西班牙专利ES2758404A2 Enhancing connectability among conductor elements

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专利摘要:
Assemblies and methods are provided for establishing an electrical connection and enhancing connectability that utilize an electrical connector having a housing and a socket for receiving an electrical conductor having multiple conductor elements or conductor layers. A conductive fastener extends through the housing into the socket. The fastener can penetrate multiple conductor elements to establish an electrical connection among conductor elements. One or more of the conductor elements can include a cutaway segment that receives a conductive fastener to establish an electrical connection among the connector, fastener, and multiple conductor elements. A conductive shim may be disposed about one or more of the conductor elements and received within the cutaway segment, and the conductive fastener can engage the conductive shim to establish electrical contact among multiple conductor elements through the shim.
公开号:ES2758404A2
申请号:ES202090013
申请日:2018-09-10
公开日:2020-05-05
发明作者:Vitaliy Yaroslavskiy
申请人:Carbine Ventures Inc D/b/a Cable Tech Laboratories；
IPC主号:

专利说明:

[0001]
[0002] Improved connectivity between conductive elements
[0003]
[0004] TECHNICAL FIELD AND BACKGROUND
[0005]
[0006] [0001] The present invention relates generally to devices and methods for improving the connectivity of stranded or multilayer conductors.
[0007]
[0008] [0002] The demands placed on power generation and distribution systems continue to increase, leading to increased electrical loads on system components such as conductors and cable connectors. Higher electrical loads increase the generation of heat that can cause cable failure.
[0009]
[0010] [0003] In addition, the components of the power system are generally designed to protect against difficult outdoor conditions, such as extreme temperatures and moisture intrusion, through the use of insulation, protective layers and absorbent materials, and for water blocking. The use of semiconductor materials results in increased electrical resistance between the conducting elements in a cable conductor. This in turn increases the heat generated by the cable and can also lead to failure, as the cable runs closer to its maximum load capacity. This problem is particularly severe at cable termination ends (terminal connectors) and at cable junctions (spliced conductors) since conventional connectors at such junctions tend to concentrate electrical current in external conductor elements (for example , outer strand layers) of a cable conductor.
[0011]
[0012] [0004] Given the drawback presented by existing connector components, it would be advantageous to provide a mechanism to improve connectivity between conductive elements or filament layers by promoting direct metal-to-metal contact between the conductive elements. This in turn would improve current distribution and resistance profiles across the cable cross section during loading conditions and avoid the resulting effects of water blocking materials. The result would be less heat generation and improved reliability. Such a mechanism should preferably be capable of convenient and reliable installation in field conditions to control costs and reduce potential system downtime associated with replacement of failed connector components.
[0013] [0005] It is, therefore, an objective of the present invention to provide devices and methods to improve the connectivity of electric cables by providing a current path between conductive elements. It is a further object of the invention to provide devices that improve connectivity while being configured for a comfortable and reliable installation.
[0014]
[0015] SUMMARY
[0016]
[0017] [0006] A first embodiment provides an electrical connector assembly having a connector housing with a first axis extending between a first end with a first opening and a second end, and a second axis transverse to the first axis (is i.e., radial direction for a tubular housing where the first axis is longitudinal), and an outer surface. The housing also includes a socket cavity positioned at least partially with the first opening. The socket cavity extends along the first axis and defines an interior surface of the housing and is dimensioned to receive an electrical cable conductor having at least two elements or at least two layers of wires. The housing also includes a passageway that extends along the second axis from the outer surface of the housing to the inner surface of the housing. The passage is dimensioned to accommodate a conductive anchor having a first anchor end, a second anchor end, and a first anchor length that extends between the first anchor end and the second anchor end. The first anchor length is dimensioned so that when the socket cavity receives the electrical conductor and the conductive anchor is secured within the passage, the first anchor end extends into the socket cavity and penetrates the multiple conductive elements or layers of threads.
[0018]
[0019] [0007] The first anchor end may be a penetrating part, such as a tapered tip or sharp edge, and the conductive anchor may be, inter alia, a screw, rivet, or shear, both with multiple break points where a part of the bolt is designed to shear when subjected to a predetermined torque load.
[0020]
[0021] [0008] The connector may be a shear bolt connector or a crimp connector that secures over an electrical conductor after a force is applied to crush a portion of the connector housing. The steps can be prefabricated in the connector housing or formed by actuating the conductive anchor through the exterior of the housing into the socket cavity.
[0022]
[0023] [0009] In one embodiment, the connector housing includes additional openings, with the socket cavities defining channels dimensioned to receive another electrical cable conductor. The first passage forms an opening in the outer surface of the housing that is at a first distance from the first end. The connector housing also includes a second passage that extends along an axis transverse to the first axis (i.e., radial direction for a tubular housing) from the outer surface of the housing to the inner surface of the housing. Similar to the first step, the second step defines a second opening on the outer surface of the housing that is located farther from the first end of the housing than the first opening. The second step is dimensioned to accommodate a second conductive anchor with two ends and a length between the two ends. The second length of the anchor is dimensioned so that, when the socket cavity receives the second electric cable, and the second conductive anchor is secured within the second passage, the anchor extends into the socket cavity and enters the at least two conducting elements or layers of wires of the second electrical conductor. One or more anchors can have a penetrating end and form as a screw, rivet, or shear bolt with multiple break points, among other types of anchors.
