EP1654788B1

EP1654788B1 - Tools for securing connectors using explosive charges and methods for using the same

Info

Publication number: EP1654788B1
Application number: EP04779342A
Authority: EP
Inventors: Owen Gregory; Willie Hernandez; Steve Mitchell
Original assignee: Tyco Electronics Corp
Current assignee: TE Connectivity Corp
Priority date: 2003-08-01
Filing date: 2004-07-28
Publication date: 2009-09-23
Anticipated expiration: 2024-07-28
Also published as: BRPI0413249B1; AU2004301925B2; AU2004301925A1; CA2534400C; BRPI0413249A; WO2005013438A3; CA2534400A1; EP1654788A2; WO2005013438A2

Description

The present invention relates to tools and methods for using tools and, more particularly, to a tool and a method for securing or terminating connectors.
Electrical cables often must be terminated or joined (spliced) in various environments, such as underground or overhead. Such cables may be, for example, high voltage electrical distribution or transmission lines. In order to form such connections, a connector may be employed. To install such connectors, it may be necessary to force two members into engagement, typically such that one or both of the members are deformed. Exemplary connectors include a C-shaped sleeve and wedge combination as disclosed in U.S.-A-4,722,189 . In order to install such connectors, it is typically necessary to apply a relatively great force between the wedge and the sleeve. However, the amount of force should not be excessive as this may compromise the formation or integrity of the connection. Because the connections are often formed in dangerous locations (e.g., high above the ground) and with high voltage lines, it is desirable to provide the necessary force in a manner that is convenient and safe under such circumstances.
To provide the application force as discussed above, explosive charge-actuated tools (sometimes referred to as 'powder-actuated tools") are commonly used. According to some designs, explosive charge-actuated tools include a tool body, a tool head secured to the tool body, and a ram slidably mounted in the tool body. In use, the connector components are placed between the ram and the tool head. An explosive charge, typically provided in a cartridge, is exploded in the tool body such that the tam is forced against the connector to thereby force the connector components into secure engagement. The explosion of the charge may generate pressurized gas in the tool body. If not first controllably released, the pressurized gas may harm the user when the user attempts to open the tool body to remove the expended explosive charge cartridge. Thus, tools of this type may provide a mechanism for pre-releasing pressurized gas from the tool body, for example, from a breech chamber that holds the cartridge. Exemplary tools of this type include the AMPACT tool available from Tyco Electronics, Inc. and the tools disclosed in US-A-4,722,189 and 4,905,603 . However, such tools may be difficult to operate under some circumstances or may require substantial and frequent maintenance to ensure safe and effective operation.
Other examples of explosive charge or powder actuated tools are described in US-A-2,799,108 , 3563439 and 4705200 . US-A-2,799,108 and 4,705,200 describe powder actuated tools of the type on which the preambles of claim 1 and 14 hereof are based. 2,799,108 is directed, more particularly, to an improved cartridge extractor adapted for tools utilizing rim-fire cases at high pressures. 4,705,200 is primarily concerned with a tool for driving a compression measuring probe into a concrete substrate. US-A-3,563,439 describes a captive piston type of powder actuated tool provided with a barrel pivotally engaged by the forward end of the tool housing so that the breech end of the barrel can be upraised into a loading position.
The present invention consists in a tool and a method of using the tool for securing a connector on a conductor as set forth in claim 1 and 14 hereof.
According to the invention, the lock pin or member is selectively movable between a locked position, in which the lock member prevents the breech cap sleeve from moving relative to the breech member from the closed position to the open position, and an unlocked position, in which the lock member permits the breech cap sleeve to move relative to the breech member from the closed position to the open position. In one embodiment, a limiting member is selectively movable between a first position, wherein the limiting member prevents movement of the lock member from the locked position to the unlocked position and a second position, wherein the limiting member permits the lock member to move from the locked position to the unlocked position. This limiting member may be in the form of a rotatable control member which is rotated relative to each of the breech member and breech cap sleeve to move the lock member between the locked and unlocked positions.
The tool may be configured such that, when the breech cap sleeve is in the closed position, the lock member is in the locked position, and the limiting member is in the first position, the limiting member must be moved to the second position prior to moving the lock member from the locked position to the unlocked position. The tool may include a gas release mechanism adapted to release pressurized gas from the breech chamber while the breech cap sleeve is in the closed position when the limiting member is moved from the first position to the second position. The tool may be configured such that, when the breech cap sleeve is in the closed position and the limiting member is in the first position, the lock member is automatically positioned in the locked position.
An ejector member may be mounted on the breech member such that, when the breech cap sleeve is slid relative to the breech member along the slide axis to move the breech cap sleeve to the open position, the ejector member is displaced relative to the breech chamber. The lock member may be arranged to engage the ejector member when the lock member is in the locked position.
With the invention, the breech cap sleeve is movable from a closed position, wherein the breech opening is closed, to an open position, wherein the breech opening is open to allow loading and unloading of the explosive charge into and from the breech chamber. The method of the invention may include releasing pressurized gas from the breech chamber while the lock member is in a locked position, wherein the lock member prevents the breech cap sleeve from moving relative to the breech member from the closed position to the open position; thereafter moving the lock member from the locked position to an unlocked position, wherein the lock member permits the breech cap sleeve to move relative to the breech member from the closed position to the open position; and thereafter moving the breech cap sleeve relative to the breech member from the closed position to the open position.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain principles of the invention. In the drawings:-

