ES2916207T3 - Cable connector assembly with releasable connectors - Google Patents

Abstract

Cable connector assembly (1) comprising two electrical cables (10) with multiple insulated electrical conductors (11, 12) and a connector assembly that forms a releasable splice between the ends of the electrical cables (10), in which the assembly cable connector (1) comprises two end connectors (20) at the meeting ends of the electrical cables (10) and an intermediate connector (60) between the end connectors (20), in which each of the connectors of end (20) comprises a first coupling (40) and an eyelet (50), in which the first coupling (40) comprises metal contacts (21, 22) that are attached to the electrical conductors (11, 12) of the cable (10) and the grommet (50) extends around the connected end of the cable (10), and in which the intermediate connector (60) comprises two second couplings with electrically conductive contacts (70, 71), in which a first coupling (40) and a second coupling together form a pair of interlocks where the contacts (21, 22; 70, 71) are electrically connected and sealed, wherein the first coupling (40) and the second coupling each comprise an insulating sleeve (42; 63) along and around each of their contacts (21, 22; 70, 71), in which the sleeves (42; 63) of the interconnection couplings slide tightly inside each other and enclose the contacts (21, 22; 70, 71), while the first couplings (40) prevent mutual interlocking, in which the end connectors (20) are aligned with the first couplings (40) towards the second couplings of the intermediate connector (60), characterized in that the cable connector assembly (1) comprises a housing (80) receiving the connectors (20), and in that the housing (80) surrounds at least the interlocking couplings, wherein the housing (80) comprises multiple housings (81, 82) that together surround the interlocking couplings, wherein each of the shells (81, 82) buy There is an outer slot (87) formed by one edge above the end connectors (20) to receive a metal or plastic sealing strip (88) that holds the housings (81, 82) firmly against each other.

Description

DESCRIPTION

Cable connector assembly with releasable connectors

Background

The invention relates to an arrangement for joining electrical cables, in particular electrical cables that are installed in the electrical signaling infrastructure of railway systems or tunnels. The cables have a usual conductive section between 16 mm2 and 400 mm2.

In these infrastructures, the splices between the cables are traditionally made on site. In this procedure, aluminum or copper conductors are assembled together by soldering, crimping, or by means of a screw connection, and are subsequently enclosed in a housing. Finally, the housing is filled with a hardening resin to provide insulation and prevent water ingress. Another solution is to enclose the connection in a heat shrink enclosure. When cables are reconfigured, the cables are cut and the splices are discarded.

The cables of an electrical signaling infrastructure are installed in public or easily accessible areas. Due to the copper conductors, the cables are vulnerable to theft. Therefore, cables increasingly comprise aluminum conductors instead of copper. Aluminum cannot be field welded as easily as copper and there are known corrosion problems if aluminum conductors are not properly prepared when used in a crimp or bolted connection. Therefore, there is a need for an alternative splice.

It should be noted that CN 101 841 113 A and GB 2343302 are known prior art.

An object of the present invention is to provide supplies for joining electrical cables, in which the splice is releasable and reusable.

An object of the present invention is to provide supplies for joining electrical cables with copper and/or aluminum conductors.

Summary of the invention

The invention provides a cable connector assembly according to claim 1, the cable connector assembly comprising two electrical cables with multiple insulated electrical conductors and a connector assembly that forms a releasable splice between the ends of the electrical cables, wherein the cable connector assembly comprises two end connectors at the meeting ends of the electrical cables, an intermediate connector between the end connectors, and a housing that receives the connectors, in which each of the end connectors comprises a first coupling and a grommet, in which the first coupling comprises metallic contacts that are attached to the electrical conductors of the cable and the grommet extends around the attached end of the cable, and in which the intermediate connector comprises two second couplings with electrically conductive contacts, wherein a first coupling and a second coupling together form a interlocking pair in which the contacts are electrically connected and sealed, while the first matings prevent interlocking, in which the end connectors are aligned with the first matings toward the middle connector second matings and the housing surrounds at least interlock couplings.

The assembly according to the invention comprises end connectors which can be factory installed on the ends of electrical cables. The first couplings and the second coupling seal the contacts, making it waterproof. This allows the use of aluminum conductors, reducing the risk of corrosion due to poorly prepared conductors as the connectors can be installed in a controlled factory environment. The end connectors do not fit together, but can only be interconnected via the intermediate connector, thus preventing installation errors. The end connectors mechanically engage the intermediate connector and are ultimately enclosed by the housing to form the splice. This splice can be released by releasing the housing and disconnecting one of the end connectors.

