BRPI0317580B1 - BUS ASSEMBLY FOR ELECTRICAL CONNECTING A PLURALITY OF DRIVERS - Google Patents

Description

Patent Descriptive Report for "BUS ASSEMBLY FOR ELECTRICALLY CONNECTING A PLURALITY OF DRIVERS".

Field of the Invention The present invention relates to electrical connectors and methods for using them and more specifically to environmentally protected electrical connectors and methods for forming environmentally protected connections.

Background of the Invention Multi-tap or bus connectors are commonly used to distribute electrical power, for example, to multiple residential or commercial structures of a common power supply. Bus connectors typically include a conductive element formed of copper or aluminum housed in a polymeric cover. The conductive element includes a plurality of cable holes. The cover includes a plurality of ports each adapted to receive a respective cable and to route the cable into a respective cable hole. An adjusting screw is associated with each cable hole to secure the cables in the respective holes and thereby electrical contact with the conductive element.

[003] Bus assemblies as described above may be used to electrically connect two or more cables. For example, a power cable may be attached to the bus connector through one of the ports and one or more branch or branch circuit cables may be connected to the bus connector through the other ports to distribute power from the power cable. . Bus connectors of this type provide significant convenience in that cables can be added and removed from the connection as needed.

[004] Power distribution connections as discussed above are typically housed in an above-ground enclosure or below-level enclosure. The various cables are usually fed through the ground and the connection (which includes the bus connector) can remain detached from the enclosure or box (ie floating inside the enclosure). The connections may be subject to moisture, and may even become submerged in water. If the conductive element and conductors are left exposed, water and environmental contaminants may cause corrosion on them. Further, the conductive element is often formed of aluminum, so that water may cause oxidation of the conductive element. Such oxidation can be significantly accelerated by the relatively high voltages (typically 120 volts to 1000 volts) employed. In order to reduce or eliminate exposure of the conductor element and the conductor portions of the cables to water, some known bus designs include dust caps or elastomeric caps. These covers or guards may be difficult or inconvenient to install properly, specifically in the field, and may not provide reliable seals.

SUMMARY OF THE INVENTION In accordance with embodiments of the present invention, a busbar assembly for electrically connecting a plurality of conductors includes a housing defining an internal cavity and a first and a second port. The first and second doors each include a conductor passage and communicate with the inner cavity. The conductor passages are one adapted to receive a conductor therethrough. An electrically conductive bus conductor element is disposed in the inner cavity. At least one retention mechanism is provided for selectively securing each conductor to the bus conductor element for electrical contact therewith. A seal is disposed in the conductor passages of each of the first and second doors. The seal is adapted to insert the conductors therethrough such that the seal provides a seal around the inserted conductors. The seal may be a gel.

In accordance with the method embodiments of the present invention, a method is provided for forming a connection between an electrical connection between a busbar assembly and a first and a second conductor, the busbar assembly including a housing, a conductive member. conductor busbar, at least one retention mechanism and a seal, the housing defining an inner cavity and a first and a second door each including a conductor passageway and communicating with the inner cavity, the busbar element being arranged in the inner cavity, the seal being disposed in the conductor passages of each of the first and second doors. The method includes inserting each of the first and second conductors through each other of the conductor passages and the seal disposed therein and into the inner cavity such that the seal provides a seal around the first and second conductors. The method further includes selectively securing each conductor to the bus conductor element for electrical contact therewith using the at least one retaining mechanism.

According to embodiments of the present invention, an electrical connector for use with a conductor includes a housing that defines a port. The door includes an inlet opening, an outlet opening, and a conductor passageway extending between and communicating with the inlet and outlet openings. The driver passage is adapted to receive the driver through it. A glove member is disposed in the conductor passage and defines a glove passage. The seal is disposed within the glove passage. The seal is adapted for insertion of the conductor therethrough such that the seal provides a seal around the inserted conductor. The seal may be a gel.

According to the additional embodiments of the present invention, an insert assembly for providing a seal to an electrical connector, the electrical connector including a housing defining a door, the door including an inlet opening, an outlet opening, and a conductor passage extending between and communicating with the inlet and outlet openings, the conductor passage being adapted to receive a conductor therethrough includes a glove member adapted to be inserted into the conductor passage. The glove element defines a glove passage. The seal is disposed within the glove passage. The seal is adapted for insertion of the conductor therethrough such that the seal provides a seal around the inserted conductor. The seal may be a gel.

In accordance with the method embodiments of the present invention, a method is provided for providing a seal to an electrical connector, the electrical connector including a housing defining a door, the door including an inlet opening, an outlet opening and a conductor passage extending between and communicating with the inlet and outlet openings, the conductor passage being adapted to receive a conductor therethrough. The method includes inserting an insert into the conductor passage. The insert includes a glove element defining a glove passage. The glove member further includes a seal disposed within the glove passage. The seal is adapted for insertion of the conductor therethrough such that the seal provides a seal around the inserted conductor.

In accordance with the additional embodiments of the present invention, an electrical connector for use with a conductor is provided. The electrical connector defines an access opening and an access passage that communicates with the access opening and includes an operable retention mechanism for securing the conductor to the electrical connector. The retention mechanism is accessible through the access opening and the access passage. The access seal is disposed within the access passage and is adapted to seal the access passage. The access seal may be a gel.

According to additional embodiments, an electrical connector for use with a conductor includes a housing that defines a port. The door includes an inlet opening, an outlet opening, and a conductor passageway extending between and communicating with the inlet and outlet openings. The driver passage is adapted to receive the driver through it. The seal is disposed within the conductor passage. The seal is adapted for insertion of the conductor therethrough such that the seal provides a seal around the inserted conductor. A penetrable closure wall extends through the conductor passage.