[0024]
[0025] [0010] In yet another embodiment that does not necessarily use penetrating anchors, the connector housing and plug receive an electrical conductor (or multiple conductors) with at least two conductor elements or layers of wires, where at least one of the elements conductors ("a first conductive element") has a cut segment. The cut segment is formed when part of the conductive element or strand layer is removed to expose a second conductive element or strand layer. The length of the conductive anchor is sized so that, when the socket cavity receives the conductor, and the conductive anchor is secured within the passage, one end of the conductive anchor extends into the socket cavity and establishes electrical communication with a second conductive element exposed through the cut segment.
[0026]
[0027] [0011] The first and second conductive elements may be concentric (eg, an external conductor surrounding the second internal conductor), and the conductive anchor establishes electrical communication with the second conductive element extending through the passage and into the cut segment to make contact with friction or couple the second conductor element. The cut segment can be formed as a notch where part of the first conductive element is removed in a square, rectangular, circular or any other suitable pattern or shape to expose the second conductor. The cutting segment can also be formed by removing an entire segment of the first conducting element through the entire cross section, such as removing a segment from the entire circumference of a circular conducting element.
[0028]
[0029] [0012] In other exemplary embodiments, a conductive spacer is disposed around the second conductive element at least partially within the cutting segment to effectively fill some or all of the void created by removing the cutting segment. The conducting spacer is in electrical communication with the second conducting element. And the conductive anchor is placed in electrical communication with the second conductive element extending the anchor through the passage into the socket cavity to couple the conductive spacer.
[0030]
[0031] [0013] Separate conductive spacers can be used to establish electrical communication with each conductive element or layer of wires. Alternatively, a single conductive spacer can be provided around the first conductive element at least partially within the cutting segment and arranged on the second conductive element so that the conductive spacer is in electrical communication with both the first conductive element and the second conductive element. In this case, the conductive spacer has characteristic features on the inner surface that correspond to the cutting segment and / or that correspond to the contours of the conductive elements so that the conductive spacer can be installed on one or more of the conductive elements while An electrical connection is established. The conductive anchor establishes electrical communication with both the first conductive element and the second conductive element extending through the passage to engage the conductive spacer.
[0032]
[0033] [0014] The conductive spacer can be formed from a malleable material such that it can be deformed, and snap fit over one or more of the conductive elements to ensure a stable mechanical fit and electrical contact. Alternatively, the conductive spacer can be formed as a compressible gland or helical element capable of mechanical deformation. In still other embodiments, the conductive spacer is an elongated hollow body with a slit extending down the length of the body to facilitate compression of the spacer.
[0034] [0015] Procedures are also provided to establish an electrical connection and improve connectivity between conductive elements or layers of conductive wires. The method includes the steps of providing a connector with a housing having a first axis extending between a first open end and a second end (for example, axial direction for a rounded cable), and a second axis transverse to the first axis ( for example, radial direction for a rounded cable) and an outer surface. The housing also has a socket cavity positioned at least partially with the first opening where the socket cavity extends along the first axis, defines an interior surface of the housing, and is dimensioned to receive an electrical cord comprising at least two elements. conductors. The housing further includes a passageway which extends along the second axis from the outer surface of the housing to the inner surface of the housing. The passage is dimensioned to accommodate a conductive anchor.
[0035]
[0036] [0016] The method further includes the step of providing a conductive anchor with a first end and a second end. An electrical cord is inserted into the first opening and into the socket cavity. The conductive anchor is then inserted into the passage at a depth such that the conductive anchor extends into the socket cavity to establish electrical communication with the at least two conductive elements.
[0037]
[0038] [0017] Electrical communication can be established by actuating the conductive anchor into the passage until it extends and penetrates the at least two conductive anchors. In another embodiment, a cut segment is formed in a first conductive element to expose a second conductive element, and the conductive anchor establishes electrical communication with a second conductive element extending through the passage and into the cut segment to engage the second conductive element.
[0039]
[0040] [0018] In another embodiment, the method includes the step of installing a conductive spacer at least partially within the cutting segment so that the conductive spacer is in electrical communication with a second conductive element. The conductive anchor establishes electrical communication with the second conductive element extending through the passage into the socket cavity to engage the conductive spacer.
[0041] BRIEF DESCRIPTION OF THE FIGURES
[0042]
[0043] [0019] The characteristic features, aspects and advantages of the present invention are better understood when reading the following detailed description of the invention with reference to the attached figures, in which:
[0044]
[0045] [0020] FIG. 1A illustrates an exemplary configuration for the construction of electrical cables.
[0046]
[0047] [0021] FIG. 1B illustrates an exemplary electrical cable that uses wire for water blocking.
[0048]