Figure 1 is a perspective view illustrating the formation of a connection using a tool assembly and methods according to embodiments of the present invention;
Figure 2 is a perspective view of a drive assembly forming a part of the toot assembly of the Figure 1 ;
Figure 3 is a front, perspective, exploded view of the drive assembly of Figure 2 ;
Figure 4 is a rear, perspective, exploded view of the drive assembly of Figure 2 ;
Figures 5A and 5B are perspective views of a breech forming a part of the drive assembly of Figure 2 as viewed from opposed sides thereof
Figure 6 is a side elevational view of the tool assembly of Figure 1 and a cartridge for use therewith, wherein the drive assembly is in an open position;
Figure 7 is a side elevational view of the tool assembly of Figure 1 wherein the drive assembly is in a further position;
Figure 8 is a side elevation view of the tool assembly of Figure 1 wherein the drive assembly is in a further position;
Figure 9 is a further perspective view of the drive assembly of Figure 2 ;
Figure 10 is a cross-sectional view of the drive assembly of Figure 2 ;
Figure 11 is a cross-sectional view of the drive assembly of Figure 2 taken along the same line as Figure 10 and wherein the drive assembly is in a further position;
Figure 12 is a cross-sectional view of the drive assembly of Figure 2 taken along the same line as Figure 10 and wherein the drive assembly in a further position;
Figure 13 is a perspective view of a drive assembly according to further embodiments of the present invention;
Figure 14 is a front, perspective, exploded view of the drive assembly of Figure 13 ;
Figure 15 is a rear, perspective, exploded view of the drive assembly of Figure 13 ;
Figure 16 is a cross-sectional view of the drive assembly of Figure 13 ;
Figure 17 is a cross-sectional view of the drive assembly of Figure 13 taken along the same line as Figure 16 and wherein the drive assembly is in a further position;
Figure 18 is a cross-sectional view of the drive assembly of Figure 13 taken along the same line as Figure 16 and wherein the drive assembly is in a further position; and
Figure 19 is a cross-sectional view of the drive assembly of Figure 13 taken along the same line as Figure 16 and wherein the drive assembly is in a further position.