According to the additional method embodiments of the present invention, a method is provided for forming a connection between an electrical connector and a conductor, the electrical connector including a housing defining a door, the door including an inlet, an outlet opening, and a conductor passage extending between and communicating with the inlet and outlet openings, the electrical connector further including a seal disposed within the conductor passage and a penetrable closure wall extending through the driver's ticket. The method includes inserting the conductor through the conductor passage and the seal disposed therein such that the seal provides a seal around the conductor. The closing wall is penetrated with the conductor.

The objects of the present invention will be appreciated by those skilled in the art of reading the figures and the detailed description of the following preferred embodiments, such description being merely illustrative of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of an electrical connection assembly including a busbar assembly in accordance with the embodiments of the present invention and a pair of cables, wherein the cables are blown from the assembly of bus;

Figure 2 is an exploded perspective view of the busbar assembly of Figure 1;

Figure 3 is a cross-sectional view of the busbar assembly of Figure 1 taken along line 3-3 of Figure 1;

Figure 4 is a cross-sectional view of the busbar assembly of Figure 1 taken along the same line as the view of Figure 3, and where a cable is installed in the busbar assembly;

Figure 5 is an exploded perspective view of a bus assembly according to the additional embodiments of the present invention;

Figure 6 is a cross-sectional view of the busbar assembly of Figure 5 taken along line 6-6 of Figure 5;

Figure 7 is a rear perspective view of a glove member forming a part of the busbar assembly of Figure 5;

Figure 8 is a cross-sectional view of the busbar assembly of Figure 5 taken along line 8-8 of Figure 5;

Figure 9 is a cross-sectional view of the busbar assembly of Figure 5 taken along the same line as the view of Figure 8, and where a cable is installed in the busbar assembly;

Figure 10 is an exploded perspective view of a bus assembly according to the additional embodiments of the present invention;

Figure 11 is a cross-sectional view of the busbar assembly of Figure 10 taken along line 11-11 of Figure 10;

Figure 12 is an exploded perspective view of a bus assembly according to the additional embodiments of the present invention;

Figure 13 is a cross-sectional view of the busbar assembly of Figure 12 taken along line 13-13 of Figure 12; and Figure 14 is a cross-sectional view of a bus assembly according to the additional embodiments of the present invention.

Detailed Description of Preferred Embodiments of the Invention The present invention will now be more fully described hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be incorporated in many different forms and should not be construed as limited to the embodiments herein; on the contrary, these embodiments are provided such that this description is extensive and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, like reference numerals refer to like elements throughout the specification.

Referring to Figures 1-4, a connector or bus assembly 100 according to embodiments of the present invention is shown herein. The busbar assembly 100 may be used to electrically connect a plurality of electrical connectors, such as conductors 5A and 7A to cables 5 and 7 (which also include electrically insulating sleeves or covers 5B, 7B), as shown in Figures 1 and 4. The busbar assembly 100 may provide an environmentally protected and preferably watertight connector and connection. For example, the busbar assembly 100 may be used to electrically connect the conductors of a power supply cable and one or more branch or branch cables, while preventing the conductive portions of the cables and busbar assembly 100 from being exposed. surrounding humidity or the like.

Looking at busbar assembly 100 in more detail, busbar assembly 100 includes a bus conductor element 110, a cover assembly 120, a plurality of set screws 102 (only two shown in Figure 2), and a mass 160. The cover assembly 120 includes a rear cover member 130 and a front cover member 140. The cover assembly 120 defines an inner cavity 122 within which the conductive member is disposed. Inner cavity 122 is environmentally protected.

Conductor element 110 includes four cable or conductor holes 112, each having a front opening 114. Conductor holes 112 are sized and formed to receive conductors 5A, 7A. Four threaded holes 116 extend orthogonally and intersect each other from the conductor holes 112. The conductor element 110 may be formed of any suitable electrically conductive material. In some embodiments, the conductive element 110 is formed of copper or aluminum. In certain preferred embodiments, the conductive member 110 is formed of aluminum. The conductive element 110 may be formed by molding, stamping, extrusion and / or machining, or by any other suitable process.

Rear cover member 130 includes a body portion 132. A plurality of transversely extending ribs 133 project into the inner cavity 122 of the body portion 132. Four access doors 134 are provided in the body portion 132. Each access port 134 includes an access tube 134A defining an access passage 134B. Access passage 134B communicates with an access opening 134C and inner cavity 122. A perimeter flange 136 extends around body portion 132 and defines a perimeter channel 136A. A plurality of latch slots 138 are formed in flange 136.

Front cover element 140 includes a body portion 142. A pair of transversely extending spacer ribs 143 (Figure 3) extend transversely of the body portion 142. Four conductor or cable ports 144 are provided in the body portion 142. Each port 144 includes a cable tube 144A defining a cable passage 144B. Cable passage 144B communicates with an inlet port 144C and an outlet port 144D. A breakable closing wall 150 extends through the passageway 144B between the openings 144C and 144D.

A perimeter flange 146 surrounds and projects rearwardly of the body portion 142. A plurality of barbed latch projections 148 extend rearward of the flange 146.

Four plugs or covers 152 are joined in the body portion 142 by a flexible connecting portion 154. The covers 152 are sized and formed to fit into respective access passages 134B and access openings 134C. An O-ring (e.g., formed of an elastomer or the like) is provided on each cap 152 to provide a seal between the caps 152 and access doors 134.

Preferably, the front cover element 140 is integrally formed and the rear cover element 130 is integrally formed. The cover elements 130, 140 may be formed of any suitable electrically insulating material. Preferably, the cover elements 130, 140 are formed of a molded polymeric material. More preferably, the cover elements 130, 140 are formed of polypropylene, polyethylene or a thermoplastic elastomer. The cover elements 130, 140 may be formed of a flame retardant material, and may include a suitable additive for rendering the flame retardant cover elements.

Each of the four set screws 102 (only two shown in Figure 2) is threadably installed in one of the respective threaded holes 116. Each of the screws 102 includes a socket 102A which may be adapted to receive a key 9 ( Figure 4), for example.