[0049] [0022] FIG. 1C illustrates an exemplary electrical cable using tape for water blocking.
[0050]
[0051] [0023] FIG. 1D illustrates an example of a stranded conductor covered with a full layer of water blocking tape.
[0052]
[0053] [0024] FIG. 1E illustrates an exemplary electrical cable using a pumpable water blocking material.
[0054]
[0055] [0025] FIG. 2 is a resistance graph between a layer of lead wires and the connector body for various cable configurations (wires, tapes, and pumpables).
[0056]
[0057] [0026] FIG. 3 is a graph of lead wire layer resistance for various connector and cable configurations.
[0058]
[0059] [0027] FIG.4 illustrates an exemplary terminal cut bolt connector.
[0060]
[0061] [0028] FIGS. 5A and 5B illustrate an exemplary splice cut bolt connector.
[0062]
[0063] [0029] FIGS. 6A-B illustrate a cutaway cross-sectional view of an exemplary connector assembly using penetrating conductive safety bolt anchors.
[0064]
[0065] [0030] FIG. 6C illustrates an isometric view of an exemplary connector assembly using penetrating conductive safety bolt anchors.
[0066] [0031] FIG. 7 is a perspective view of an exemplary penetrating conductive anchor configuration.
[0067]
[0068] [0032] FIG. 8 illustrates an exemplary splice connector assembly using penetrating conductive safety bolt anchors.
[0069]
[0070] [0033] FIG. 9 illustrates an exemplary shear bolt.
[0071]
[0072] [0034] FIG. 10 illustrates an exemplary splice cut bolt connector assembly using penetrating conductive screw anchors.
[0073]
[0074] [0035] FIG. 11 illustrates an exemplary crimp connector assembly using penetrating conductive screw anchors.
[0075]
[0076] [0036] FIG. 12A illustrates a layered stranded conductor with notched cuts.
[0077]
[0078] [0037] FIGS. 12B-D illustrates an exemplary connector assembly using penetrating conductive safety bolt anchors.
[0079]
[0080] [0038] FIG. 13A illustrates a layered stranded conductor with circumferential cuts.
[0081]
[0082] [0039] FIG. 13B illustrates a layered stranded conductor with circumferential cuts and a coiled wire spacer.
[0083]
[0084] [0040] FIG. 14A is a side view of a layered stranded conductor with circumferential cuts including fixed bolt spacers that achieve electrical contact.
[0085]
[0086] [0041] FIG. 14B is a cross sectional view of a layered stranded conductor with circumferential cuts and spacers.
[0087]
[0088] [0042] FIG. 15 illustrates a layered stranded conductor with a stepped unitary spacer.
[0089]
[0090] [0043] FIG. 16 illustrates a unitary spacer with longitudinal grooves.
[0091] [0044] FIG. 17 is a graph of the connector and conductor test loop resistance factor for various conductor configurations during the current cycle test.
[0092]
[0093] [0045] FIG. 18 is a graph of the connector and conductor test loop temperature for various conductor configurations during the current cycle test.
[0094]
[0095] [0046] FIG. 19 is a graph of the connector and conductor test loop temperature during current cycle testing for conductors using water blocking tapes and penetrating safety bolt anchors.
[0096]
[0097] DETAILED DESCRIPTION
[0098]
[0099] [0047] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. However, the invention can be carried out in many different ways and should not be considered as limited only to the representative embodiments set forth herein. Exemplary embodiments are provided so that the present disclosure is exhaustive and complete and fully conveys the scope of the invention and enables one skilled in the art to make, use and practice the invention.
[0100]
[0101] [0048] Relative terms such as minor or inferior; greater or greater; up, out, or down; forward or backward; and vertical or horizontal can be used herein to describe the relationship of one element to another element illustrated in the figures. It will be understood that the relative terms are intended to encompass different orientations in addition to the orientation represented in the drawings. As an example, if a component is flipped in the drawings, the elements described as being "at the bottom" of the other elements would then be oriented "at the top" of the other elements. Relative terminology, such as "substantially" or "about", describes the specified materials, steps, parameters, or ranges, as well as those that do not materially affect the basic and novel features of the claimed inventions as a whole (as would be appreciated by one skilled in the art).
[0102] [0049] Devices and procedures are disclosed to improve the connectivity between conductive elements in a multilayer conductor by establishing a current path between the conductive elements, thereby avoiding the insulating effects of blocking water and other insulating materials used in the construction of cables. . The construction and configuration of electrical cables vary widely, but the exemplary embodiments of electrical cables are depicted in Figures 1A to 1F. Exemplary cables use stranded metallic conductive elements 12, insulated conductive jacket 18 and one or more water blocking materials 14, 16 and 17. The exemplary cable shown in Figure 1B illustrates the use of a water blocking wire 14. The Example cable shown in Figure 1C illustrates a stranded conductor 12 using a water blocking tape material 16, and Figure 1D illustrates a complete layer of water blocking tape 16 applied to conductor 12. The use of a material pumpable water blocking 17 is shown in Figure 1E, where pumpable material 17 is applied to the braided cable in a viscous or gelatinous state that penetrates between the strands before solidifying.
[0103]
[0104] [0050] The multitude of layers and materials surrounding the conductive elements 12 improve the physical integrity of the cables and protect the cables from environmental conditions, but have the detrimental effect of preventing electrical communication between conductive elements. Preventing electrical communication between conductive elements increases the overall resistance of the cable, which in turn leads to increased heat generation within the cable when an electrical charge is carried. Increased heat is an important factor contributing to cable failure. The cable overheating problem is exacerbated by conventional connectors that establish an electrical connection primarily with external conductive elements or wire layers, thereby concentrating the generation of current and heat in a smaller cross-sectional area of the cable.
[0105]
