KR20090108541A - Basic insulating plug and method of manufacture - Google Patents

Abstract

PURPOSE: A basic insulating plug and a manufacturing method thereof are provided to remove a process for forming an insulator made by epoxy materials having a long hardening time, thereby providing an effective manufacturing process. CONSTITUTION: A basic insulating plug and a manufacturing method thereof include the first conductive insert(14) and the second conductive insert(16). An insulating coupling separates and supports the first and second conductive inserts. An insulator is formed about the first and second conductive inserts. A flow passage of an insulating material is formed so that a basic insulating plug(10) surrounds the first and second conductive inserts. Flow of the insulating material enters one of the conductive inserts through coupling.

Description

BASIC INSULATING PLUG AND METHOD OF MANUFACTURE}

This application claims the priority of U.S. Provisional Patent Application 61 / 044,076, filed April 11, 2008, which is incorporated herein by reference.

The present invention generally relates to a basic insulating plug (BIP) for connecting to a deadbreak connector. More specifically, the present invention relates to a method of manufacturing the basic insulating plug.

The connection in an underground power distribution system, such as between a cable and a transformer, is generally achieved by a specially designed detachable male and female electrical connector. One type of such connector is a cable terminated at the main portion of the T-shape and a generally T-shaped deadbreak connector having a connection capability to one of the two branches of the T-shape.

Often, it is desirable to perform an auxiliary action on the connector and cable system without operating the system. This action includes active voltage sensing for predetermined control and instantaneous voltage surge arresting for lightning protection. In this state, an interface is provided to allow electrical access to the system. This interface is typically provided on opposite ones of the T-shaped branches.

In order to close the interface when the auxiliary action is not performed, a basic insulating plug (BIP) is used. The plug is a detachable connector component insertable into the interface of an existing deadbreak connector. The plug provides a dead-end terminating an access point that prevents direct access to the connector.

A typical plug of this type includes an insulative body having at one end an electrically conductive internal threaded insert for attaching to a screw stud at the interface of the deadbreak connector. The insulator also supports a top hex shaped insert that allows a plug to be connected at the deadbreak interface and torques to a specific value.

While these plugs function properly for their intended purpose, as long as the insulator is formed from an epoxy material that typically has a long curing time, manufacturing the plugs is time consuming, expensive, and limits manufacturing capability and multiple operations. Done.

It is desirable to provide a more efficient manufacturing process and so to provide a final plug structure.

The present invention provides a basic insulating plug for closing the electrical interface to the deadbreak connector. The plug includes a first conductive insert and a second conductive insert. An insulating coupling supports the insert in spaced relation. An insulator is molded around substantially the coupling and the first and second conductive inserts. One of the conductive insert and the insulating coupling may be formed of an insulating material such that the insulating material surrounds the coupling and substantially surrounds the first and second conductive inserts to form an elastomeric body around the coupling. A flow passage for allowing entry into one of the conductive inserts.

In a method feature of the invention, a method of forming a basic insulating plug is provided. The method includes providing a first conductive insert having a penetrating flow passage. In addition, a second conductive insert is provided. An annular coupling having a side wall and an opposing open end is provided, wherein the side wall comprises at least one opening therethrough. The first and second conductive inserts are attached to the open end of the coupling to establish a flow path from the first conductive insert through the coupling. An annular coupling is placed in the mold with the conductive insert attached thereto. An insulating material is injected into the first conductive insert through the flow passage to fill the mold against the coupling and the conductive insert.

As such, the present invention provides a more efficient manufacturing process and thus provides a final plug structure.

The present invention provides a basic insulated plug or BIP (hereinafter referred to as "plug") for use in combination with a deadbreak connector (not shown). 1 to 4, the plug 10 of the present invention is spaced apart from the insulator 12, the first conductive insert 14, the second conductive insert 16, and the insulator 12. An insulating coupling 18 supporting the inserts 14 and 16.

The insulator 12 is designed to insert into the interface at the deadbreak connector. As is well known in the art, the interface of the deadbreak connector may be used to perform auxiliary actions on the connectors and cables of the system without operating the system. Thus, the particular shape of the insulator 12 is designed to provide a sealing coupling with the interface of the deadbreak connector.

The insulator 12 has opposing ends 20 and 22 and a generally tapered elongate 24 designed to couple the deadbreak interface.

The insulator 12 is formed of an insulating material such as, for example, a molded elastomer, which is a quick-curing rubber-like material that provides manufacturing convenience, as described later. In many existing plugs, the insulator is formed from a solid block of epoxy with a long curing time. This generally increases the price of manufacturing the plug.

As further shown in FIGS. 5 and 6, a connecting subassembly 30 is supported in the insulator 12. The subassembly 30 has an insulating coupling 18 for supporting the first conductive insert 14, the second conductive insert 16, and the first and second conductive inserts 14 and 16 in a spaced apart relationship. It includes.

The first conductive insert 14 is generally of conventional construction having a hexagonal head 14a and an elongated hexagonal body 14b. In particular, as shown in FIG. 6, the conductive insert 14 is generally a hollow member with a passage 15 extending therethrough. The first conductive insert 14 also includes an opening 17 formed through its lower end 17a in flow communication with the passage 15. The first conductive insert 14 is formed of an electrically conductive high strength material such as copper or aluminum.

The second conductive insert 16, which may also be formed of a high strength conductive material such as copper or aluminum, includes an upper portion 16a and a lower portion 16b having a long opening 19 threaded therein. The screw opening 19 is of conventional construction, allowing the plug 10 to be threadedly attached to the interface of the deadbreak connector.