As best seen in Figures 2 and 3, seal 160 is disposed within cover assembly 120. More specifically, a body seal portion 164 of seal 160 is disposed in a front portion of inner cavity 122. A plurality of door seal portions 162 are disposed on respective doors 144. In some embodiments and as illustrated, each door seal portion 162 extends from the inner side of closing wall 150 to outlet port 144D of associated door 144. and adjoins the body seal portion 164. The seal portion 164 includes a perimeter portion 166 that is disposed within channel 136A to form a surrounding seal between the cover members 130, 140.

According to some embodiments of the invention, seal 160 is a gel. The term "gel" has been used in the prior art to cover a vast network of grease materials to tetropropic compositions to extended fluid polymer systems. As used herein, "gel" refers to the category of materials which are solids extended by a fluid extender. The gel may be a substantially diluted system that does not exhibit a steady state flow. As discussed in Ferry, "Viscoelastic Properties of Polymers", 3- ed. P. 529 (J. Wiley & Sons, New York 1980), a polymer gel may be a crosslinking solution or bonded by chemical bonds or crystallites or some other type of junction. The absence of steady state flow can be considered to be the key definition of properties as solid while substantial dilution may be required to provide the relatively low modulus of gels. Solid nature can be achieved by a continuous network structure formed in the material generally by crosslinking the polymer chains through some kind of junction or by creating associated substitute domains from various polymer branch chains. Crosslinking may be either physical or chemical provided that the crosslinking sites may be sustained under the conditions of use of the gel.

Preferred gels for use in this invention are silicone gels (organopolysiloxane), such as the extended fluid systems disclosed in U.S. Patent No. 4,634,207 to Debbaut (hereinafter "Debbaut '207"); U.S. Patent No. 4,680,233 to Camin et. there.; U.S. Patent No. 4,777,063 to Dubrow et al .; and U.S. Patent No. 5,079,300 to Dubrow et al. (here after "Dubrow '300"), the descriptions of which are hereby incorporated herein by reference. These fluid-extended silicone gels may be created with non-reactive fluid extenders as in the aforementioned patents or with an excess of reactive liquid, for example a vinyl rich silicone fluid, such that it acts as an extender. as exemplified by the commercially available Sylgard® 527 product of Dow-Corning of Midland, Michigan or as described in US Patent No. 3,020,260 to Nelson. As curing is involved in the preparation of these gels, these are sometimes referred to as thermocure gels. An especially preferred gel is a silicone gel made from a mixture of divinyl-terminated polydimethylsiloxane, tetrakis (dimethylsiloxy) silane, a divinyl tetramethyldisiloxane platinum complex, commercially available from United Chemical Technologies, Inc. of Bristol, Pennsylvania, polydimethylsiloxane, and 1,3,5,7-tetravenyl tetramethylcyclotetrasiloxane (reaction inhibitor to provide adequate pot life).

Other types of gels may be used, for example, polyurethane gels as set forth in the above-mentioned De-bbaut '261 and US Patent Number 5,140,476 to Debbaut (hereinafter "Debbaut' 476") and gels based in styrene-ethylene butylene styrene (SEBS) or styrene-ethylene propylene styrene (SEPS) extended with a lower naphthenic or non-aromatic or low aromatic hydrocarbon oil extender oil, as described in US Patent No. 4,369 .284 to Chen; U.S. Patent No. 4,716,183 to Gamarra et al .; and U.S. Patent Number 4,942,270 to Gamarra. SEBS and SEPS gels comprise vitreous styrene microphases interconnected by an extended elastomeric fluid phase. The separate stasis domains of microphase serve as the junction points in the systems. SEBS and SEPS gels are examples of thermoplastic systems.

Another class of gels which may be considered are EPDM rubber-based gels, as described in U.S. Patent No. 5,177,143 to Chang et al.

Still another class of gels which may be suitable are based on anhydride-containing polymers as described in WO 96/23007. These gels have been reported to have good heat resistance.

The gel may include a variety of additives, including stabilizers and antioxidants, retarded phenols (eg Irganox® 1076, commercially available from Ciba-Geigy Corp. of Tarrytown, New York), phosphites (eg Irgafos® 168, commercially available from Ciba-Geigy Corp. of Tarrytown, New York), metal deactivators (for example, Ciba-Geigy Corp.'s Irganox® D1024 from Tarrytown, New York), and sulfides ( for example Cyanox LTDP, commercially available from American Cyana-mid Co. of Wayne, New Jersey), light stabilizers (for example, Cyasorb UV-531, commercially available from American Cya-namid Co. of Wayne, New York). Jersey), and flame retardants such as halogenated paraffins (eg Bromoklor 50, commercially available from Ferro Corp. of Hammond, Indiana) and / or phosphorus-containing organic compounds (eg Fyrol PCF and Phosflex 390, both commercially available from Akzo Nob el Chemicals Inc. of Dobbs Ferry, New York) and acid sequestrants (e.g. DHT-4A, commercially available from Kyowa Chemical Industry Co. Ltd through Mitsui & Co. of Cleveland, Ohio, and hydrotalcite). Other suitable additives include dyes, biocides, tackifiers and the like described in "Additives for Plastics, Edition 1" published by D.A.T.A., Inc. and The International Plastics Selector, Inc., San Diego, California.

Hardness, stress relief, and stickiness can be measured using a commercially available Texture Technologies Corp. TA-XT2 Texture Technologies Analyzer. Scarsdale, New York, or similar machines, which have a five kilogram load cell to measure force, a 5 gram trigger, and a 6.35 mm (1/4 inch) stainless steel ball probe as described in Dubrow '300, the disclosure of which is incorporated herein by reference in its entirety. For example, to measure the hardness of a gel a 60 ml glass vial with approximately 20 grams of gel, or alternatively a stack of nine 50.8 mm x 50.8 mm x 3.2 mm (2 inch x 2 inch x 1/8 inch) is placed on the Texture Technologies Texture Analyzer and the probe is forced into the gel at a rate of 0.2 mm per second at a penetration distance of 4.0 mm. Gel hardness is the force in grams, as recorded by a computer, required to force the probe at this speed to penetrate or deform the specified gel surface by 4.0 mm. Higher numbers mean the hardest gels. TA-XT2 Texture Analyzer data can be analyzed on an IBM PC or similar computer running Microsystems Ltd.'s XT.RA Dimension Version software.