[0106] [0051] Figure 2 illustrates the impact of water blocking materials on the resistance of the conductive wire layer at a splice point for an aluminum conductor with a cross-sectional area of 1,000 circular thousandths (kcmil). In particular, conductors that use wires (lines Y1A and Y1B) and tapes (T2A and T2B) for water blocking have significantly higher resistance than flat conductors without water blocking materials (P1A and P1B), and conductive wires Internal threads (counterclockwise on the horizontal axis) have greater resistance than external threads. These trends are valid for all types of connectors, as illustrated in Figure 3, which compares the use of water blocking materials in cables with crimp connectors and safety pins with the use of a cable without water blocking materials. Both crimp connectors (lines B1 and B2) and safety pin connectors (lines C1 and C2) used in combination with water blocking tapes have a resistance approximately 100 times greater than a crimp connector that does not use a material of water blocking (lines A1 and A2). In summary, water-blocking materials have a significant detrimental impact on cable strength at splice points, and the detrimental impact is most pronounced on internal conductive elements or strand layers of a cable.
[0107]
[0108] [0052] The devices and procedures discussed herein are intended to improve electrical resistance characteristics at conductor junction and termination points and are particularly effective for conductors using water blocking materials or other insulators . The disclosed embodiments are generally described with reference to splice, locking pin, and barrel connectors used in combination with multilayer stranded conductors. However, those skilled in the art will appreciate that the exemplary embodiments described herein are not intended to be limiting.
[0109]
[0110] [0053] The devices and techniques according to the invention are generally applicable to electric cables with multiple conductive elements, such as those shown in Figures 1A-E, or with multiple layers of conductive wires, such as those shown in Figures 6A-6C, 7, 12A, 13A-13B and 14A-14B which are discussed in more detail below. The devices and techniques according to the invention are also generally applicable to various types and geometries of connectors, including, for example, terminal or splice connectors, safety pin or crimp connectors, or connectors with circular cross-sections, in the form of C or square, as well as multidirectional splices.
[0111]
[0112] [0054] Terminal connectors generally comprise a partially hollow conductive body or housing with one or more plug openings defining the interior of the housing. The plug is configured to firmly house and secure the end portion of one or more cables. The plug can define a channel through the housing, or the plug can be formed from connector housing halves or housings joined together to form a channel.
[0113] [0055] On crimp connectors, the end portions of the cables are secured in position within the connector plug by crimping the connector housing on the cables after insertion into the plug. With safety pin connectors, the end parts of the cables are secured inside the plug by safety pins that extend through the connector housing to apply force to the cables. A shear bolt terminal connector 40 is shown in Figure 4, and includes a hollow tubular body or housing 41 with a single plug opening 44 to accommodate one cable end, a plurality of safety bolt anchors 42 threaded to through the connector housing 41 to the plug, and a tab 46 to secure the connector to a terminal.
[0114]
[0115] [0056] Similarly, splice connectors generally comprise a conductive hollow body or housing with one or more plug openings configured to house and secure the end portions of two or more cables to be electrically connected. An exemplary shear bolt splice connector 50 is shown in Figures 5A and 5B and includes: (i) a hollow tubular housing 51 with a socket 52 defining a channel or cavity through the interior of housing 51; (ii) two plug openings 53 and 54 each housing one cable end 62 and 64; and (iii) a plurality of threaded security bolt anchors 58 within passages 59 that extend through the side wall of connector housing 51.
[0116]
[0117] [0057] To electrically couple the cables, a first cable end 62 is inserted into the second connector plug opening 53 in a first end 56 of the connector housing 51, and a second cable end 64 is inserted into the second opening plug 54 at a second end 57 of the connector. Locking bolt anchors 58 are threaded in steps 59 until locking bolt anchors 58 extend into socket 52 to engage and pressure the cable ends to secure the cable ends in place within the socket of connector 52. The cutting bolt anchor head 58, and in some cases part of the shank, is designed to shear when screw 58 is subjected to a predetermined torque load. At least a portion of the cut bolt shank remains within pitch 59 after shear. Preferably, the bolt shears so that the stem does not extend beyond the outer surface of connector housing 51.
[0118]
[0119] [0058] Security bolts will commonly establish metal-to-metal contact primarily or exclusively with external conductive elements, either because the protective insulating layers were removed during connector installation or because pressure exerted by the safety bolt anchors pierced the protective insulation surrounding the external conductive elements.
[0120]
[0121] [0059] In other cases, piercing connectors including serrated edges or teeth within the plug that are configured to pierce the protective insulation or the protective layers surrounding the external conducting elements are used to establish a direct current path between the external conducting elements. and the connector housing. Establishing a current path between the outer conductor elements and the connector housing effectively reduces the electrical resistance of the outer conductor elements relative to the inner conductor elements. However, these connectors are not intended to pierce the conductive layers to provide continuity to the inner member of the wire layers.
[0122]
[0123] [0060] Electrical resistance profiles and current concentration through a cable cross section can be improved by using the penetrating conductive shear anchor design shown in Figures 6A-6C and 7. The connector assembly shown in Figures 6A-C it uses conductive penetrating shear anchors 70 arranged in connector housing 51 which extend into socket 52 through multiple layers of conductive wires 76. Figures 6B and 6C illustrate the layers of wires 76 which are they are displacing the tapered penetrating portion of shear anchor 70 as shear anchor 70 extends into socket 52. In this way, a direct current path is created between conductive elements or wire layers 76 by of the conductive penetrating shear bolt anchor 70, thereby more evenly distributing the load current between the conductive elements or the strand layers 76 and reducing the tendency to charge current concentration within the external conducting elements or strand layers 76.
[0124]