In the embodiment according to the invention, the first coupling and the second coupling each comprise an insulating sleeve along and around each of their contacts, in which the sleeves of the interconnecting couplings slide hermetically within each other. another and enclose the contacts. Intermeshing insulating sleeves prevent water ingress along the contacts, thus preventing electrical failure and contact corrosion.

In one embodiment, the first coupling and the second coupling comprise a key body or a corresponding receiving space for the key body on one side of their contacts. The corresponding key body and the receiving space ensure that the first coupling and the second coupling are locked in only one way with respect to the contacts. In this way it is possible to consistently continue the individual electrical conductors, so it is known whether it is a neutral conductor or a phase conductor, for example.

In a combined embodiment, the key body forms part of or adjoins the insulating sleeves.

In one embodiment, at least one of the first coupling and the second coupling comprises an insulating shield that extends apart from and around all of the sleeves to form an additional water barrier. In one embodiment thereof, the other of the first coupling and the second coupling comprises a flexible sealing lip that sealingly engages the protector along the circumference of the first coupling and the second coupling.

In one embodiment, the first coupling and the second coupling comprise a form-retaining flexible body in which their contacts are enclosed. The flexible bodies can provide a releasable snap fit between the engaging parts that remains releasable.

In one embodiment thereof, the flexible bodies are a mold of a thermoplastic polymer or copolymer, elastomer, or a thermoplastic elastomer.

Preferably, the flexible bodies are a mold comprising an elastomer, such as natural rubber or a thermoplastic elastomer, such as styrene-butadiene rubber (SBR) or ethylene propylene diene monomer (EPDM) rubber. These provide good insulation, durability, tightness, and resistance to vibration and shock to the connectors.

In one embodiment, the second matings of the intermediate connector are arranged back-to-back, wherein the contacts are continuous from one mating to the other. This intermediate connector forms a compact unit that is easy to handle.

In one embodiment, each of the contacts of the first coupling and the second coupling have one of a pin and a corresponding socket.

In one embodiment thereof, the plugs or sockets of the end connectors are electrically connected to the electrical conductors of the cables.

In one embodiment, the wire connector assembly comprises an electrically insulating end cap at the distal end of the plug, whereby the plug itself cannot be reached from the outside. This allows the handling and joining of electrical cables when they are already under tension or powered.

In one embodiment, the contacts of the first coupling comprise a crimp connector around the end of the attached electrical conductor. A crimp connector can be mechanically fastened to electrical conductors of any type of metal, such as copper and aluminum.

In one embodiment, the material of the crimp connector differs from the material of the plug or socket, making the contacts bimetallic. Materials for the crimp connector and plug or socket can be optimized for their specific function. Parts can be joined to form a unit by welding or melting.

In one embodiment, the pins or sockets are made of copper or an alloy comprising copper, such as brass.

In one embodiment, the pins or sockets are tin-plated or silver-plated copper or an alloy thereof, such as brass.

In one embodiment, the cables comprise aluminum electrical conductors, which makes them less vulnerable to theft.

In one embodiment, the crimp connector is primarily aluminum or an alloy comprising aluminum, eg, an aluminum-copper alloy.

In one embodiment, the crimp connector is primarily copper or an alloy comprising copper, such as brass.

In one embodiment, the end connectors and the intermediate connector have a cross-sectional circumference that is partially circular outside the outer contacts and flat therebetween. When there are more than two electrical conductors, the attached contacts may extend in the same plane.

In the embodiment according to the invention, the housing comprises multiple casings which together surround the interlocking coupling, wherein each of the casings comprises an outer groove formed by an edge above the end connectors for receiving a strip of metal or plastic seal that holds the shells firmly against each other. This housing can be easily assembled on site.

In one embodiment, each of the end connectors comprises a gripping groove on its outer side to provide sufficient grip to push the couplings into one another.

In one embodiment, the housing comprises an engaging portion with an edge that engages the grip groove to lock the interlocking couplings.

In one embodiment, the cable connector assembly comprises a tool that is configured to engage an end connector and move it toward the intermediate connector. The tool makes it easier to lock the couplings together and can provide more pushing force than is provided by hand.

In one embodiment, the tool comprises an engaging part with an edge that engages the gripping groove.

In one embodiment, the electrical cables comprise individual insulation around each electrical conductor.

In one embodiment, the electrical cables comprise individual insulation, where the insulations collectively define a circular outer circumference.

In one embodiment, the cables comprise a round sheath around the bundle of individually insulated electrical conductors.