With reference to Figure 1 , a tool assembly 40 according to embodiments of the present invention is shown therein. The tool assembly 40 may be used to form a connection 5 as shown in Figure 1 , for example. The connection 5 includes a pair of conductors 7, 9 securely and electrically coupled by a connector 20. The connector 20 includes a C-shaped sleeve 22 and a wedge 24. Connectors of this type are well-known to those of skill in the art and will not be described in further detail herein except as needed to describe embodiments of the present invention. Generally, and as described in more detail below, the tool assembly 40 may be used to force or impel the wedge 24 and the sleeve 22 into engagement using an explosive charge 32 (e.g., as provided in a cartridge 30; see Figure 11 ).
With reference to Figure 1 , the tool assembly 40 includes an explosively actuated industrial tool 45 and an anvil or tool head 80. The tool 45 includes a barrel or coupling 50, a coupling nut 60, a drive assembly 100 joined to the coupling 50 by the coupling nut 60, and a ram 70 slidably mounted in the coupling 50. With reference to Figure 6 , the drive assembly 100 includes a breech 102, an ejector sleeve 130, and a breech cap assembly 150. Each of these components will be described in more detail below. The coupling 50, the coupling nut 60 and the ram 70 are omitted from Figures 11 and 12 for clarity.
The coupling 50 includes threads 52 ( Figure 10 ) on its outer surface. A bore or barrel passage 54 extends through the coupling 50 and communicates with opposed end openings 56 ( Figures 1 and 10 ).
The breech 102 has opposed front and rear ends 104A and 104B. A breech chamber 106 ( Figure 11 ) is defined in the breech 102, which is generally tubular. The breech chamber 106 communicates with a front breech opening 108A ( Figure 3 ) and a rear breech opening 108B ( Figure 4 ). A coupling thread 110 ( Figure 5A ) is formed on the outer surface of the breech 102 on the front end 104A thereof. A radially extending coupling set screw bore 112 ( Figure 3 ) is also formed on the front end 104A for securing the breech 102 to the coupling nut 60. A pair of opposed, axially extending guide channels 114A, 114B ( Figures 5A and 5B ) are defined in the outer surface of the breech 102 on opposed sides thereof. A pair of circumferentially extending guide channels 116A and 116B ( Figures 5A and 5B ) are also defined in the outer surface of the breech 102 on opposed sides thereof and intersect the axially extending channels 114A and 114B, respectively, adjacent the front end 104A. A pair of opposed, radially extending screw holes 118 ( Figure 4 ) are formed in the rear end 104B. A recessed end portion 120 and an end flange 122 are also provided on the rear end 104B ( Figure 4 ).
The ejector sleeve 130 is mounted on the recessed end portion 120. The ejector sleeve defines a front opening 134A ( Figure 3 ), a rear opening 134B ( Figure 4) and a bore 132 ( Figure 3 ) communicating with each of the openings 134A, 134B. The rear opening 134B is defined by a radially inwardly extending, circumferential flange 136 ( Figure 4 ). The bore 132 receives the recessed end portion 120 such that the flange 136 surrounds the end flange 122. Opposed guide screws 140 ( Figures 3 and 10 ) extend from the screw holes 118 in the recessed end portion 120 and are slidably received in opposed axially extending slots 138 ( Figure 3 ) defined in the ejector sleeve 130. Grip ribs 146 ( Figure 6 ) are provided on opposed sides of the ejector sleeve 130. The ejector sleeve 130 further includes a lock pin recess 142 and a support recess 144 ( Figure 4 ).
The coupling nut 60 includes a threaded bore 62 ( Figure 10 ). The threaded bore 62 is configured to threadedly engage the coupling threads 110 of the breech 102. The coupling nut 60 serves to secure the coupling 50 to the drive assembly 100. The coupling 50 is slidable in the coupling nut 60 so as to allow a small gap 78 (see Figure 10 ).
The ram 70 is a generally cylindrical rod having a strike end 72 ( Figure 10 ) and an opposed driven end 74 ( Figure 1). A firing pin 76 ( Figure 10 ) projects from the driven end. The ram 70 is slidable in the coupling 50 and the breech 102.
The breech cap assembly 150 includes a breech cap sleeve 152, a pin guide housing 170, a pin guide 180, a retaining spring 181, a gas release member or knob 190, a piercer pin 184, a stop screw 199, and a lock pin 179. The breech cap assembly 150 is movable between a closed position ( Figures 2 and 12 ) and an open position ( Figure 6 ) as described in more detail below.
The breech cap sleeve 152 is generally tubular and defines an axially extending passage 154 that, in the closed position, surrounds the breech 102 and the ejector 130. A front opening 154A ( Figure 3 ) and a rear opening 154B ( Figure 4 ) communicate with the passage 154 on either end. Internal threads 156 ( Figure 4 ) are formed adjacent the rear opening 154B. A lock pin guide slot 158 extends axially through the threads 156. Knurling may be formed on the outer surface of the breech cap sleeve 152 to facilitate gripping. Opposed slots 162, 164 ( Figure 3 ) are defined in the breech cap sleeve 152 adjacent and in communication with the front opening 154A. The slot 164 is longer than the slot 162. The slots 162,164 define opposed, axially extending arms 166. Opposed guide projections or tabs 167 extend radially inwardly from respective ones of the arms 166 and into respective ones of the channels 116A,116B when the breech cap assembly 150 is in the closed position. An end groove 168 formed in the breech cap sleeve 152 adjacent the rear end 154B and is adapted to receive the retaining spring 181.
With reference to Figures 3 and 4 , the pin guide housing 170 defines a front opening 174A, a rear opening 174B, and a bore 172 communicating with each of the openings 174A, 174B. Internal threads 175 are provided in the bore 172. A knurled flange 176 is provided for manipulating the pin guide housing 170. A tab 177 extends axially rearwardly from the flange 176. External threads 178 are formed adjacent the front opening 174A and are configured to mate with the threads 156 of the breech cap sleeve 152. Slots are formed in the groove 168 of the breech cap sleeve 152 to allow the retaining spring 181 to extend therethrough and engage the threads 178, thereby preventing full withdrawal of the pin guide housing 170 from the breech cap sleeve 152.
As best seen in Figures 3 and 10 , the lock pin 179 is mounted on the threads 178 of the pin guide housing 170 such that the threads 178 are received in an intermediate cutout 179A of the lock pin. A front portion of the lock pin 179 is slidably received in the lock pin guide slot 158 of the breech cap sleeve 152 and, when the breech cap assembly 150 is in the closed position, into the lock pin recess 142 of the ejector sleeve 130. A rear portion of the lock pin 179 extends rearwardly from the breech cap sleeve 130 and abuts the flange 176 of the pin guide housing 170.
The pin guide 180 is disposed in the bore 172 of the pin guide housing 170. External threads on the outer surface of the pin guide 180 mate with the internal threads 175. An axially extending passage 182 ( Figure 12 ) is defined in the pin guide 180. The piercer pin 184 is slidably received in the passage 182. According to some embodiments, the pin guide 180 and the pin guide housing 170 may be unitarily formed.