[0125] [0061] The current distribution over a cable cross section improves as electrical communication is established between additional conductor elements or additional wire layers 76. However, conductive anchors 70 need not extend through all conductive elements or strand layers 76 to effect a significant improvement in the current concentration profile. This is in part because most of the cross sectional area for a multilayer cable is encompassed within the outermost conductor elements or layers of wires 76.
[0126] [0062] The embodiment of Figure 6A shows three penetrating safety bolt anchors 70 oriented at an angle of approximately forty-five degrees to each other, but those skilled in the art will appreciate that any suitable number of conductive anchors can be used. 70 in any suitable relative orientation. The embodiment shown in Figure 7 illustrates the use of four penetrating safety bolt anchors 70 arranged at alternate angular positions along the axial direction of a multilayer braided conductor. The embodiment shown in Figure 8 illustrates the use of the same alternating four-bolt security anchor configuration on both sides 78 and 79 of a splice connector 50 where four penetrating security bolt anchors 70 are used to secure each one of the two cable ends inserted into opposite sides of the connector housing 51.
[0127]
[0128] [0063] Details of an exemplary conductive penetrating shear bolt anchor are shown in Figure 9. The conductive penetrating shear bolt anchor includes an anchor head 84, a shank 86 that may include one or more break points 88, a threaded portion 89, and a tapered penetrating portion 90 or tip. The embodiments of the conductive penetrating shear bolt 70 shown in the accompanying figures are secured within the connector housing by threading the anchors 70 through threaded passages 59 in the housing 51. The penetrating end portion 90 facilitates penetration through the conductive elements or strand layers 76, in contrast to the planar or flat end of a conventional shear bolt anchor depicted in Figure 5B that simply contacts the external conductive elements.
[0129]
[0130] [0064] The use of threaded conductive penetrating safety bolt anchors 70 and multiple shear break points 88 allows the anchors 70 to be screwed to a desired depth within the conductive elements before breaking a portion of the anchor 70 into one of breakpoints 88. This allows a single conductive penetrating shear bolt anchor 70 to accommodate connectors and cables of different thicknesses or cables with a variable number of layers of wires 76 to be penetrated. Although threaded conductive penetrating safety bolt anchors offer the advantage of comfortable and precise control over penetration depth, those of skill in the art will recognize that other types of fastening means can be used to secure conductive anchors within the connector housing. and penetrate conductive elements, such as nails, screws, or rivets. Steps 90 can be formed previously in connector housing 51 or created when conductive anchors 70 are actuated through connector housing 51 during fabrication or installation.
[0131]
[0132] [0065] Figures 10 and 11 illustrate the use of screws 92 as conductive penetrating anchors in both a shear bolt connector (Figure 10) and a crimp connector (Figure 11). As with the penetrating shear bolt configuration shown in Figure 6, screws 92 are driven to the desired depth through connector housing 51 and through multiple conductive elements or wire layers 76 to improve connectivity by establishing a direct current path between conductive elements or strand layers 76 via penetrating anchor 92. Screw length and drive depth can be selected so that the screw head does not extend significantly beyond the outer surface of the connector housing 51, thereby avoiding the need to shear the anchor head as in security bolt anchors.
[0133]
[0134] [0066] In other embodiments, the conductive elements or strand layers 76 can be modified (during splicing, for example) to improve connectivity between conductive elements or strand layers and allow the use of penetrating anchors or bolt anchors of conventional safety while establishing a current path between conductive elements or layers of wires. The exemplary embodiment shown in Figure 12A uses notches 102a-b, or cut segments from each strand layer or through successive strand layers. For example, the first notch 102a in Figure 12A cuts the outermost yarn layer while the second notch 102b cuts the two outermost yarn layers.
[0135]
[0136] [0067] The notches 102a-b are arranged in an alternate or offset manner that corresponds to the arrangement of the anchors 70 that extend through the connector housing 51, as illustrated in Figures 12B-12D. In this way, after extending through the connector housing 51 via passage 59, each anchor 70 can contact a different conductive element or strand layer 76 of varying depth within the cable without having to penetrate the conductive elements or strand layers 76. This also allows the radius or thickness of the cable at an axial distance from the anchors 70 to remain unchanged so that a design pressure between the external surface of the cable and the internal surface of the connector remains large enough. to secure the cable inside the connector. A current path is established between the wire layers through the anchor 70 and the connector housing 51. Notably, with the procedure shown in Figure 12A, each anchor 70 must be driven to a different depth through connector housing 51, which can complicate connector installation.
[0137]
[0138] [0068] The embodiment shown in Figures 13A-B and 14A-B illustrates the use of stepped circumferential shear segments 106 and conductor spacers 108 to provide a current path between the layers of wires 76 or conductor elements without the need of driving the anchors at different depths through a connector housing 51. During splicing, a series of circumferential segments 106 are cut from each successive conductor element or strand layer 76 to create a staggered configuration where, for example, a first circumferential segment 106a is removed from the outer conductive element or strand layer 76, a second circumferential segment 106b is removed from the second outer conductive element or strand layer 76, and so on. The staggered configuration is created by removing the circumferential segments 106 in an offset manner along the axial direction of the cable.
[0139]