Stickiness and stress relief are read from the stress curve generated when XT.RA Dimension version 2.3 software automatically plots the force versus time curve experienced by the load cell when the penetration speed is 2.0 mm. / second and the probe is forced into the gel at a penetration distance of approximately 4.0 mm. The probe is maintained at 4.0 mm penetration for 1 minute and withdrawn at a speed of 2.00 mm / second. Stress relief is the ratio of the initial force (F) resisting the probe at the predetermined penetration depth minus the resisting force of the probe (Ff) after 1 minute divided by the initial force Fi, expressed as a percentage. That is, the percent strain relief is equal to [f] f x 100% F, where F, and Ff are in grams. In other words stress relief is the ratio of the initial force minus the force after 1 minute to the initial force. It may be considered to be a measure of the gel's ability to relax any induced compression placed on the gel. Stickiness may be considered to be the amount of resistance force in grams on the probe as it is pulled out of the gel when the probe is withdrawn at a rate of 2.0 mm / sec of the predetermined penetration depth.

An alternative way to characterize gels is by cone penetration parameters according to ASTM D-217 as proposed in Debbaut '261; Debbaut '207; Debbaut '746; and U.S. Patent Number 5,357,057 to Debbaut et al., each of which is incorporated herein by reference in its entirety. Cone penetration ("CP") values may range from approximately 70 (101 mm) to approximately 400 (101 mm). Harder gels can generally have CP values from approximately 70 (101 mm) to approximately 120 (101 mm). The softer gels may generally have CP values from approximately 200 (101 mm) to approximately 400 (101 mm), with a specifically preferred range from approximately 250 (101 mm) to approximately 375 (101 mm). For a specific material system, a relationship between CP and hardness in grams Voland can be developed as proposed in U.S. Patent No. 4,852,646 to Dittmer et al.

Preferably, the gel has a Voland hardness, as measured by a texture analyzer, between about 5 and 100 grams strength, more preferably between about 5 and 30 grams strength, and more preferably between about 10 and 100 grams. 20 grams strength. Preferably, the gel has an elongation as measured by ASTM D-638 of at least 55%, more preferably at least 100%, and most preferably at least 1,000%. Preferably, the gel has a stress relief of less than 80%, more preferably less than 50%, and more preferably less than 35%. The gel has a tackiness preferably greater than approximately 1 gram, more preferably greater than approximately 6 grams, and most preferably between approximately 10 and 50 grams. Suitable gel materials include POWER-GEL sealing gel available from Tyco Electronics Energy Division of Fuquay-Varina, NC under the brand name RAYCHEM.

Alternatively, seal 160 may be a silicone grease or a hydrocarbon based grease.

Referring to Figure 4, busbar assembly 100 may be used in the following manner to form an electrical connection assembly 101 as shown herein. Connection assembly 101 includes busbar assembly 100 and cable 5, and may include additional cables attached to busbar assembly 100 in the manner immediately described hereinafter.

With the set screw 102 in an elevated position as shown in Figure 3, cable 5 is inserted into the selected port 144. More specifically, the terminal end of cable 5 (which has an exposed portion of conductor 5A) is inserted through inlet opening 144C, passageway 144A, and outlet opening 144D, and into conductor hole 112. Making that is, the closing wall 150 is broken by the cable end and the seal 160 is displaced as shown in Figure 4. Preferably and as shown, the busbar assembly 100 is configured such that the inner cavity 122 includes a volume of a compressible gas (e.g., air) to allow cable 5 to be inserted without a proportional displacement of seal 160 out of inner cavity 122.

The adjusting screw 102 is then rotatably driven (e.g. using the wrench 9) into the threaded hole 116 to force the exposed portion of the conductor 5A against the opposite wall of the hole 112. The cover 152 is then replaced over the access opening 134C.

In this way, cable 5 is mechanically attached to or captured within busbar assembly 100 and electrically connected to conductor element 110. One or more additional cables may be inserted through other ports 144 and secured using the other set screws 102. Thus, such other cables are thereby electrically connected to the cable 5 and to each other via the conductive element 110.

When, as preferred, seal 160 is a gel, cable 5 and tube 144A apply a compressive force to seal 160 as cable 5 is inserted into busbar assembly 100. The gel is thereby elongated and it is generally deformed and substantially conforms to the outer surface of the cable 5 and the inner surface of the tube 144A. The elongated gel may extend into and through the conductor bore 112. Further, the elongated gel may extend beyond the conductive member 110 into an expansion chamber 135 created by the ribs 133. Some shear of the gel may also occur. . Preferably at least part of the gel deformation is elastic. The restoring force in the gel resulting from this elastic deformation causes the gel to operate like a spring exerting an outward force between tube 144 and cable 5.

The ruptured closure wall 150 may serve to prevent or limit the movement of gel seal 160 out of door 144 toward inlet opening 144C, thereby promoting displacement of gel into inner cavity 122. preferably the busbar assembly is adapted such that when the cable 5 is installed the gel has an elongation at the interface between the gel 160 and the inner surface of the tube 144A of at least 20%.

Each of the closing walls 150 serves as a containment for the gel or other seal 160 in use. In addition, closing walls 150 serve as mechanical covers (for example to prevent or reduce dust ingress and the like). Further, the closing walls 150 may serve as containments for the gel or other seal 160 during manufacture as described below. It will be appreciated that in some embodiments of the present invention closing walls 150 may be omitted.