The gas release knob 190 includes an end wall 191. A flange 193 (which may be knurled) surrounds the end wall 191 for manipulating the gas release knob 190. The piercer pin 184 is fixed within a pin bore 194 formed in the end wall 191. A pair of gas release passages 196 formed in the end wall 191 provide fluid communication between the breech chamber 106 and the environment. External threads 197 are formed on the front end of the gas release knob 190 and mate with the threads 178 of the pin guide housing 170. A threaded stop screw hole 198 extends axially through the flange 193. The stop screw 199 is mounted in the stop screw hole 198 with a portion 199A ( Figure 10 ) of the stop screw 199 extending axially forward from the flange 193 such that the portion 199A engages the tab 177 of the pin guide housing 170 upon rotation of the knob 190. That is, the portion 199A and the tab 177, or respective portions thereof, are located at the same positions along the axis S-S and the same radial distance from the axis S-S.
According to some embodiments, the piercer pin guide 184 and the gas release knob 190 may be unitarily formed. According to some embodiments, the pin guide housing 170 may be omitted. In this case, the piercer pin guide 180 may be secured to or formed as a part of the breech cap sleeve 152 and the lock pin 179 may be mounted directly on and operatively engaged by the threads 197 in a manner corresponding to that described above and illustrated for the pin guide housing 170.
With reference to Figure 11 , the cartridge 30 may be a cartridge of any suitable design and construction. Suitable cartridges are available from Tyco Electronics, Inc. The cartridge 30 as illustrated includes a shell 34 having a side wall 34A, an end wall 34B, and a radially outwardly extending flange 34C, and defining a shell cavity 34D. A quantity of primer 36 and the main charge 32 are disposed in the shell cavity 34D. The primer 36 may be, for example, a quantity of nitroglycerin packaged in a cap or the like. The charge 32 may be, for example, a quantity of gun powder or other suitable propellant. The charge 32 is separated from the primer by a gas check 39. The gas check has upstanding prongs 39A. The cartridge may be formed of a polymeric material such as polyethylene, for example.
With reference to Figure 1 , the tool head 80 includes an abutment 82, a driver mount portion 84, and a cradle 88 defined therebetween. A threaded coupling bore 86 is formed in the driver mount portion 84. The tool head 80 is exemplary, and any suitable tool head may be employed.
The foregoing components may be formed of any suitable materials. According to some embodiments, with the exception of the cartridge 30, all of the components are preferably formed of metal and, more preferably, steel of appropriate strength and hardness.
The tool assembly 40 may be used to form the connection 5 in the following manner. For the purposes of explanation, the procedure will be described starting with an initially open configuration wherein no cartridge 30 is installed in the drive assembly 100 and the drive assembly is in the open position. It will be appreciated from the description herein that certain of the steps discussed below can be revised in order.
The connection 5 may be temporarily formed by installing the sleeve 22 on and about the conductors 7, 9, and forcing the wedge 24 into the sleeve 22 by hand or using a hammer.
When the drive assembly 100 is in the open position as shown in Figure 6 , the breech cap assembly 150 is located such that it does not cover the breech opening 108B. The pin guide housing 170 and the gas release knob 190 are each unscrewed or backed out to respective open positions as shown in Figure 10 . Accordingly, the piercer pin 184 is retracted with respect to the pin guide 180.
According to some embodiments, it is preferable to load the tool 45 with the tool vertically oriented such that the coupling points upwardly. In order to maintain the breech cap assembly 150 in the open position, an edge of the breech cap sleeve 152 may be inserted into the support recess 144 whereby the breech cap assembly 150 is supported. Such a configuration, which is shown in Figure 6 , allows the user to use one hand to hold the tool 45 and the other hand to hold the cartridge 30 while the breech cap assembly 150 remains properly positioned.
The cartridge 30 is inserted into the breech chamber 106 through the breech opening 108B. In doing so, the ram 70 is inserted into the forward portion of the shell cavity 38 such that the driven end 74 of the ram is positioned above the primer 36 but separated therefrom by the prongs 39A. According to some embodiments, the shell 34 is sized such that it will be temporarily retained in the opening 134B by a moderate friction fit. The shell 34 may include compressible ribs on its outer surface for this purpose.
With the cartridge 30 in place, the breech cap assembly 150 is lifted from the support recess 144 and slid downwardly parallel to a slide axis S-S a short distance to assume the position illustrated in Figure 7 . The breech cap assembly 150 is then pivoted about the tabs 167 about a pivot axis P-P in a direction B. The breech cap assembly 150 is pivoted into a position as shown in Figure 8 , wherein the breech cap assembly 150 is substantially coaxial with the breech 102. It will be appreciated that the pivoting path may not be restricted to pivoting about a single point, but may instead by somewhat accurate, for example.
The breech cap sleeve 152 is then pushed forward on the breech 102 along the slide axis S-S in a direction D. The slide axis S-S is transverse (and, according to some preferred embodiments, perpendicular) to the pivot axis P-P. The tabs 167 slide within the axially extending channels 114A, 114B to thereby guide the breech cap sleeve 152 with respect to the breech 102. The breech cap sleeve 152 is slid onto the breech 102 until the breech cap assembly 150 reaches the position as shown in Figure 9 . This movement will serve to push the cartridge 30 fully into the breech 106 until the flange 34C abuts the flange 136 of the ejector sleeve 130 if the cartridge 30 is not already so positioned.
The breech cap sleeve 152 is then rotated relative to the breech 102 about the slide axis S-S in a rotational direction E ( Figure 9 ). The tabs 167 slide within the circumferentially extending channels 116A, 116B to thereby guide the breech cap sleeve 152 with respect to the breech 102. The breech cap sleeve 152 is rotated in this manner on the breech 102 until the breech cap sleeve 152 reaches the position as shown in Figures 2 and 10 . In this position, the tabs 167 and the circumferentially extending channels 116A,116B cooperate to prevent relative movement between the breech cap sleeve 152 and the breech 102 along the axis S-S.
The pin guide housing 170 may then be rotated in a direction F ( Figure 9 ) about the axis S-S to screw the pin guide housing 170 into the breech cap sleeve 152 along a lock axis T-T ( Figure 10 ) and closer to the breech 102. According to some embodiments and as illustrated, the lock axis T-T is substantially parallel to the axis S-S about which the pin guide housing 170 is rotated. The threads 178 slide within the cutout 179A of the lock pin 179 so that the lock pin 179 does not rotate but is driven forwardly through the slot 158 into the lock pin recess 142. The pin guide housing 170 is screwed into the breech cap sleeve 152 until the forward end of the pin guide housing 170 engages the ejector sleeve 130 and forces the ejector sleeve forwardly against the breech 102. The resulting position is shown in Figure 11 . In this position, the breech cap sleeve 152 is prevented from rotating relative to the breech 102 by the engagement between the lock pin 179 and the ejector sleeve 130. Additionally, according to some embodiments the cartridge 30 is driven forward by the housing 170 such that the prongs 39A are crushed by the ram 70.
The gas release knob 190 is then rotated in a direction G ( Figure 9 ) about the axis S-S to screw the gas release knob 190 into the pin guide housing 170 and closer to the breech 102 until the gas release knob 190 reaches a sealing position as shown in Figure 12 . In this manner, the piercer pin 184 is forced forwardly such that it pierces and the end wall 34B of the cartridge 30. The piercer pin 184 remains in the end wall 34B to seal the hole in the end wall 34B thus formed.