[0140] [0069] Next, a conductive spacer 108 is placed around each conductive element or strand layer 76 to replace the volume of material removed by removal of the circumferential segments 106. 108, therefore, are installed concentrically so that each spacer 108 can establish electrical communication with the conductive spacers 108 arranged on adjacent conductive elements or strand layers 76, creating a current path between the conductive elements or strand layers 76. A shear bolt or penetrating conductor anchor Conventional 70 is operated at a depth so that it establishes electrical communication with conductive spacer 108 arranged around the external conductive element or wire layer 76, thereby creating a current path between conductive elements or wire layers 76 by of the conductor spacers 108, the anchors 70 and the connector housing 51, which It limits the need to drive anchors 70 at varying depths through each conductive element or layer of wires 76. In this configuration, conventional conductive penetrating or safety bolt anchors 70 can be operated at a constant depth that comes into contact with the outermost conductive spacer 108 at the same time that improved connectivity between conductive elements or wire layers 76 is achieved.
[0141]
[0142] [0070] As an alternative to placing a separate conductor spacer 108 around each conductor element or strand layer 76, a single unitary spacer with a stepped or recessed inner surface 110 that conforms to the circumferential cutting segments 106 of the conductive spacer, as shown in Figure 15. The interior dimensions of spacer 108 are greater than the exterior dimensions of the conductive elements or Strand layers 76 so that spacer 108 can be easily arranged around conductive elements or strand layers 76. Unitary conductive spacer 108 could also be formed with protrusions extending from the inner surface of spacer 108 corresponding to the notches. 102 in the conductive elements or strand layers 76 so that spacer 108 is placed in electrical communication with multiple conductive elements or strand layers 76 when arranged on the cable.
[0143]
[0144] [0071] Conductive spacer 108 can be made compressible so that spacer 108 deforms to fit securely around the conductive element or wire layer 76 as the connector is crimped or secured with one or more anchors on the Cable end portions 62 and 63 received within socket 52. Conductive spacer 108 can be formed from a compressible material or formed as a compressible helical element, as shown in Figure 13B. Conductive spacer 108 can be formed, if necessary, from materials available in the field during connector installation, such as forming the helical spacer shown in Figure 13B using a segment of a conductive wire. In another embodiment depicted in Figure 16, one or more longitudinal grooves 112 are formed in the conductive spacer 108 running along the axial axis over the majority of the spacer length to facilitate compression of the spacer.
[0145]
[0146] [0072] The improved connectivity of connector assemblies using current devices and procedures was validated by current cycle testing. Connector assemblies with and without water-blocking materials underwent repeated charging cycles while suspended in the air in a draft-free room. The test conductor loops were tested against straight conductor segments called control conductors that were placed in series with the test loop. Each charge cycle was intended to bring the control conductor temperature to 100 ° C above ambient temperature with a cycle duration long enough to stabilize the temperature within / - 2 OC. According to industry standards, the resistance of the test loop and the temperature difference between a particular test loop and the control conductor must remain stable during the duration test through repeated charging cycles. Figures 17 and 18 show that this was not the case with conventional connector assemblies that do not use the devices and methods of the invention described herein.
[0147]
[0148] [0073] Figure 17 illustrates the change in resistance factor for a 750 kcmil aluminum conductor used in various test loops for more than thirty test cycles. The use of a resistance factor facilitates the comparison of different sizes of conductors, samples, etc., and is defined as the ratio of the actual resistance of a sample to that of the nominal value for a single conductor of the same length. A resistance factor below 1 indicates a relatively low resistance for a connector, while an increase in resistance factor over time is an indication of connector degradation. Connectors with flat conductors (without water blocking materials) remained relatively stable over time (bottom three lines) with a lower resistance factor than the control conductor for the duration of the test cycle. Connectors with conductors that have water blocking wires (three lines above the control conductor) showed a relatively slow increase in resistance over time, while connectors with conductors with water blocking tapes (three lines higher) demonstrated a strong increase in resistance that can be considered catastrophic out-of-control that would invariably lead to overheating and connector failure.
[0149]
[0150] Similar results were achieved with temperature tests, as illustrated in Figure 18. The temperature of the control conductor remained relatively stable for more than thirty cycles, as did the temperature of connectors with flat conductors that do not have water blocking materials. Connectors with a conductor that uses water blocking wires showed a slow increase in temperature during the course of the test, while connectors with conductors with water blocking tapes showed a strong temperature increase over time. In particular, aluminum joints begin to degrade rapidly as temperatures reach approximately 140 ° C due to annealing and movement of the aluminum lattice. Therefore, connectors using water blocking tapes shown in Figure 18 would be particularly susceptible to failure since temperatures reached more than 140 ° C after less than fifteen cycles. Splices made of other materials, of course, would exhibit similar failures at various temperature points.
[0151] [0075] Substantial improvements achieved using the devices and procedures according to the invention described herein are illustrated in Figure 19. For each of the lines shown in Figure 19, conductors having water blocking tapes were used with a connector assembly having penetrating anchors to establish a current path between the conductive wire layers. Despite the fact that conductors having water-blocking tapes performed the worst in the test shown in Figures 17 and 18, the connectors shown in Figure 19 exhibited a relatively stable temperature below that of the control conductor for approximately 675 charge cycles.
[0152]
[0153] [0076] Although the above description provides exemplary embodiments of the invention, it is envisioned that other embodiments may perform similar functions and / or achieve similar results. Any and all of these embodiments and equivalent examples are within the scope of the present invention.