Busbar assembly 100 may provide a reliable (and at least in some embodiments moisture-tight) seal between busbar assembly 100 and cable 5, as well as any additional cables attached to ports 144. Seal 160 , specifically the gel seal, can accommodate cables of different sizes within a prescribed range. Ports 144 which do not have cables installed thereon are similarly sealed by seal 160. Upon removal of a cable, the associated port 144 may be reversed by reforming the gel seal 160.

Various properties of the gel as described above can ensure that the gel seal 160 maintains a reliable, long-term airtight seal between tube 144 and cable 5. Elastic memory and retained or restoring force in the elongated gel Elasticly deformed generally causes the gel to rest against the corresponding surfaces of the cable 5 and the inner surface of the tube 144A. Also, the stickiness of the gel may provide an adhesion between the gel and these surfaces. The gel, even when cold applied, is generally able to flow around cable 5 and connector 100 to accommodate their irregular geometries.

Preferably, seal 160 is a self-healing or self-amalgamating gel. This feature, combined with the aforementioned compression force between cable 5 and tube 144A, may allow seal 160 to form a continuous body if the gel is clamped by inserting cable 5 into connector 100. The gel may Also reform if cable 5 is removed from the gel.

Seal 160, specifically when formed of a gel as described herein, can provide a reliable moisture barrier for cable 5 and conductor element 110, even when the connection 101 is submerged or subjected to extreme temperatures and changes in temperature. temperature. Preferably, the cover elements 130, 140 are made of an abrasion resistant material that resists being pierced by abrasive forces. The gel may also serve to reduce or prevent fire. The gel is typically a more efficient thermal conductor than air and thereby can conduct more heat from the connection. In this mode, the gel may overheat the connection 101 which could otherwise tend to deteriorate the insulation of the cable and cause a thermal leak and result in an electrical arc in the connection 101. Further, the gel may be flame retardant. .

Bus assembly 100 may be formed as follows. If seal 160 requires curing, such as a curable gel, the seal may be cured in situ. Front cover member 140 is vertically oriented with body portion 142 over ports 144. Uncured liquid seal is applied within front cover member 140 such that it fills cable passages 144B above closing walls 150 and also fill a portion of the body member 142 (the flange 146 serving as a surrounding lateral containment). The seal is then cured in situ.

The cover elements 130, 140 are then joined and interlocked by the latch slots 138 and the latch projections 148 around the conductive element 110. The set screws 102 are installed in the threaded holes 116 through the locking doors 116. 134. O-rings 156 are installed over covers 152.

According to some embodiments, the following dimensions may be preferred. Preferably, the length L1 (Figure 3) of the 144B cable passages is at least 25.4 mm (1.0 inch) and more preferably between about 25.4 mm and 63.5 mm (1.0 mm). 2.5 inches). Preferably, the length L2 (Figure 3) of seal 160 is at least 0.75 inch (19.05 mm) and more preferably between 0.75 to 2 inch (19.05 to 128.58 mm). 25 inches). Preferably, the nominal diameter D1 (Figure 3) of cable passages 144B is at least 25.4 mm (1.0 inch). More preferably, the diameter D1 is between about 25.4 and 50.8 mm (1.0 and 2.0 inches). Preferably the diameter D1 is between about 15 and 30% larger than the larger cable diameter (including the insulating cover) that the door is intended to accommodate. Preferably, the busbar assembly 100 is adapted to accommodate. Preferably, the busbar assembly 100 is adapted to accommodate cables having a total diameter (including the insulating cover) between about 3.17 and 22.22 mm (0.125 to 0.875 inch). Preferably the expansion chamber 135 has a volume of at least 16.38 cm3 (1.0 inch3).

Preferably, each closing wall 150 has a maximum thickness T1 (Figure 3) not greater than 6.35 mm (0.25 inch), preferably each closing wall 150 has an insertion force (i.e. that is, the force required to penetrate the plane of the closure wall 150 with the desired cable) is approximately 0.45 kg (1 lb) to 18.1 kg (40 lb) and more preferably between approximately 0.45 kg (1 Ib) and 4.53 kg (10 Ib). Each closing wall 150 may be molded with thinned or pre-cut or cracked lines after molding to create tear lines 150A (Figure 1) which reduce the required mounting force to the desired level. Each closing wall 150 may be constructed as a membrane that substantially entirely seals the conductor passage 144B before being ruptured.

Referring to Figures 5-9, a busbar assembly 200 according to the additional embodiments of the present invention is shown herein. The busbar assembly 200 includes a busbar conductor 210, a cover element 220, four set screws 202, four covers 252, and four insert assemblies 270. Figure 9 shows an electrical connection assembly 210 that includes a cable 5 connected to busbar assembly 200.

Conductor member 210 includes conductor holes 212, front apertures 214 and threaded holes 218 corresponding to elements 112, 114, 118 as discussed above, except that conductor holes 212 do not extend through the entire conductor element 210. However, it will be appreciated that conductor holes 212 may be formed in the same manner as conductor holes 112.

Covering element 220 is a one-piece design and includes four access doors 234 corresponding to access ports 134. Covering element 220 also includes four cable ports 244 corresponding to cable ports 144 except that cable passages 244B preferably have a slightly larger inner diameter. Caps 252 are separately formed and adapted to removably seal access doors 234.

Each insert assembly 270 is positioned in a respective cable port 244. Each insert assembly 270 has a glove member 272, each glove member 272 defines a passageway 272A, an inlet port 272B, and an opening. output 272C. Each sleeve member 272 has an outwardly extending flange 272D surrounding its inlet opening 272B. A closure wall 274 extends through the passage 272A of each glove member 272. Each insert assembly 270 includes a sealant mass 276 disposed within its passage 272A.

Glove elements 272 may be formed of any suitable material. In some embodiments, the glove members 272 are formed of a polymeric material such as polypropylene, polyethylene, or polyurethane.