Using an alternative sequence, the housing 170 may not be screwed into the breech cap sleeve 152 as described above prior to rotating the gas release knob 190. Instead, the gas release knob 190 is first rotated in the direction G. The rotation of the gas release knob 190 will also rotate the housing 170 into the proper position after the gas release knob 190 has reached the proper position in relation to the housing 170. More particularly, at this time, the stop screw 199 will engage the tab 177, thereby causing the housing 170 to rotate with the gas release knob 190. The gas release knob 190 and the housing 170 will continue to turn together until the forward end of the housing 170 engages the ejector sleeve 130. With the lock pin 179 and the ejector sleeve 130 interlocked in this manner, the breech cap sleeve 152 cannot be rotated relative to the breech 102 about the slide axis S-S. This procedure for rotating the housing 170 and the knob 190 may be more convenient for execution by the operator.
The breech cap assembly 150 is now in the closed position as shown in Figures 2 and 12 . In this position, the rear breech opening 108B is covered by the breech cap assembly 150 and thereby effectively sealed. The front end opening 108A is substantially sealed by the ram 70. The ram 70 is positioned such that its forward end is substantially flush with the forward opening of the coupling 50. According to some embodiments, the prongs 39A may be partially crushed by the rear end of the ram 70; however, the strike pin 76 is spaced apart from the primer 36. A small gap 78 ( Figure 10 ) is defined between the coupling 50 and the breech 102 in the coupling nut 60. The tool 45 is now prepared for firing.
Prior to or following loading of the cartridge 30 as described above, the coupling 50 of the tool assembly 40 is screwed into the coupling bore 86 of the tool head 80 such that sufficient spacing between the front end of the coupling 50 and the abutment 82 remains for inserting the sleeve 22 and the wedge 24. The tool assembly 40 thus formed is then installed about the sleeve 22 and the wedge 24 as shown in Figure 1 such that the components 22, 24 are received in the cradle 88. The coupling is screwed into the bore 86 until the sleeve 22 abuts the abutment 82 and the forward end of the coupling 50 abuts the wedge 24.
With the tool assembly 40 prepared and positioned as described above, the user next strikes the end wall 191 of the gas release knob 190. The gas release knob 190 may be struck using a hammer 15 ( Figure 1 ), for example. The strike force may be directed generally along the axis S-S. By striking in this manner, the user forces the coupling 50 against the wedge 24, which in turn slides the coupling 50 rearward in the coupling nut 60 to close the gap 78 ( Figure 10 ). The ram 70 is also thereby driven back into the cartridge 30 and the breech 102 such that the firing pin 76 is thereby driven into contact with the primer 36 to ignite the primer 36. The primer 36 in turn ignites the main charge 32. The explosion of the main charge 32 is contained by the closed breech 102 so that the ram 70 is driven forwardly by the explosion and forces the wedge 24 into the sleeve 22, thereby forming the connection 5.
The fired cartridge 30 can be removed and the tool 40 reloaded with a fresh cartridge using the following procedure. Typically, following the firing of the cartridge 30, a pressurized gas from the exploded charge 32 will remain in the breech chamber 106. Immediately removing the breech cap sleeve 152 from the breech 102 may cause the gas to be released in a manner potentially harmful to the user, bystanders, or the tool itself. Thus, it is desirable to first pre-release the gas in a controlled fashion. To accomplish this, the gas release knob 190 is rotated in a direction H ( Figure 9 ) about the axis S-S to unscrew the gas release knob 190 from the pin guide housing 170 to the gas release position as shown in Figure 11 . In this manner, the piercer pin 184 is pulled rearwardly such that it is withdrawn from the end wall 34B of the cartridge 30. The pressurized gas trapped in the breech chamber 106 and the cartridge 30 is allowed to escape through the hole in the end wall 34B, the bore 182 in the pin guide 180, and the gas release passage 196 in the gas release knob 190.
The user then continues to rotate the gas release knob 190 in the direction H such that the stop screw 199 engages the tab 177 and causes the pin guide housing 170 to rotate in the direction H with the gas release knob 190. The rotation of the housing 170 causes the housing 170 to translate rearwardly along the axis S-S, thereby withdrawing the locking pin 179 from the locking pin recess 142, and placing the drive assembly 100 in the position shown in Figure 10 . According to some embodiments, the stop screw 199 will engage and begin rotating the housing 170 after the gas release knob 190 has been rotated less than 360 degrees.
The breech cap sleeve 152 is thereafter rotated relative to the breech 102 in a direction I ( Figure 9 ) about the axis S-S to align the tabs 167 with the axially extending channels 114A, 114B, as shown in Figure 9 .
The breech cap sleeve 152 is then slid (e.g., pulled) relative to the breech 102 in a direction J ( Figure 8 ) along the axis S-S with the axially extending channels 114A, 114B serving to guide the breech cap sleeve 152. The breech cap sleeve 152 is slid such that the tabs 167 engage the ejector sleeve 130 and force the ejector sleeve 130 rearwardly relative to the breech 102. In this manner, the cartridge 30 may be dislodged from the breech 102. The user may grasp and pull the ejector sleeve 130 using the ribs 146 to facilitate removal of the cartridge.
The breech cap assembly 150 is next pivoted about the axis P-P in a direction K ( Figure 8 ). In this manner, the breech cap assembly 150 is returned to the open position as shown in Figure 7 . The breech cap assembly 150 may be further lifted to the supported position of Figure 6 . The spent cartridge 30 is now partially exposed and dislodged and can be easily removed and discarded. After the cartridge 30 has been removed, a new cartridge can be inserted into the drive assembly 100 and the tool 45 again prepared and fired in the manner described above.
The tool assembly 40 according to the present invention may provide a number of advantages. Because the drive assembly 100 is one integral or interconnected unit, it can be conveniently loaded and unloaded. In particular, it is not necessary to remove the breech cap assembly 150 or any portion thereof to access the breech chamber 102. Nonetheless, when the breech cap assembly 152 is in the open position, the breech opening 108B can be fully exposed to allow easy and effective insertion or removal of the cartridge. The drive assembly 100 may provide an effective, durable and reliable mechanism for safely releasing pressurized gas from the breech chamber 106 prior to opening the breech cap assembly 150. Moreover, according to some embodiments including those illustrated in the figures, the drive assembly 100 requires that the gas release knob 190 be axially withdrawn relative to the breech 102 in order to withdraw the locking pin 179 before the breech cap sleeve 152 can be rotated relative to the breech 102. This required sequence ensures that the piercer pin 184 will first be withdrawn from the cartridge, thereby ensuring that any pressurized gas will be released before the breech cap sleeve 152 is removed from its interlock with the circumferentially extending channels 116A, 116B.