权利要求:
Claims (22)
[1]
1. An electrical connector assembly comprising:
(a) a connector having a housing comprising (i) a first axis extending between a first end with a first opening and a second end, and (ii) a second axis transverse to the first axis, and (iii) a outer surface;
(b) a socket cavity placed at least partially with the first opening, in which the socket cavity (i) extends along the first axis, (ii) defines an interior surface of the housing, and (iii) is dimensioned to receive an electrical conductor that has at least two conductive elements; and
(c) a passage through the housing, in which (i) the passage extends along the second axis from the outer surface of the housing to the interior surface of the housing, and (ii) the passage is dimensioned to accommodate a conductive anchor, in which
(A) The conductive anchor comprises a first anchor end, a second anchor end, and a first length of the anchor that extends between the first anchor end and the second anchor end, and where
(B) The first length of the anchor is dimensioned so that, when the socket cavity receives the electrical conductor and the conductive anchor is secured within the passage, the first anchor end extends within the socket cavity and into the at least two conductive elements.
[2]
2. The electrical connector assembly of claim 1, wherein the first anchor end is a penetrating portion and the conductive anchor is selected from the group consisting of a shear bolt, screw, or rivet.
[3]
3. The electrical connector assembly of claim 1, wherein the first anchor end is a penetrating portion and the conductive anchor is a shear bolt having a plurality of break points.
[4]
4. The electrical connector assembly of claim 1, wherein the connector is a crimp connector.
[5]
5. The electrical connector assembly of claim 1, wherein the passage is formed by actuating the conductive anchor toward the outer surface of the housing.
[6]
6. The electrical connector assembly of claim 4, wherein the passage is formed by actuating the conductive anchor toward the outer surface of the housing.
[7]
7. The assembly according to claim 1, wherein:
(a) the second end of the housing includes a second opening;
(b) the socket cavity defines a channel extending from the first opening to the second opening, wherein the second opening is dimensioned to receive a second electrical conductor having at least two conducting elements;
(c) the passage defines an opening in the outer surface of the housing, in which the opening is located at a first distance from the first end of the housing; and in which
(d)
[8]
8. The electrical connector assembly of claim 7, wherein the first anchor end is a penetrating portion and the conductive anchor is selected from the group consisting of a shear bolt, screw, or rivet.
[9]
9. The electrical connector assembly of claim 8, wherein the third anchor end is a penetrating portion and the second conductive anchor is selected from the group consisting of a shear bolt, screw, or rivet.
[10]
10. An electrical connector assembly comprising:
(a) a connector having a housing comprising (i) a first axis extending between a first end with a first opening and a second end, and (ii) a second axis transverse to the first axis, and (iii) a outer surface;
(b) a socket cavity placed at least partially with the first opening, in which the socket cavity (i) extends along the first axis, (ii) defines an interior surface of the housing, and (iii) it is dimensioned to receive an electrical conductor comprising at least two conducting elements, in which a first conducting element comprises a cutting segment; and
(c) a passage through the housing, in which (i) the passage extends along the second axis from the outer surface of the housing to the interior surface of the housing, and (ii) the passage is dimensioned to accommodate a conductive anchor, in which
(A) The conductive anchor comprises a first anchor end, a second anchor end, and a first length of the anchor that extends between the first anchor end and the second anchor end, and where
(B) The first length of the anchor is dimensioned so that, when the socket cavity receives the electrical conductor and the conductive anchor is secured within the passage, the first anchorage end extends into the socket cavity and establishes electrical communication. with a second conductive element.
[11]
11. The assembly according to claim 10, wherein:
(a) when the socket cavity receives the electrical conductor, the pitch is aligned with the cutting segment; and in which
(b) the conductive anchor establishes electrical communication with the second conductive element extending through the passage and into the cutting segment to engage the second conductive element.
[12]
12. The assembly according to claim 11, wherein:
(a) the first conducting element and the second conducting element are concentric; and in which
(b) the cutting segment is a notch formed by removing a part of the first conductive element.
[13]
13. The assembly according to claim 11, wherein:
(a) the first conducting element and the second conducting element are concentric; and in which
(b) the cutting segment has a segment length that extends along the first axis, and the cutting segment is formed by removing the entire cross section of the first conducting element through the length of the segment.
[14]
14. The assembly according to claim 10, wherein:
(a) the first conducting element and the second conducting element are concentric;