According to some embodiments, seal 276 is a gel as described above. Each insert assembly 270 is positioned within the cable passage 244B of associated port 244 such that seal 276 is positioned between inlet opening 244C and outlet opening 244D within cable passage 244B of cable tube 244A. Insert assembly 270 is held in position by flange 272D, which limits insertion depth, and by friction mounting, welding, adhesive, or other suitable securing means between the outer wall of the glove member 272 and the inner wall. of cable tube 244A. The ribs 272E extend lengthwise along and project into the passageway 272A. Ribs 272E provide an additional surface area for securing seal 276.

Preferably, glove member passages 272A and seal masses 276 have dimensions that correspond to those discussed above with respect to cable passages 144A and seal 160, respectively. In some embodiments, the wall thickness of the glove member 272 is not greater than 3.17 mm (0.125 inch).

The busbar assembly 200 may be used in the same manner as described above for the busbar assembly 100. The busbar assembly 200 may be preferred for ease of mounting, specifically where a one-piece cover element 220 is desired. Insert assemblies 270 may be separately molded or otherwise formed. Seal 276, such as a gel, may be installed within sleeve members 272 by curing in situ in the manner described above for cover member 140 and gel seal 160. Cover member 220 may be molded around the member conductor 210 in the conventional mode. Insert assemblies 270 may then be inserted into respective cable ports 244 and properly secured in place. Insert assemblies 270 may also be used to recondition conventional bus connectors.

Referring to Figures 10 and 11, a busbar assembly 300 according to the additional embodiments of the present invention is shown herein. Bus set 300 corresponds to bus set 100, except as follows. Access pipes 334A of access ports 334 are shortened and a cap assembly 380 is installed over each. Each lid assembly 380 includes a lid body 382 defining a passageway 382A. Each cap body 382 includes a flange 384 and a closure wall 386. Each cap body 382 is secured, for example, by friction mounting, welding, adhesive, locking latch and / or other suitable means to one of the latter. access pipes 334A. A sealant mass 388, preferably a gel as described above, is disposed within each passageway 382A and in an upper portion of the associated access pipe 334A. Sealant masses 388 and closure walls 386 serve to protect busbar assembly 300 from infiltration of moisture and / or contaminants.

Busbar assembly 300 may be used in the same manner as busbar assembly 100 except that in order to rotate each set screw 302 to secure or release a cable, key 9 is inserted through closing wall 386. and seal 388. After screw 302 is positioned as desired, key 9 is withdrawn from seal 388. Where, as preferred, seal 388 is a gel as described above, gel 388 reshapes to again form a barrier to prevent or Reduce moisture and contaminant infiltration.

The lid bodies 382 are preferably formed of the same material as the glove elements 272 as described above. The seal (e.g., a gel) may be installed in the same manner as seal 276. In alternative embodiments, cap bodies 382 may be integrally formed with access pipes 334A.

Referring to Figures 12 and 13, a busbar assembly 400 according to the additional embodiments of the present invention is shown herein. Bus set 400 corresponds to bus set 100 except as follows. The busbar assembly 400 includes a conductive member 410, a cover assembly 420, a cover member 430, 440, and a seal 460 generally corresponding to the elements 110, 120, 130, 140 and 160 discussed above, respectively. Each port 444 includes a cable tube 444A defining a cable passage 444B. Cable passage 444B communicates with an inlet port 444C and an outlet port 444D.

A penetrable closing wall 451 extends through the passage 444B between the openings 444C and 444D. Closing wall 451 may be integrally molded with tube 444A. Referring to Figure 13, closing wall 451 includes a plurality of discrete fingers or tabs 452 separated by spaces 452A. The flaps 452 are flexible. In some embodiments, the flaps 452 are also resilient.

In some embodiments, the flaps 452 are concentrically arranged and inwardly conforms in one direction A from inlet opening 444C to outlet opening 444D to form a generally conical or frustoconical shape. According to some embodiments, the inclination angle is between about 10 and 60 degrees. Closing wall 451 defines a hole 452B that may be centrally located. In some embodiments, the inner diameter D2 of hole 452B is smaller than the outer diameter of the cable or cables (e.g. cables 5, 7) with which the assembly 400 is to be used. The thickness of the flaps 452 may conform in a radially inward direction. In some embodiments, the thickness of the flaps 452 conforms radially inwardly at a rate of from about zero to about 50 percent / inch.

An insert 490 is disposed within the passage 444B adjacent the outlet opening 444D. The insert 490 is seated in a recess 444E within the tube 444A and positively captured between a shoulder 444F and the front face of the conductive member 410. Additionally or alternatively, the insert 490 may otherwise be trapped within the passageway. 444B, for example, by welding, adhesive, frictional mounting, a mechanical latch or latches, one or more fasteners or the like.

Insert element 490 includes a tubular body defining a passageway 490A. The insert 490 further includes a penetrable closure wall 491 extending through the passageway 490A. The closing passage 491 may be integrally formed with the body 493. The closing wall 491 may be constructed in the same manner as discussed above with respect to the closing wall 451, and includes a plurality of tabs 492 separated by spaces 492A and defining a hole 492B.

Closing walls 451 and 491 define a chamber or sealing region 499 therebetween (Figure 13). A portion 462 of seal 460 is disposed in sealing region 499. In some embodiments, seal 462 fills sealing region 499. An additional portion 464 of seal 460 is disposed between closure wall 491 and member 410. An additional portion 466 of seal 460 is disposed within channel 436A.

Assembly 400 may be used in the same manner as assembly 100 to provide an environmentally protected connection between the conductors (e.g. of cables 5, 7). When inserting a cable through one of the ports 444, the cable penetrates and displaces the closing wall 451. The cable may resiliently deflect the tabs 452 as the cable passes through the hole 452B. As the cable is additionally inserted, the cable passes through and displaces the sealing portion 462. The cable thereafter penetrates and displaces the closing wall 491 and passes into the inner cavity 422 of the housing 420. The cable is inserted into the conductive member. 410 and secured using the adjusting screw as described above.

