IE990191A1 - End cap for insulation piercing connectors - Google Patents

Abstract

An end cap assembly for covering the end of an insulated cable comprises a cap 8 to go over the end of the cable and a support member 10. The support member has a mounting portion 32 at one end which engages a flange 27 on the cap, a guide portion 34 at the other end for going round the cable and a bridging portion 38 joining these which goes around the insulation piercing connector 2.

Description

This invention relates to an end cap assembly for covering an end of a cable positioned in an insulation piercing connector.

Insulation piercing connectors for tapping power from one cable to another typically comprises a pair of insulated clamping housings with insulation piercing blades mounted therein, the housings having a first set of teeth on one side thereof interconnected with a second set of teeth on another side thereof, each side for connection to a cable. Piercing of an outer insulation layer of the cables is effected by bolting the connector clamping halves together. Such connectors are widely used and for example shown in European patent 0 007 706, or in US 5,015,198, or FR 2 634 070. In the latter two prior references, the clamping insulation piercing connector is provided on one side thereof with an end cap that can be filed with sealing gel and which is received over an end of a cable. In this application, the connector is used for tapping off power from a continuous main conductor to a branch conductor (that commences at the connector) . In order to prevent •Tigress of fluid into the conductor strands of the branch le, and also to prevent exposure of live bare ^cLnductors, it is typical to provide a cap over the end of 'ObLanch cables. Typically, as in FR 2 634 070, the end cap ί .ιέ fixed to the connector and the end of the cable is inserted into the connector until abutment against the end tap. Subsequently, the clamping halves are bolted together ^QEor the contacts to pierce through the cable outer , » •-ipsulation and connect with the inner conducting strands tkereof. By positioning the end cap securely on the .-plnnector prior to insertion of the cable into the end cap, an easy and secure means of assembling live cables to the connector is provided. f”' , —, A'TCL nOlblilbIE 990191 -2It would be desirable to provide a secure and easy means of connecting insulated cables to insulation piercing clamping connectors that is more versatile. In particular, it would be advantageous to enable clamping of cables with different configurations, without requiring a different connector for each configuration. For example, it would be advantageous to provide a secure and reliable insulation piercing clamping connector that enables two cable ends to be connected together, the cable ends protected from the environment and preventing exposure of live bare conductor ends .

Objects of this invention have been achieved by providing the end cap assembly for insulation piercing connectors according to claim 1. Disclosed herein is an end cap assembly for covering the end of an insulated cable receivable between jaws of an insulation piercing connector, the assembly comprising a cap insertable over the cable end, and a support comprising a cap mounting portion at one end thereof adapted to secure the cap to the support, and extending therefrom to a guide portion proximate another end thereof for locating and supporting the assembly on the cable. Bridging portions of the support interconnect the mounting and guide portions, the bridging portions adapted to allow mounting of the cable in a conventional insulation piercing clamping connector and enable insulation piercing of the cable by jaws of the connector, between the mounting and guide portions. Advantageously therefore, the end cap assembly can be preassembled to an end of a cable which can then be terminated to a conventional insulation piercing clamping connector. Pre-assembly of the end cap by means of the support ensures a stable and secure mounting of the cap to the cable, where exposed conductor ends are covered during the clamping operation, thereby enhancing operating safety. Further advantageously, the end cap assembly enables various -3configurations of through-cables and end-cables to be interconnected, for example two end-cables extending in the same direction, or in opposite directions. Further advantageously, the end cap assembly can implemented with clamping connectors that are not provided with end caps thereon .

The mounting and guide portions may be substantially in the form of rings for encircling the cable received therethrough, the rings preferably closed rings. It is also possible to provide open rings that encircle the cable by more than 180°. The bridge portion may comprise one, two or more relatively thin bars extending approximately in the direction of the cable between the guide and mounting portions. In an- embodiment where one or two bridging extensions are provided, the bridging extensions may be oriented in a plane substantially perpendicular to the direction of clamping of the connector, such that they do not interfere with clamping of the jaws and insulation piercing of the cable. The support may be formed of an integral part, for example of moulded plastic or other mouldable material, whereas the end cap may be formed from an elastomeric material. It is possible to provide the end cap assembly as a single part by bonding the end cap to the support, or otherwise attaching the end cap to the support, or alternatively by moulding the end cap and support together, for example by a two-shot moulding process.