In one embodiment, the electrical conductors are stranded conductors to provide enough flexibility to install the cables in small gutters.

In one embodiment, the electrical conductors have an individual conductor section between 16 mm2 and 400 mm2.

The various aspects and features described and shown in the specification can be applied, individually, whenever possible. These individual aspects, in particular the aspects and features described in the appended dependent claims, may be the subject of divisional patent applications.

Brief description of the drawings

The invention will be elucidated starting from an illustrative embodiment shown in the attached drawings, in which:

Figures 1A, 1B and 1C are an isometric view, a longitudinal section and a detail of a cable connector assembly according to a first embodiment of the invention, in a connected state;

Figures 2A and 2B are views of the cable connector assembly according to Figures 1A and 1B, before connecting;

Figures 3A and 3B are an isometric view of the cable connector assembly according to Figure 1A, together with a connection tool; Y

Figure 4 is an isometric view of a cable connector assembly according to a second embodiment of the invention, before connecting.

Detailed description of the invention

Figures 1A, 1B and 1C are an isometric view, a longitudinal section and a detail of a cable connector assembly 1 according to a first embodiment of the invention, in a connected state. Figures 2A and 2B show assembly 1 before connecting.

The cable connector assembly 1 is configured to form a series of joined electrical cables 10 having at least two electrical conductors 11, 12, usually made of aluminum or copper, each with a conductive section usually between 16 mm2 and 400 mm2. These electrical cables 10 are typically used in the signaling electrical infrastructure of railway systems, where a ground conductor is not necessary in the electrical cables 10. The conductors 11, 12 are individually enclosed by flexible plastic insulation 13, 14 with unique colors to identify conductors 11, 12, as the neutral and the phase, or two phases. In this embodiment, the insulators 13, 14 together define a circular outer side and are enclosed in a flexible sleeve 15. The sleeve 15 typically has an elastomer or silicone base. In this embodiment, the conductors 11, 12 have a semicircular cross section. Typically, the conductors 11, 12 are twisted to conductor cross-sections greater than 120 mm2 to provide sufficient flexibility for the cables 10. The flexibility is necessary to be able to configure the cables 10 in small gutters that run along and across railway tracks. . The electrical cables 10 may have an alternate cross-sectional geometry. The conductors can have any other section, such as circular. The insulated conductors can form a (twisted) bundle together or lie in the same plane.

The cable connector assembly 1 comprises two identical end connectors 20 at the ends of the electrical cables 10. The end connectors 20 are installed in a controlled factory environment rather than on site to ensure the quality of the final splice. Each end connector 20 comprises a grommet 50 and a socket 40 or a first coupling which forms a molded unit, or, as shown in Figure 2B, may be mechanically joined by means of a tongue-and-groove connection 52. The grommet 50 is provided of a grip groove 51 extending around the circumference for connecting a housing and a tool as described below. The socket 40 and grommet 50 are typically molded parts of a thermoplastic polymer or copolymer, elastomer, or a thermoplastic elastomer to provide a shape-retaining socket. have some flexibility. Suitable materials are usually natural rubber or a thermoplastic elastomer such as styrene-butadiene rubber (SBR) or ethylene propylene diene monomer (EPDM) rubber. These provide good insulation, durability, tightness, and vibration and shock resistance to end connectors 20.

The socket 40 comprises a base 41 and two parallel inner sleeves 42 and an outer shield 43 extending from the base 41. The sleeves 42 extend apart from each other. Shield 43 extends apart from the two sleeves 42 over the same intermediate distance to provide an insertion gap 44 having a constant width at the outer curved sections and on one side of the pair of sleeves 42 alone to form a key body 48. The free ends of the sleeves 42 and the protector 43 define a straight front face A. The sleeves 42 have an insertion opening 46 on the front face A and the protector 43 comprises a convex circumferential sealing groove 45 next to the front face. A.

Each of the first connectors 20 is provided with a bimetallic socket assembly 21, 22 or contact for each conductor 11, 12. Each of the socket assemblies 21, 22 comprises a cylindrical bearing 25 and a mounting base more wide 28 tinned or silver plated copper. In the cylindrical bearing 25 there is an insertion channel 26, in which an additional helical spring 27 can be enclosed for optimal electrical contact. The mounting base 28 is provided with a circumferential groove 29. The socket assemblies 21, 22 are sealed in the sleeves 42 to open behind the smaller insertion opening 46 of the sleeves 42. The enclosure is locked by a tab 47 of base 41 in slot 29, which tab 47 is formed when socket 40 is molded around socket assemblies 21, 22. Socket assemblies 21, 22 further comprise an aluminum gasket 30 which it has a crimp connector 31 which is crimped tightly around the aluminum conductors 21,22 while maintaining its usual semi-circular section. The aluminum splices 30 and the bare ends of the cables 10 are completely enclosed by the grommet 50.

