 212. Nut 220
holds the assembly together by being threaded on shaft 252
until it engages wall 24.
The final step takes place by further rotating nut
220 to draw blocks 214 down to surface 22 of member 212.
In so doing, blocks 214 push against conductors 42,44 to
compress them and accordingly are mechanically gripped and
electrically interconnected. To the extend required by
the dimensions of conductors 42,44, channel portions 20
are resiliently spread apart which insures continued
compressive forces on conductors 42,44 even in the event
of conductor creep, a well known phenomenon experienced by
aluminum cables and wires.
As conductors 42,44 are being compressed, the
individual strands move and rub against each other,
thereby scrubbing oxides and the like away to enhance
current flow therebetween.
The connec~ion is complete with blocks 214 flat or,
as shown in Figures 10 and 11, slightly cammed over center
whlch locks them in position. To break the connection,
bolt 218 must be backed out to withdraw blocks 214 from
body member 212. Connector 210 can be re-used within
reason.
As can be discerned, an electrical connector for
electrically connecting two conductors has been disclosed.
The connector includes a C-shaped body member having
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parallel, facing conductor receiving channels and a pair
of pivotally engaging toggle blocks which are received in
the body member between the channels. The combined width
of the toggle blocks exceed the space between conductors
positioned in the channels so that they are compressed and
mechanically gripped upon forcing the toggle blocks
therebetween. The conductivity of the body member and
toggle blocks provide an electrical interconnection
between the conductors.
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