While the drive assembly 100 includes the rotatable housing 170 and the separately rotatable gas release knob 190, in accordance with other embodiments of the invention the housing and the gas release knob may be integrally formed or assembled. However, the separately rotatable housing and gas release knob of the drive assembly 100 may provide enhanced safety and convenience. For example, the drive assembly 100 allows for release of pressurized gas by retracting the gas release knob 190 while still maintaining the breech cap sleeve 152 and the cartridge 30 in a secure arrangement by means of the housing 170.
With reference to Figures 13-19 , a drive assembly 200 according to further embodiments of the present invention is shown therein. The drive assembly 200 can be used in place of the drive assembly 100, for example. Accordingly, the foregoing discussion of the use and operation of the drive assembly 100 in combination with the tool 45 and/or the anvil 80 to form the tool assembly 40 likewise applies to the drive assembly 200.
The drive assembly 200 includes a breech 202, an ejector sleeve 230 ( Figure 14 ), and breech cap assembly 250.
The breech 202 corresponds generally to the breech 102 except as follows. The end portion 220 of the breech 202 has opposed, upstanding flanges 206 adjacent the rear end 204B ( Figures 14 and 15 ).
The ejector sleeve 230 is mounted on the end portion 220 in generally the same manner as the ejector sleeve 130. Opposed crossbars 240 extend across the inner diameter of the ejector sleeve 230 and cooperate with the upstanding flanges 206 to slidably retain the ejector sleeve 230 on the end portion 220. A lock pin recess 242 is formed in the rear end of the ejector sleeve 230.
The breech cap assembly 250 includes a breech cap sleeve 252, a pin guide member 280, a retaining spring 281, a piercer pin 284, a gas release knob 290, and a lock pin assembly 287.
The breech cap sleeve 252 corresponds to the breech cap sleeve 152 except as follows. The breech cap sleeve 252 has an enlarged head portion 253A and an elongated grip portion 253B. The enlarged head portion 253A may provide additional strength and protection of the front portion of the breech 202. The elongated grip portion 253B may provide a longer and more ergonomic handle for the operator. The breech cap sleeve 252 is tubular and defines an axial passage 254. A lock pin guide slot 258 extends axially through the threads 256. A second axially extending lock pin guide slot 259 extends radially fully through the breech cap sleeve 252. A marker line 253C or other suitable indicia may be provided on the head portion 253A to assist in properly orienting the breech 202 with respect to the coupling nut 60.
The pin guide member 280 may be integrally or unitarily formed. The pin guide member 280 is mounted in the passage 254 such that outer threads 283 of the pin guide member 280 operatively engage the threads 256. An axial pin guide passage 282 extends through the pin guide member 280. A circumferential collar 280A ( Figure 15 ) extends axially rearwardly from the pin guide member 280. An integral tab 286 extends axially rearwardly from the pin guide member 280 and is radially spaced apart from the collar 280A.
The gas release knob 290 includes a flange 293, a pin bore 294, gas release passages 296, and external threads 297 generally corresponding to the flange 193, pin bore 194, gas release passages 196, and external threads 197 of the gas release knob 190. The front portion of the gas release knob 290 is mounted in the passage 254 such that the outer threads 297 of the gas release knob 290 operatively engage the threads 256. The piercer pin 284 is mounted in the pin bore 294 in the same manner as the piercer pin 194 in the gas release knob 190. The piercer pin 284 may be removably retained in the pin bore 294 by a set screw 294A. An integral collar 290A ( Figure 14 ) extends axially forwardly from the front end of the gas release knob 290 and is rotatably positioned between the collar 280A and the tab 286. An integral tab 299 extends radially outwardly from the collar 290A such that at least a portion of the tab 299 engages the tab 286 of the pin guide member 180 upon rotation of the knob 290. That is, the tab 299 and the tab 286, or respective portions thereof, are located at the same positions along the axis S-S and the same radial distance from the axis S-S.
The lock pin assembly 287 includes a lock pin 279 and a slide member 288. The slide member 288 is joined to the lock pin 279 by screws 289 that extend through the slot 259 and holes 288A into threaded holes 289A in the lock pin 279. A leaf spring 288B is interposed between the slide member 288 and the breech cap sleeve 252. The lock pin 279 is slidably mounted in the slot 258. The lock pin 279 may have an axial channel defined on its underside to provide clearance for the front portion of the gas release knob 290. An anti-bind washer 285 surrounds the gas release knob 290 between the front side of the flange 293 and the rear end of the lock pin 279.
The foregoing components may be formed of any suitable materials. According to some embodiments, all of the components are preferably formed of metal and, more preferably, steel of appropriate strength and hardness.
As noted above, the drive assembly 200 may be used in the same manner as the drive assembly 100 in a tool assembly such as the tool assembly 40 to form a connection 5. The use of the drive assembly 200 differs from that of the drive assembly 100 in the manner in which the cartridge 30 may be loaded and unloaded and pressurized gas may be released from the breech 202. Methods for releasing gas from and for loading and unloading a cartridge 30 in and from the drive assembly 200 will be described hereinafter. It will be appreciated from the description herein that the order of certain of the steps discussed below can be revised.
The drive assembly 200 may be placed in an open position as shown in Figure 16 and generally corresponding to the open position of the drive assembly 100 as shown in Figure 6 and, alternatively, a closed position as shown in Figure 17 and generally corresponding to the closed position of the drive assembly 100 as shown in Figure 12 .
Beginning with the drive assembly 200 in an open position corresponding to that shown in Figure 6 , the breech cap assembly 250 is located such that it does not cover the breech opening 208B. The pin guide member 280 and the gas release knob 290 are each unscrewed or backed out to respective open positions as shown in Figure 16 . Accordingly, the piercer pin 284 is retracted with respect to the pin guide member 280. In order to maintain the breech cap assembly 250 in the open position, an edge of the breech cap sleeve 252 may be inserted into a support recess to support the breech cap assembly 250 as discussed above for the drive assembly 100. The lock pin 279 is in an unlocked or retracted position.
With the drive assembly 200 in the open position, the cartridge 30 is inserted into the breech chamber 206 through the breech opening 208B. In doing so, the ram is inserted into the forward portion of the shell cavity in the manner described above. With the cartridge 30 in place, the breech cap assembly 250 is lifted and pivoted into a position corresponding to that shown in Figure 8 , wherein the breech cap assembly 250 is substantially coaxial with the breech 202.
The breech cap sleeve 252 is then pushed forward on the breech 202 along the slide axis S-S in a direction D. The tabs 267 slide within the axially extending channels 214A (opposing channel not shown in figures) to thereby guide the breech cap sleeve 252 with respect to the breech 202. The breech cap sleeve 252 is slid onto the breech 202 until the breech cap assembly 250 reaches the position corresponding to that as shown in Figure 9 . This movement will serve to push the cartridge 30 fully into the breech chamber 206 as discussed above with regard to the drive assembly 100.