Closure walls 451 and 491 may serve to retain seal 462 in sealing region 499 to enhance sealing performance of connector assembly 400. By retaining seal 462 within sealing region 499, an adequate amount of Compressive force may be maintained between the seal and the surfaces to be sealed. Further, a sufficient amount of the seal may be retained within the seal passage to reform into a seal plug when removing the cable from the opening 444. In the absence of the closing wall 491, there may be a tendency for the cable to displace the seal. 462 into inner cavity 422 so that there is insufficient seal 462 remaining within passage 444B (and more specifically within passage 499) to effectively seal around the cable or seal when removing the cable. Closing wall 451 may likewise retain seal 462 in sealing region 499 as the cable is withdrawn from port 444. Closing walls 451, 491 may scrape cable seal 462 as the cable is inserted through them. Thus, closing walls 451, 491 may reduce the amount of seal required to provide the desired seal performance, specifically in the case of multiple insertions and removals of the cable or cables.

Features targeted at addressing other concerns may exacerbate the above problems. For example, it may be desirable or even required that a chamber 435 be provided in addition to set screw 401 to allow an additional length of the cable conductor to be inserted into the conductor block 410. This additional length may serve to provide a greater length. margin of error in cable installation and improve clamping integrity (eg to reduce the risk of extruding cable out under set screw 402). However, chamber 435 may allow a greater undesirable amount of seal 462 to be displaced from passage 444B. Closing wall 491, preventing or limiting the movement of seal 462 into chamber 435, permits provision of chamber 435 without an undue loss of seal performance.

Bus assembly 400 may be formed in the same manner as assembly 100 described above. However, in the case of assembly 400, insert 490 may be placed into recess 444E prior to curing seal 460 (and typically prior to applying uncured seal to front cover member 440). Thus, seal 460 may assist in securing insert member 490 in place in front cover member 440.

Referring to Figure 14, a busbar assembly 500 according to further embodiments of the present invention is shown herein. Bus set 500 corresponds to bus set 200, except as follows.

Bus assembly 500 includes an insert assembly 570 on one or more ports 444 (one shown in Figure 14). Insert assembly 570 corresponds to insert element 270, except as follows. Insert assembly 570 has a penetrable closure wall 551 constructed as described above for closure wall 451 in place of breakable closure wall 274. Insert assembly 570 further includes an insert 590 corresponding to the insert element. 490 and secured (e.g. by retention, adhesive, frictional mounting, or other suitable means) within sleeve passage 544A 572. Insert member 590 includes an additional penetrable closure wall 591 constructed as described above for the wall of closure 491. Closure walls 551 and 591 define a chamber or sealing region 599 therebetween. The seal 562 is disposed within the sealing region 599. In some embodiments, the seal 562 substantially fills the sealing region 599. According to some embodiments, and as shown, the seal 562 extends to the outlet opening 572C.

Set 500 may be used in the same manner as set 200 as described above. However, by providing the additional closing wall 591, the assembly 500 and more specifically, the insert assembly 570, may provide the advantages discussed above over the busbar assembly 400.

Where the closing walls 150, 274, 386, 451, 491, 551 and 591 are resiliently resilient, they will be spring-loaded against the outer surface of the inserted cable when displaced by the cable. This tensioned coupling may serve to improve the coupling of the closing wall against the cable thereby retaining pressure on the seal. The tensioned coupling may also serve to enhance the scraping effect as the cable is inserted or removed. The geometry of the closing wall may further assist in improving the sealing and scraping effect.

Various modifications may be made to the above 100, 200, 300, 400, 500 bus sets in accordance with the present invention. For example, body seal portion 164 may be omitted. In some embodiments, the closing walls 150, 274, 386 may be omitted.

The closing walls 150, 274, 386 may otherwise be constructed to be penetrable and displaceable. For example, the closing walls 150, 274, 386 may be constructed in the manner described above for the closing walls 451, 491, 551, 591. Similarly, the closing walls 451, 491, 551, 591 may be constructed to be totally or partially breakable. Closing walls of different designs and constructions can be used on the same connector as well as the same door. For example, the outer closure may be breakable and formed as described for the closing wall 150 while the inner closing wall is formed as described for the closing wall 451.

Further, several features of the closing walls described above can be combined. For example, one or more of the closure walls may be breakable with a preformed hole corresponding to the hole 452B formed therein and / or conical in shape. Closing walls including a plurality of flaps may be formed such that they do not form a predefined hole (e.g., hole 452B). As a further alternative, each closure wall may be constructed as a resilient, resilient membrane or panel having a preformed hole therein, the closure wall being adapted to stretch around the hole to accommodate the penetrating cable without breaking . In such a case, the hole is preferably smaller in diameter than the desired outside diameter of the cable.

Insert assembly 570 may be of one-piece construction wherein closure wall 591 is integrally molded with sleeve 572 of insert element 570. Closure wall 491 may be integrally molded with or otherwise secured. in tube 444A without using a separate insert 490, for example.

The inner closing walls (for example, the closing walls 491, 591) can be used without the outer closing walls (for example, the closing walls 451, 551). More than two closing walls may be employed. For example, a third closing wall may extend through the cable passage 444B in the sealing region 499.

Although three or four cable ports and conductor holes and three or four access ports, screw holes and set screws are shown on each of the 100, 200, 300, 400, 500 busbar assemblies, Bus assemblies according to the present invention may include more or less cable ports and / or access ports and corresponding or associated components as required to allow the connection of more or less cables.

Several of the features and inventions discussed herein may be combined differently than in the illustrated embodiments. For example, cap assemblies 380 may be used on connector 200 as well.

Although the present invention has been described herein with reference to busbar assemblies, several of the features and inventions discussed herein may be provided in other types of connectors. For example, penetrable closure walls and insert assemblies may be employed in connectors to hold a single cable or the like.

Although, according to some embodiments, seals 160, 276, 388, 460, 562 are gels as described above, other types of seals may be employed.

The connectors according to the present invention may be adapted to various voltage ranges. It is particularly contemplated that multi-tap connectors of the present invention employing aspects as described above may be adapted to effectively manipulable voltages in the range of 120 to 1000 volts.