Other advantageous aspects of the invention are set forth in the claims, or will apparent from the following description and drawings.

An embodiment of this invention will now be described by way of example with reference to the figures in which; figure 1 is a top view of an insulation piercing connector assembly interconnecting a main through-cable to an end-cable over which is mounted an end cap; -4figure 2 is a top view of an insulating piercing clamping connector interconnecting a pair of end-cables, one of which is provided with an end cap assembly according to this invention; figure 3 is a view in the direction of arrow 3 of figure 2; figure 4 is a view similar to figure 2 except that the cable ends are oriented in opposite directions; figure 5 is a perspective view of a support of the end cap assembly; figure 6 is a perspective view of an end-cable on which is pre-assembled the end cap assembly according to this invention; figure 7 is- a cross-sectional view through line 7-7 of figure 4.

Referring first to figure 1, a conventional insulation piercing contact (IPC) connector 2 interconnects a thoughcable 4 to an end-cable 6. The through-cable 4 may for example be a main cable, off which electrical power is tapped to a branch, tap, or distribution cable 6 (hereinafter end-cable). Both cables 4, 6 are comprised of inner conducting strands surrounded by an outer insulating layer. Over the end of the end-cable 6, is a cap 8 which may be filled but could also be left dry. The cap 8 is assembled to a cap mounting member 9 fixed to the connector housing 12. The connector 2 is provided with a pair of clamping halves, each comprising insulation piercing contacts for piercing through the cable outer insulation layers and contacting the inner conducting strands. Such connectors are well known in the art, and may for example be provided with clamping halves and contacts according to EP 0 007 706, FR 2 634 070, or US 5,015,198. The clamping halves are clamped together by means of a bolt 14 centrally positioned between cable receiving sides 5, 7 of the connector. As such insulation piercing connectors -sare well known in the art, the connector 2 will not be described in further detail.

In order to interconnect the end-cable 6 to the through-cable 4, the through-cable is positioned between the insulation piercing contacts of one side 5 of the connector, and the end cable 6 is inserted between the clamping halves of the other side 7 of the connector, until the severed end of the end cable abuts a smaller diameter shoulder 18, or end 20 of the end cap 8. The end cap 8 is provided with a succession of stepped (smaller diameter) sections 22, 23, 24, 25 for receiving end cables of different diameters in a snug fit. As the end cap 8 is securely located and held to the connector 2, the end cable 6 can be inserted into the connector and into the end cap with reduced risk of contact by an operator with the bare conductor strands at the severed end of the cable, which may be live or become live when the connector bolt 14 is tightened and the cables electrically interconnected.

Referring to figures 2-7, an embodiment of the invention will now be described. An end cap assembly 30 according to this invention comprises the end cap 8 and a support 10. The end cap assembly 30 is for assembly on an end-cable 6'. The cap 8 may made from a plastic or elastomeric material (for example by moulding) and comprise a cavity with successively reduced size portions extending from an open end 2 6 of the cap towards the closed end 20 thereof, for the reasons already described above. At the open end 2 6, the cap 8 is provided with an outwardly (radially) directed mounting flange 27 for reception either in the connector support 9 as best seen in figure 7, or for engaging a retention portion 32 of the end cap assembly support 10 as best seen in figure 6.