The two end connectors 20 are in direction B only connectable to an intermediate connector 60, not to themselves. The intermediate connector 60 comprises a plug housing 61, which is a molded part of a thermoplastic polymer or copolymer, elastomer, or a thermoplastic elastomer to provide a shape retaining plug housing having some flexibility. Suitable materials are usually natural rubber or a thermoplastic elastomer such as styrene-butadiene rubber (SBR) or ethylene propylene diene monomer (EPDM) rubber. These provide good insulation, durability, tightness, and resistance to vibration and shock to the intermediate connector 60.

the plug housing 61 comprises a base 62 and two second couplings with, among others, two pairs of sleeves 63 extending parallel and opposite each other from the base 62. Only on one side of each pair of sleeves 63 is a key body 67 between the sleeves 63. The sleeves 63 are aligned with the sleeves 42 of the sockets 40 and receive and seal them under a slight local elastic deformation or impression. Plug housing 61 comprises two circumferential sealing ridges 64 defining insertion spaces 65 for shields 43 of sockets 40, wherein sealing ridges 64 engage sealing grooves 45 in a self-locking manner. As shown in Figure 1C, the plug housing 61 comprises two circumferential grooves 49 which extend opposite the sealing lips 64. A flexible O-ring, not shown, is locked in the grooves 49. Sealing ridges 64 and O-rings hermetically enclose inset protectors 43. Plug housing 61 further comprises a gripping groove 66 extending around the circumference for engaging a housing or tool as described below.

The intermediate connector 60 comprises two pin assemblies 70, 71, each comprising a mounting base 72 and two oppositely extending pins 73 which are all tin-plated or silver-plated brass or copper, and two end caps. of plastic 74. The free ends of the sleeves 63 and end caps 74 define a straight front face C on both sides that is free of tangible electrical parts. The mutual engagement of sleeves 42, 63 and guard engagement 43 ensures that socket assemblies 21, 22 and pin assemblies 70, 71 are hermetically sealed.

The end connectors 20 can only be connected to the intermediate connector 60 when the key bodies 48, 67 are opposite their corresponding receiving space of the opposite connector 20, 60. The key bodies 67 of the intermediate connector 60 itself are located symmetrically in mirror. In this way it is ensured that the same conductors 11, 12 are only continued in the correct way. A cable 10 with two end connectors 20 forms a prefabricated unit, which can be interconnected in series using intermediate connectors 60 in between. In said series, the only conductors 11, 12 remain distinguishable.

The cable connector assembly 1 comprises a housing 80 having two corresponding shells 81, 82 of a rigid material that can be metallic or plastic. Each of the shells 81, 82 comprises a central part 83 which receives the intermediate connector 60 and two end parts 85 which receive the majority of the end connectors 20. The shells 81, 82 are provided with inner edges 84, 86 which they engage with the gripping grooves 66, 51 of the intermediate connector 60 and the end connectors 20, respectively. The casings 81, 82 further comprise two outer slots 87 formed by edges above the end connectors 20 for receiving a strip of metal or plastic seal 88 that holds the shells 81, 82 firmly against each other.

Figure 3 schematically shows a connection tool 90 for connecting connectors 20, 60 to each other. The tool 90 comprises a first clamp 91 and a second clamp 92 which can be moved linearly relative to each other by means of guides 93 and a lever 94. The closing clamps 91 engage the intermediate connector 60 and an end connector 20 in the slots gripper 66, 51 after the intermediate connector 60 has been loosely placed in front of it, and press the connectors 20, 60 firmly against each other by turning the lever 94.

Figure 4 shows a connector assembly 101 according to a second embodiment of the invention. Features corresponding to the first embodiment are provided with corresponding reference numerals. Only additional features are described below.

The connector assembly 101 comprises an intermediate connector 160 which is further provided with a branch socket 110 or coupling having metal contacts which are electrically connected with the pin assemblies 70. The upper casing 81 has been provided with an opening for the branch socket 110. The branch socket 110 is configured to receive a branch connector 111 at the end of a branch cable 112.

It should be understood that the foregoing description is included to illustrate the operation of the preferred embodiments and is not intended to limit the scope of the invention. Numerous variations will become apparent to one skilled in the art from the foregoing discussion which would already be included within the scope of the present invention as defined by the appended claims.