The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. While few exemplary embodiments of this invention have been described, those skilled in the art will appreciate that many modifications are subject to exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. However, it should be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments described, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the invention.

Claims (19)

1. Busbar assembly (100) for electrically connecting a plurality of conductors (5A, 7A), busbar assembly (100) comprising: a) a housing (120) defining: - an inner cavity (122); and - first and second ports (144), each including a conductor passage (144B) and communicating with the inner cavity (122), the conductor passages (144B) being adapted to receive a respective conductor (5A, 7A) through from them; b) an electrically conductive bus conductor element (110) disposed in the inner cavity (122); c) at least one retaining mechanism (102, 134) for selectively securing each conductor (5A, 7A) to the bus conductor element (110) for electrical contact therewith; and d) a seal (160) disposed in the conductor passages (144B) of each of the first and second ports (144), the seal (160) being adapted for insertion of the conductors (5A, 7A) through them, such that the seal (160) provides sealing around the inserted conductors (5A, 7A), the busbar assembly (100) being characterized by the fact that: - the inner cavity (122) communicates with the conductor passages (144B); - bus conductor element (110) is positioned in inner cavity (122) - inner cavity (122) includes a volume filled with a compressible fluid to receive seal (160) when seal (160) is displaced by conductors (5A, 7A), and - the volume is located on one side of the seal (160) opposite an inlet opening (144G), A busbar assembly (100) according to claim 1, characterized in that the carrier (160) is a gel. Busbar assembly (100) according to claim 2, characterized in that the gel is adapted to be elongated and elastically deformed by inserting the conductors (5A, 7A) into the conductor passages (144B). Busbar assembly (100) according to claim 1, characterized in that: - each of said first and second doors (144) includes a penetrable closing wall (150) extending through the respective passage of conductor (144B); and - at least portions of the seal (160) are disposed in the conductor passages (144B) between the closing walls (150) and the interior cavity (122). Busbar assembly (100) according to claim 4, characterized in that the closing walls (150) are frangible. Busbar assembly according to claim 4, characterized in that the closing walls (150) have a thickness of at most 0.635 cm (0.25 inch). Busbar assembly (100) according to claim 1, characterized in that the housing (120) includes a projection extending into at least one of the conductor passages (144B) to increase the contact of surface between the housing (120) and the seal (160) in the conductor passage (144B). Busbar assembly (100) according to claim 1, characterized in that: - the housing (120) includes first and second housing parts in combination; and - the busbar assembly (100) further includes a joint seal along an interface between the first and second housing parts. Busbar assembly (100) according to Claim 8, characterized in that the joint seal is a gel. Busbar assembly (100) according to Claim 1, characterized in that it includes a glove member (272) disposed in at least one of the conductor passages (244B), wherein the seal (276) is provided. disposed on the glove member (272). Busbar assembly (100) according to claim 1, characterized in that said at least one retaining mechanism (102, 134) includes first and second adjusting screws (102). Busbar assembly (100) according to claim 11, characterized in that the housing (120) includes first and second access openings (134G) adapted to receive a tool (9) therethrough to rotate the first and second set screws (102). Busbar assembly (300) according to claim 12, characterized in that it includes: - first and second access passages (382A) communicating with the first and second access openings (334) and adapted to receive a tool (9) therethrough to turn the first and second set screws (302); and - an access seal disposed in each of the first and second access passages (382A), the access seal being adapted to seal the first and second access passages (382A) and allow insertion of the tool (9) through the to turn the first and second set screws (302). Busbar assembly (400) according to claim 1, characterized in that: - the first door (444) includes an inlet opening (444C) and an outlet opening (444D); - the conductor passage (444B) of the first door (444) extends between and communicates with the inlet and outlet openings (444C, 444D); the housing (420) further includes a penetrable closing wall (451) extending through the conductor passage (444B) of the first door (444); and - the penetrable closing wall (451) inwards conforms along one direction of the inlet opening (444C) to the outlet opening (444D) prior to insertion of the conductor (5A, 7A) into the first port (444). . Busbar assembly (400) according to claim 1, characterized in that: - the first port (444) includes an inlet opening (444C) and an outlet opening (444D); - the conductor passage (444B) of the first door (444) extends between and communicates with the inlet and outlet openings (444C, 444D); - the bus assembly (400) further includes an insert member (490) separately formed from the housing (420) and positioned in the conductor passage (444B) of the first door (444); - the insert (490) including an integrally penetrable closure wall (491) forming a part of the insert (490), the closure wall (491) extending through the conductor passage (444B) of the first door (444); and - the insert member (490) is cooperatively attached to the conductor passage (444B) of the first door (444) by the bus conductor member (410) and the housing (420). Busbar assembly (400) according to claim 1, characterized in that: - the first port (444) includes an inlet opening (444C) and an outlet opening (444D); - the conductor passage (444B) of the first door (444) extends between and communicates with the inlet and outlet openings (444C, 444D); - the busbar assembly (400) further includes: - a first penetrable closing wall (451, 491) extending through the conductor passage (444B) of the first door (444); and a second penetrable closure wall (451, 491) extending through the conductor passage (444B) of the first door (444), so that the first and second penetrable closure walls (451, 491) define a sealing region (499) therebetween, wherein at least a portion of the seal (462) is disposed in the sealing region (499). Busbar assembly (400) according to claim 16, characterized in that the first and second penetrable closure walls (451, 491) are operative to retain the sealant in the sealing region (499). Busbar assembly (400) according to claim 17, characterized in that it includes an insert element (490) separately formed from the housing (420) and positioned in the conductor passageway (444B) of the first door (444B). 444) wherein at least one of the first and second penetrable closure walls (451) forms a portion of the insert element (490). Busbar assembly (400) according to claim 18, characterized in that the first penetrable closing wall (451,491) is integrally formed with the housing (420) and the second penetrable closing wall (451 491) forms a part of the insert element (490),