Coupling 18 supports the first and second conductive inserts 14 and 16 in spaced apart relationship in the subassembly 30. The coupling 18 is generally a tubular member comprising annular sidewalls 35 that form opposing open ends 32 and 34. The coupling 18 also forms an inner cavity 36 and generally defines a plurality of openings 38 through the side walls 35 therein. A coupling 18 formed of a suitable insulating material to electrically insulate the first and second conductive inserts 14 and 16 supports the inserts in spaced apart relation at the opposing open ends 32 and 34. . In addition, the coupling 18 allows the torque applied to the first conductive insert 14 to be transferred directly to the second conductive insert 16 in such a way that the first and second conductive inserts 14 and 16). In particular, as shown in FIG. 6, the insert and the device of the coupling form a space in the inner cavity 36 between the first and second conductive inserts 14 and 16.

The shape of the coupling 18 comprising the inner cavity 36 and the opening 38 together with the passage 15 and the opening 17 of the first conductive insert 14 is via a coupling 14. And through the opening 38 of the side wall 35 of the coupling 18 an outward flow passage. As will be described in more detail later, the flow passage allows the insulator 12 to be molded relative to the subassembly 30.

Next, the formation of the plug 10 of the present invention will be described with reference to FIG. The subassembly 30 comprising the coupling 18 and the first and second conductive inserts 14 and 16 shown in FIGS. 5 and 6 is a mold of a conventional injection molding machine (not shown). 50). The mold 50 includes a mold component that forms a mold cavity 51 having the shape and shape necessary to form the insulator 12 with respect to the subassembly 30. The mold component includes an upper mold component 52 and a lower mold component 53 and 55. The upper mold component 52 includes an injection port 54 in communication with the passageway of the first conductive insert 14. The injection port 54 is used to inject the insulating material into the cavity 51 using a flow passage formed through the subassembly 30.

As shown by the arrows in FIG. 7, the insulating material may be sprayed through the port 54, outward through the passage 15 and through the opening 17 of the first conductive insert 14. Extend. The sprayed insulating material is then discharged through the opening 38 of the side wall 35 to fill the cavity 36 and to fill the mold cavity 51 forming the insulator 12. The insulating material used to form the insulator 12 can be a rapid curing rubber type elastomer, and the cycle time for forming the plug 10 is greatly reduced. This increases the efficiency of the manufacturing process and reduces the manufacturing cost of the plug.

While the present invention has been described in terms of preferred embodiments thereof, those skilled in the art can make them without departing from the spirit and scope of the invention as defined by the appended claims.

1 and 2 are a side view and a plan view of the basic insulating plug of the present invention.

3 and 4 are vertical cross-sectional views of the plugs of FIGS. 1 and 2 taken along lines 3-3 and 4-4 of FIG.

5 is a plan view of a subassembly of the insulative coupling of the conductive insert and plug of FIG.

FIG. 6 is a vertical sectional view of the subassembly of FIG. 5; FIG.

FIG. 7 shows in cross section the subassembly of FIG. 5 supported in a mold to form an insulator in the mold; FIG.

Claims (13)

Basic insulated plug (BIP) to close the electrical interface on the deadbreak connector, First conductive insert; Second conductive inserts; An insulating coupling supporting the first and second conductive inserts in a spaced apart relationship; An insulator formed substantially relative to the first and second conductive inserts; One of the conductive inserts and the insulating coupling allows a flow of insulating material to flow through the coupling and enter one of the conductive inserts so as to surround the coupling and substantially surround the first and second conductive inserts. Basic insulating plugs to form flow passages in order to. The method according to claim 1, And the first and second conductive inserts are elongate members having opposite ends for connecting the plugs to the electrical interface. The method according to claim 2, The insulating coupling has a first end for releasably receiving the first conductive insert, and a second end for receiving the second conductive insert, the annular body defining a cavity therebetween. Primary insulated plug. The method according to claim 3, And the insulating coupling comprises at least one opening to form the flow passage. The method according to claim 4, The one conductive insert has an opening in flow communication with the opening in the coupling to also form the flow passage. The method according to claim 1, And the insulating material is an elastomer. Basic insulated plug, A connecting subassembly; A body of insulating material molded relative to the connection subassembly, wherein the connection subassembly comprises: A first conductive insert having a passage therethrough; A second conductive insert; An insulated annular coupling having opposite open ends and sidewalls having at least one opening therethrough; The coupling supports the first and second conductive inserts in a spaced apart relationship at the opposite open end and permits a flow of the insulating material to form the body with respect to the subassembly of the first insulating insert. A basic insulating plug defining a flow passage from the passage and through the at least one opening in the side wall. The method according to claim 7, And the first conductive insert is a hollow member. The method according to claim 7, And the first and second conductive inserts are formed of a conductive material selected from the group consisting of copper, aluminum and combinations thereof. The method according to claim 7, The coupling is a basic insulating plug for supporting the first and second conductive insert electrically insulated. As a method of manufacturing a basic insulated plug, Providing a first conductive insert having a penetrating flow passage; Providing a second conductive insert; Providing an annular coupling having a sidewall, an opposing open end, and at least one opening through the sidewall; Attaching the first and second conductive inserts to the open ends of the coupling to establish a flow passage from the first conductive insert through the coupling; Positioning an annular coupling with the conductive insert in the mold; Spraying insulating material into and through the flow passage to fill the mold with respect to the coupling and the first conductive insert. The method according to claim 11, The spraying step comprises the step of spraying a rubber-type elastomer. The method according to claim 11, And the mold is an injection mold.

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