The breech cap sleeve 252 is then rotated relative to the breech 202 about the slide axis S-S in a rotational direction corresponding to the rotational direction E ( Figure 9 ). The tabs 267 slide within the circumferentially extending channels 216A (opposing channel not shown in figures) to thereby guide the breech cap sleeve 252 with respect to the breech 202. The breech cap sleeve 252 is rotated in this manner on the breech 202 until the breech cap sleeve 252 reaches the position as shown in Figure 13 . In this position, the tabs 267 and the circumferentially extending channels cooperate to prevent relative movement between the breech cap sleeve 252 and the breech 202 along the axis S-S.
The gas release knob 290 is then rotated relative to the breech 202 and the breech cap sleeve 252 in a clockwise direction L about the axis S-S to screw the gas release knob 290 into the breech cap sleeve 252 and closer to the breech 202. As the gas release knob 290 is rotated, the tab 299 thereof engages the tab 286 of the pin guide member 280 so that the pin guide member 280 is thereafter also rotated clockwise (i.e., as a follower) into the breech cap sleeve 252 and closer to the breech 202. The gas release knob 290 and the pin guide member 280 continue to turn together until the forward end of the pin guide member 280 engages the ejector sleeve 230. In this manner, the pin guide member 280 and the gas release knob 290 are placed in a sealing position (as shown in Figure 17 ) whereby the breech 202 is sealed. Additionally, the piercer pin 284 is advanced through the passage 282 and into the breech 202 to pierce the end wall 34B and the cartridge 30.
When the gas release knob 290 is in the sealing position, the lock pin 279 will be in a locked position as shown in Figure 17 . More particularly, when the lock pin 279 is in the locked position, a forward portion of the lock pin 279 is disposed in the engagement recess 242. In this position, the lock pin 279 serves as a safety latch that prevents the breech cap sleeve 252 from being rotated relative to the breech 202 as discussed above with regard to the lock pin 179 of the drive assembly 100.
The lock pin 279 may be transitioned from the unlocked position of Figure 16 to the locked position of Figure 17 in two ways. While the gas release knob 290 and the breech cap sleeve 252 are positioned generally as shown in Figure 16 , the operator may slide the lock pin 279 forwardly in a direction M along a slide axis V-V into the locked position, and thereafter rotate the gas release knob 290 clockwise into the sealing position. If the operator fails to position the lock pin 279 in this manner, the gas release knob 290 will automatically push the lock pin 279 forward in the direction M into the locked position as the gas release knob 290 advances toward the breech cap sleeve 252. In either case, when the gas release knob 290 is in the sealing position of Figure 17 , the gas release knob 290 serves as a limiting member by abutting the rear end of the lock pin 279 so as to prevent the lock pin from being slid rearwardly into its unlocked position until the gas release knob 290 is retracted (i.e., rotated counterclockwise into a gas release position). That is, the gas release knob 290 must be moved to the gas release position before moving the lock pin 279 to the unlocked position. According to some embodiments and as shown, the slide axis V-V is substantially parallel to the rotation axis S-S.
The breech cap assembly 250 is now in the closed position as shown in Figure 17 . In this position, the breech cap assembly 250 effectively seals the rear breech opening 208B and the ram 70 substantially seals the front end opening 208A so that the tool 45 is now prepared for firing. The tool 45 may then be positioned and fired to form a connection as described above.
The fired cartridge 30 can be removed from the drive assembly 200 and the drive assembly 200 can be reloaded with a fresh cartridge using the following procedure. Typically, and as discussed above, following the firing of the cartridge 30, a pressurized gas from the exploded charge 32 will remain in the breech chamber 206. To pre-release the pressurized gas in a controlled fashion, the gas release knob 290 is rotated counterclockwise in a direction N about the axis S-S to unscrew the gas release knob 290 from the pin guide member 280 to the gas release position as shown in Figure 18 . In this manner, the piercer pin 284 is pulled rearwardly such that it is withdrawn from the end wall 34B of the cartridge 30. The pressurized gas trapped in the breech chamber 206 and the cartridge 30 is allowed to escape through the hole in the end wall 34B, the bore 282 in the pin guide member 280 (e.g., through the gap provided by the clearance between the piercer pin 284 and the wall of the bore 282), and the gas release passages 296 in the gas release knob 290.
The user then continues to rotate the gas release knob 290 counterclockwise such that the tab 299 engages the tab 286 and causes the pin guide member 280 to rotate counterclockwise as a follower with the gas release knob 290. The rotation of the pin guide member 280 causes the pin guide member 280 to translate rearwardly along the axis S-S, placing the drive assembly 200 in the position shown in Figure 19 . The amount of rotation of the gas release knob 290 required before the tab 299 will engage and begin rotating the pin guide member 280 may depend on the locations of the tabs, the thread type and size, etc.
Thereafter, the operator slides the lock pin 279 rearwardly along the axis V-V in a direction O from the locked position as shown in Figure 19 to the unlocked position as shown in Figure 16 using the slide member 288.
The breech cap sleeve 252 may thereafter be rotated, slid and pivoted to its open position in the manner described above with regard to the drive member 100. In doing so, the cartridge may be withdrawn or dislodged by the ejector sleeve 230 as discussed above.
It will be appreciated by those of skill in the art that the drive assembly 200 provides certain of the advantages as discussed above with regard to the drive assembly 100. In accordance with some embodiments and as shown, it is not possible for the operator to accidentally or deliberately move the lock pin 279 from the locked position to the unlocked position until after the gas release knob 290 has been placed in the gas release position. Rather, the gas is released automatically as the gas release knob 290 is transitioned from a position limiting or blocking the lock pin 299 to a position permitting the lock pin 279 to be unlocked. In this manner, the drive assembly 200 may prevent the operator from opening the breech cap sleeve 252 while the breech 202 is filled with potentially dangerous pressurized gas.
The drive assembly 200 may provide enhanced ease of use. For example, the independently operable lock pin 279 and the externally engageable slide member allow the operator to lock the breech 202 and the breech cap sleeve 252 against relative rotation before rotating the gas release knob 290 into the sealing position. This prevents unintended rotation or disengagement of the breech 202 and the breech cap sleeve 252 as the gas release knob 290 is being manipulated.
As will be appreciated by those of skill in the art upon reading the description herein, the drive assemblies 100, 200 and other drive assemblies in accordance with the present invention may be used with explosive charge-actuated tools of other designs.
While the lock pins 179, 279 are discussed above, it will be appreciated that lock members of other configurations may be used.
While the ejector sleeves 130, 230 are discussed above, it will be appreciated that ejector members of other configurations may be used.
While gas release and locking mechanisms of the present embodiments have been described herein in combination with tool members adapted to be opened and closed by sliding and pivoting, it will be appreciated that these and other mechanisms and features described herein may be used in explosive charge connector tools of other types and configurations.