(b) the cutting segment has a segment length extending along the first axis, and the cutting segment is formed by removing the entire cross section of the first conducting element through the length of the segment;
(c) a conductive spacer is arranged around the second conductive element at least partially within the cutting segment, in which the conductive spacer is in electrical communication with the second conductive element; and in which
(d) the conductive anchor is in electrical communication with the second conductive element extending through the passage to engage the conductive spacer.
[15]
15. The assembly according to claim 10, wherein:
(a) a conductive spacer arranged at least partially within the cut segment, in which the conductive spacer is in electrical communication with the first conductive element;
(b) the conductive anchor establishes electrical communication with the first conductive element extending through the passage to couple the conductive spacer.
[16]
16. The assembly according to claim 10, wherein:
(a) a conductive spacer is disposed around the first conductive element at least partially within the cutting segment and disposed around the second conductive element, wherein the conductive spacer is in electrical communication with both the first conductive element and the second element driver; and in which
(b) the conductive anchor establishes electrical communication with both the first conductive element and the second conductive element extending through the passage to couple the conductive spacer.
[17]
17. The electrical connector assembly of claim 15, wherein the conductive spacer is formed of a malleable material.
[18]
18. The electrical connector assembly of claim 15, wherein the conductive spacer comprises (i) an elongated hollow body having a longitudinal axis and spacer length, and (ii) a recess in the hollow body, in the that the slit extends in the direction of the axis length and has a slit length that is less than the length of the spacer.
[19]
19. A procedure to establish an electrical connection that includes the steps of:
(a) providing a connector having a housing comprising:
(i) a first axis extending between a first end with a first opening and a second end,
(ii) a second axis transverse to the first axis,
(iii) an outer surface;
(iv) a socket cavity placed at least partially with the first opening, in which the socket cavity (A) extends along the first axis, (B) defines an interior surface of the housing, and (C) is dimensioned to receive an electrical conductor comprising at least two conductive elements; and
(v) a passage through the housing, in which (A) the passage extends along the second axis from the outer surface of the housing to the interior surface of the housing, and (B) the passage is dimensioned to accommodate a conductive anchor;
(b) providing a conductive anchor comprising a first anchor end and a second anchor end;
(c) inserting the electrical conductor into the first opening and into the socket cavity; and
(d) inserting the conductive anchor into the passage at a depth such that the conductive anchor extends into the socket cavity to establish electrical communication with the at least two conductive elements.
[20]
20. The method for establishing an electrical connection of claim 19, wherein the conductive anchor establishes electrical communication with the at least two conductive elements extending within the at least two conductive elements.
[21]
21. The procedure for establishing an electrical connection of claim 19, wherein:
(a) the electrical conductor comprises a first conducting element having a cutting segment;
(b) the conductive anchor establishes electrical communication with a second conductive element extending through the passage and into the cutting segment to engage the second conductive element.
[22]
22. The procedure for establishing an electrical connection of claim 19, wherein:
(a) the electrical conductor comprises a first conducting element having a cutting segment;
(b) the procedure also includes the steps of:
(i) provide a conductive spacer; and
(ii) install the conductive spacer at least partially within the cutting segment, in which (A) the conductive spacer is in electrical communication with a second conductive element, and in which (B) the conductive anchor establishes electrical communication with the second conductive element extending through the passage to couple the conductive spacer.

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公开号 | 公开日

JP6984011B2|2021-12-17|

JP2020537809A|2020-12-24|

US10594075B2|2020-03-17|

KR20200070279A|2020-06-17|

US20190103703A1|2019-04-04|

ES2758404R1|2020-09-25|

WO2019070369A8|2020-03-26|

WO2019070369A1|2019-04-11|

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法律状态:
2020-05-05| BA2A| Patent application published|Ref document number: 2758404 Country of ref document: ES Kind code of ref document: A2 Effective date: 20200505 |

2020-09-25| EC2A| Search report published|Ref document number: 2758404 Country of ref document: ES Kind code of ref document: R1 Effective date: 20200918 |

2021-06-03| PA2A| Conversion into utility model|Effective date: 20210528 |

优先权:

申请号 | 申请日 | 专利标题

US201762567377P| true| 2017-10-03|2017-10-03|

PCT/US2018/050224|WO2019070369A1|2017-10-03|2018-09-10|Enhancing connectability among conductor elements|

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