Claims (13)

1. Cable connector assembly (1) comprising two electrical cables (10) with multiple insulated electrical conductors (11, 12) and a connector assembly that forms a releasable splice between the ends of the electrical cables (10), in which The cable connector assembly (1) comprises two end connectors (20) at the meeting ends of the electrical cables (10) and an intermediate connector (60) between the end connectors (20), in which each of the end connectors (20) comprises a first coupling (40) and an eyelet (50), in which the first coupling (40) comprises metal contacts (21,22) that are attached to the electrical conductors (11, 12) of the cable (10) and the grommet (50) extends around the connected end of the cable (10), and in which the intermediate connector (60) comprises two second couplings with electrically conductive contacts (70, 71), in which a first coupling (40) and a second coupling together form an interlocking pair tion in which the contacts (21,22; 70, 71) are electrically connected and sealed, wherein the first coupling (40) and the second coupling each comprise an insulating sleeve (42; 63) along and around each of their contacts (21, 22; 70, 71), in which the sleeves (42; 63) of the interconnection couplings slide tightly inside each other and enclose the contacts (21, 22; 70, 71), while the first couplings (40) prevent mutual interlocking, in which the end connectors (20) are aligned with the first couplings (40) towards the second couplings of the intermediate connector (60), characterized in that the cable connector assembly (1) comprises a housing (80) receiving the connectors (20), and in that the housing (80) surrounds at least the interlocking couplings, wherein the housing (80) comprises multiple housings (81, 82) that together surround the interlocking couplings, wherein each of the shells (81,82) buy an outer slot (87) formed by one edge above the end connectors (20) to receive a metal or plastic sealing strip (88) that holds the shells (81, 82) firmly against one another. Cable connector assembly (1) according to any one of the preceding claims, in which the first coupling (40) and the second coupling comprise a key body (48; 67) or a corresponding receiving space for the key body (48; 67) on one side of its contacts (21, 22; 70, 71). Cable connector assembly (1) according to claims 1 and 2, in which the key body (48; 67) forms part of the insulating sleeves or is adjacent to them (42; 63). Cable connector assembly (1) according to any one of the preceding claims, wherein at least one of the first coupling (40) and the second coupling comprises an insulating shield (43) that extends apart from and around the entirety of the sleeves (42; 63), wherein the other of the first coupling (40) and the second coupling preferably comprises a flexible sealing lip (64) that sealingly engages the protector (43) along the circumference of the first coupling (40) and the second coupling. 5. Cable connector assembly (1) according to any one of the preceding claims, wherein the first coupling (40) and the second coupling comprise a shape-retaining flexible body (61) in which their contacts are enclosed (21, 22; 70, 71). Cable connector assembly (1) according to claim 5, in which the flexible bodies (61) are a mold of a thermoplastic polymer or copolymer, elastomer or a thermoplastic elastomer. 7. Cable connector assembly (1) according to any one of the preceding claims, in which the second couplings of the intermediate connector (60) are placed side by side, in which the contacts (70, 71) are continuous from a coupling up to the other. 8. Cable connector assembly (1) according to any one of the preceding claims, in which each of the contacts (21, 22; 70, 71) of the first coupling and the second coupling have one of a pin and a corresponding female plug (25; 73), wherein the wire connector assembly (1) preferably comprises an electrically insulating end cap (74) at the distal end of the plug (73). Cable connector assembly (1) according to any one of the preceding claims, in which the contacts (21, 22) of the first coupling (20) comprise a crimp connector (31) around the end of the attached electrical conductor (21, 22). Cable connector assembly (1) according to claims 8 and 9, in which the material of the crimp connector (31) differs from the material of the plug or socket. 11. Cable connector assembly (1) according to any one of the preceding claims, in which each of the end connectors (20) and the intermediate connector (60) comprise a gripping groove (51; 66) in its outer side, wherein the housing (80) preferably comprises an engaging part with edges (84, 86) engaging with the gripping grooves (51; 66). 12. Cable connector assembly (1) according to any one of the preceding claims, in which the intermediate connector (60) comprises a third coupling (110) with metallic contacts that branches electrically from the contacts of the second couplings, wherein the housing (80) comprises preferably a lateral opening that is located between the second couplings, in which the third coupling is located in the opening or is accessible through it. 13. Cable connector assembly (1) according to any one of the preceding claims, in which the electrical conductors (11, 12) have an individual conductive section between 16 mm2 and 400 mm2.