Claims

A tool (45) for securing a connector (5) on a conductor (7,9) using an explosive charge (32), comprising:
a breech member (102, 202) having a breech chamber (106, 206) adapted to receive the explosive charge and a breech opening (108B, 208B) communicating with the breech chamber;

a breech cap sleeve (152, 252) movably mounted on the breech member and surrounding at least a portion of the breech member; and

a drive member (70) which is adapted to be forcibly moved by the tool in response to an explosion of the explosive charge in the breech chamber,

said breech cap sleeve (152, 252) being movable between a closed position, in which the breech opening (108B, 208B) is closed, and an open position in which the breech opening is open to allow loading and unloading of the explosive charge (32) into and from the breech chamber (106, 206), by rotating the breech cap sleeve relatively to the breech member about a slide axis (S-S), sliding it relatively to the breech member along the slide axis and then pivoting the breech cap sleeve relatively to the breech member about a pivot axis (P-P) transverse to the slide axis, characterised by;

a lock pin (179, 279) selectively movable between a locked position in which the lock pin prevents relative rotation between the breech cap sleeve (152, 252) and the breech member (102, 202), and an unlocked position in which the lock pin permits relative rotation between the breech cap sleeve and the breech member.
The tool of claim 1 including a guide projection (167,267) extending from the breech cap sleeve and an axially extending guide channel (114A, 214A) defined in the breech member, the axially extending guide channel and the guide projection being co-operatively configured to guide the breech cap sleeve as the breech cap sleeve is slid relative to the breech member along the slide axis to move the breech cap sleeve between the open and closed positions.
The tool of claim 2 including a circumferentially extending guide channel (116A, 216A) defined in the breech member and intersecting the axially extending guide channel (114A, 214A), the circumferentially extending guide channel and the guide projection being co-operatively configured to secure the breech cap sleeve in the closed position.
The tool of claim 1, 2 or 3 wherein a control member (170,290) is mounted on the breech cap sleeve, and the lock pin (179, 279) is movable between the locked and unlocked positions by rotating the control member relative to the breech cap sleeve.
The tool of any preceding claim include a lock pin guide slot (158, 258) defined in the breech cap sleeve, wherein the lock pin is slidably received in the lock pin guide slot.
The tool of claim 2 including an ejector sleeve (130, 230) adapted to engage a cartridge (30) containing the explosive charge, the ejector sleeve being mounted on the breech member such that, when the breech cap sleeve is slid relative to the breech member along the slide axis to move the breech cap sleeve to the open position, the guide projection displaces the ejector sleeve relative to the breech chamber.
The tool of any preceding claim including a gas release member (190, 290) coupled to the breech cap sleeve and rotatable relative to the breech cap sleeve between a sealing position and a gas release position.
The tool of any preceding claim wherein the breech member includes a holding structure (144) adapted to maintain the breech cap sleeve in the open position.
The tool of any preceding claim wherein the drive member is a ram (70).
The tool of claim 9 including an elongated coupling portion (50).
The tool of claim 10 wherein the tool is operable to explode an explosive charge in the breech chamber (106,206) by striking a portion of the tool such that the ram (70) is forcibly driven into the barrel passage (54) toward the explosive charge, whereupon the explosive charge drives the ram through the barrel passage away from the explosive charge.
The tool of any preceding claim including a tool head (80) mounted on the breech member and adapted to engage the connector.
The tool of any preceding claim including a cartridge (30) disposed in the breech chamber (106,206), the cartridge containing the explosive charge.
A method for using a tool (45) for securing a connector (5) on a conductor (7,9) using an explosive charge (32), the tool including a breech member (102, 202) having a breech chamber (106, 206) adapted to receive the explosive charge, a breech opening (108B, 208B) communicating with the breech chamber, a breech cap sleeve (152, 252) movably mounted on the breech member, and a drive member (70) forcibly movable by the tool in response to an explosion of the explosive charge in the breech chamber, comprising the steps of;
rotating the breech cap sleeve (152, 252) relatively to the breech member about a slide axis (S-S),
sliding the breech cap sleeve relatively to the breech member along the slide axis, and
pivoting the breech cap sleeve relatively to the breech member about a pivot axis (P-P) transverse to the slide axis, thereby moving the breech cap sleeve from a closed position, in which the breech opening (108B, 208B) is closed, to an open position in which the breech opening is open to allow loading and unloading of the explosive charge (32) into and from the breech chamber (106,206), characterised by;
moving a lock pin (179, 279) from a locked position, in which the lock pin prevents relative rotation between the breech cap sleeve (152, 252) and the breech member (102, 202), to an unlocked position in which the lock pin permits relative rotation between the breech cap sleeve and the breech member.
The method of claim 14 including rotating a control member (170,290) to move the lock pin from the locked position to the unlocked position.
The method of claim 14 or 15 wherein the step of moving the lock pin includes sliding the lock pin in a lock pin guide slot (158, 258) defined in the breech cap sleeve.
The method of claim 14, 15 or 16 wherein the step of sliding the breech cap sleeve relative to the breech member along the slide axis includes displacing an ejector sleeve (130,230) relative to the breech chamber (106, 206), the ejector sleeve being engageable with a cartridge (30) containing the explosive charge.
The method of claim 14, 15, 16 or 17 including the step of maintaining the breech cap sleeve in the open position using a holding structure (144) of the breech member.
The method of any preceding claim 14 to 18 including the step of inserting the explosive charge into the breech chamber through the breech opening while the breech cap sleeve is in the open position.
The method of claim 19 wherein the step of inserting the explosive charge into the breech chamber includes inserting a cartridge (30) containing the explosive cartridge into the breech chamber through the breech opening while the breech cap sleeve is in the open position.
The method of claim 20 including the steps of exploding the explosive charge in the breech chamber, and thereafter withdrawing the cartridge from the breech chamber through the breech opening.
The method of any preceding claim 14 to 21 including the steps of
a) moving a gas release member (190, 290) to release pressurized gas from the breech chamber; thereafter

b) rotating the breech cap sleeve relative to the breech member about the slide axis (S-S); thereafter

c) sliding the breech cap sleeve relative to the breech member along the slide axis; and thereafter

d) pivoting the breech cap sleeve relative to the breech member about the pivot axis (P-P).
The method of claim 22 including, prior to the step of rotating the breech cap sleeve relative to the breech member about the slide axis (S-S), moving the lock pin (179, 279) from a lock position, wherein the lock pin prevents relative rotation between the breech member and the breech cap sleeve, to an unlocked position, wherein the lock pin permits relative rotation between the breech member and the breech cap sleeve.
The method of claim 14 including, following the step of pivoting the breech cap sleeve, the steps of
a) inserting the explosive charge (32) into the breech chambers (106, 206) through the breech opening; thereafter

b) pivoting the breech cap sleeve relative to the breech member about the pivot axis (P-P); thereafter.

c) sliding the breech cap sleeve relative to the breech member along the slide axis (S-S); thereafter

d) rotating the breech cap sleeve relative to the breech member about the slide axis; and

e) moving a gas release member (190, 290) into a sealing position to restrict the release of pressurized gas from the breech chamber.
The method of any preceding claim 14 to 24 where in the drive member is a ram (70) and including the step of exploding the explosive charge (32) in the breech chamber by striking a portion of the tool such that the ram is forcibly driven into a barrel passage (54) of the tool toward the explosive charge, whereupon the explosive charge drives the ram through the barrel passage away from the explosive charge.
The method of any preceding claim 14 to 25 including the steps of mounting a tool head (80) on the breech member and adapted to engage the connector (5), and engaging the tool head with a connector.