The end cap assembly support 10 further comprises a guiding portion 34 proximate an end 35 of the support remote from an opposite end 36 where the retention portion -632 is situated. Extending between the retention portion 32 and guide portion 34, is an elongate bridging portion 33, substantially in the form of an elongate beam. In the present embodiment, a pair of bridging extensions 38 extend substantially parallel on opposite sides of the support. The retention portion 32 is provided in the form of a closed ring having.a hole 40 for receiving the end-cable 6' therethrough, the size of the hole 40 adapted to receive the end cap 8 therethrough until abutment of the open end flange 27 against an inner side 42 of the retention portion 32, whereby the flange 27 is provided with a greater diameter then the hole 40 for abutment against the retention ring and securing of the end cap thereto. The guide portion 34- may also be provided in the form of a closed ring having a hole 44 with a size adapted to receive the end cable 6' therethrough. It is also possible to provide the retention and guide rings 32, 34 in the form of rings which are not closed, although the closed rings may be preferred for their higher rigidity.'The support 10 may be formed by moulding, for example from a plastic material, an integral part, whereby the end cap is assembled thereto. Alternatively the end cap could be either bonded or overmoulded to the retention portion 32 such that the end cap assembly is handled as a single inseparable part.

The bridging portions 38 are provided with a length sufficient to position the retention and guide portions 32, 34 sufficiently apart from each other for reception on either end 46, 47 of the connector 2, as best seen in figure 2. This enables the connector upper and lower insulation piercing teeth to pierce directly into the end cable 6' , free from hindrance from either the bridging extensions 38 or ring portions 32, 34. Furthermore, the guiding portion 34 prevents removal of the end cap assembly 30 from the cable, once the cable is clamped in the connector. -7By provision of the end cap assembly 30, two end cables 6, 6' can thus be interconnected in a safe and secure manner to a conventional insulation piercing connector 2, where the cables may be provided in the same orientation as shown in figure 2, or in opposite orientations as shown in figure 4. End cables can be interconnected in. a secure and safe manner even when employed with connectors that are not provided with an end cap. As shown in figure 6, the end cap assembly 30 may be pre-mounted to a cable end 6' prior to assembly in the connector, such that the safety of operating live cables is enhanced.

Claims (8)

1. -8CLAIMS

1. An end cap assembly (30) for covering the end of an insulated cable (6, 6') receivable between jaws of an insulation piercing clamping connector (2) , the assembly comprising a cap (8) insertable over the cable end, characterised in that the assembly further comprises a support (10) comprising a mounting portion (34) at one end thereof adapted to secure the cap to the support, and extending therefrom via a bridging portion (38), a guide portion (32) proximate another end thereof for locating and supporting the assembly (30) on the cable (6, 6').

2. The assembly of claim 1 wherein the bridging portion (38) comprises an elongate extension having a length sufficient to position the mounting and guiding portions (34, 32) on either end (46, 47) respectively of the insulation piercing connector (2).

3. The assembly of claim 1 or 2 wherein the guide portion (34) is substantially in the form of a ring having a hole (44) adapted to receive the cable (6, 6') therethrough.

4. The assembly of anyone of the preceding claims wherein the mounting portion (32) is substantially in the form of a ring having a hole (40) adapted to receive the end cap (8) therethrough.

5. The assembly of claim 4 wherein an inner side (42) of the mounting portion (32), facing the guiding portion (34), provides a retention surface for abutment of an outwardly extending flange (27) of the end cap thereagainst.

6. The assembly of anyone of the preceding claims wherein the bridging portion comprises a pair of elongate beams -9(38) extending approximately in the direction of the cable (6, 6') received in the assembly, and positioned substantially on opposite sides of the assembly. 5

7. A connector assembly comprising a pair of housings (11, 13) with insulation piercing contacts mounted therein, for clamping and .electrically interconnecting a pair of cables (4, 6, 6'), the connector comprising a bolt (14) for effecting the clamping together of the connector housings 10 (11, 13), characterised in that the assembly further comprises an end cap assembly (30) according to any one of the preceding claims.

8. An end cap assembly or a connector assembly 15 substantially as herein described with reference to and as shown in Figures 2 to 7 of the accompanying drawings.