NZ537149A - A cable terminal lug - Google Patents

Abstract

A cable terminal lug (100) has a barrel (101) defining a first tunnel (103) for receipt of a mains cable core strand (2). A palm (102) extends from the barrel and defines a generally flat first face (104). A mounting aperture (109) extends through the palm generally perpendicular to, and extending through, the first face. A first threaded aperture (110) extends through a wall of the barrel into the first tunnel. A first fastener (111) is threadingly received in the first threaded aperture. The first fastener has a leading end (111a) extendable into the first tunnel (103). A second tunnel (112) is provided for receipt of a first cable (12/14). A second threaded aperture (113) intersects the second tunnel. A second fastener (114) is threadingly received in the second threaded aperture. The second fastener has a leading end (114a) extendable into the second tunnel.

Description

537 1 9 PATENTS FORM 5 PATENTS ACT 1953 OurRef: 687135NZ Dated: 10 December 2004 COMPLETE SPECIFICATION A Cable Terminal Lug We, Cable Accessories (Australia) Pty. Ltd., an Australian company, ACN 002 184 616 of 26 Derby Street, Silverwater, New South Wales 2128, Australia, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: INTELLECTKAI ORnPCRfv~^jgg t - MAR 2005 iLLCEiVED [R:\LIBF] 14009.doc:gxt 1 A CABLE TERMINAL LUG Field of the Invention The present invention relates to cable terminal lugs, and particularly relates to cable terminal lugs for mains power cables.

Background of the Invention Underground mains power cables, utilised for residential power distribution, are buried within the ground and have their ends extending up through the ground surface where they are terminated in distribution units, from where service cables that distribute power to individual properties are joined. A typical arrangement within such a 10 distribution unit is depicted in Figure 1.

Each mains power cable 1 typically comprises four core strands 2 of aluminium wires that are each individually sheathed. The four sheathed core strands 2 are retained within a mains cable sheath 3.

To terminate the mains cable within the above-ground distribution unit 4, a 15 length of approximately 300 mm of the cable 1 is exposed above the ground surface 5, and each of the four core strands 2 are separated by removing the mains cable sheath 3 above the ground surface 5. Each of the four core strands 2 is then terminated by crimping the barrel 6 of a standard crimping-type cable terminal lug 7 onto the exposed wires at the end of each core strand 2. Heatshrink tubing (not depicted) is applied to the 20 terminal lug barrel 6 and adjacent portion of sheathed core strand 2. The four terminated core strands 2 are divided into two pairs, with each pair of terminated core strands 2 being joined by way of a bolt 8 and bus bar 9. The bolt 8 passes through the aperture in the palm 10 of one of the terminal lugs 7, through the corresponding aperture in the bus bar 9 and then through the aperture in the palm 10 of the second terminal lug 7, with a nut 25 completing the connection.

Service cables 12, which are routed to individual properties for distribution of power to those properties, are also terminated in the distribution unit. Again, these service cables 12 are terminated by crimping a crimping-type cable terminal lug 13 onto the exposed end of the cable 12. The terminated service cables 12 are connected to the 30 mains cable 1 by passing the bolt 8 securing a pair of mains cable core strands 2 together through the aperture provided in the service cable terminal lug 13. An earth cable 14 is similarly terminated by a crimping-type cable terminal lug and connected to the mains cable in the same manner as a service cable. Lighting power cables (not depicted), which [R:\LIB LL]687135nz.doc:gxt HliiunuwLWECTY OFFICE] 13 CSC 2004 ECEH/Fn provide power directly to street lighting, are also terminated by way of a crimping-type cable terminal lug and are connected to one of the core pair assemblies by way of the bolt 8. Each core pair assembly is then covered in heatshrink material.

The mains cable core strands 2 typically have a cross-sectional area of approximately 240mm2 (for aluminium wire core strands), whilst the service and earth cables are much smaller, typically having a cross-sectional area of approximately 50 mm2. The lighting cables are smaller again, with a cross-sectional area of approximately 10 mm2. Terminating these three varying sized cables requires a range of expensive crimping tools and associated dies. These crimping tools and dies, apart from being rather expensive, require frequent maintenance and are often poorly maintained, resulting in poor quality terminal connections. Lack of operator skill and care also compromises the quality of the terminal connections.

The process of crimping a cable terminal lug onto a cable, particularly a large mains cable core strand, can also be quite tedious. When a pair of mains cable core strands 2 are to be connected by way of a bus bar 9, the cable terminal lugs 7 also need to be closely aligned when secured to the cable core strand 2, as the short length of cable core strand 2 protruding from the ground surface 5 cannot be readily twisted into alignment. Even when the cable terminal lug 7 appears to be aligned prior to operation of the crimping tool, movement of the cable terminal lug 7 as the tool is applied often occurs, resulting in misaligned cable terminal lugs 7 which cannot be readily connected by way of a bus bar 9.

Object of the Invention It is the object of the present invention to overcome or substantially ameliorate at least one of the above disadvantages.

Summary of the Invention There is disclosed herein a cable terminal lug comprising: a barrel defining a first tunnel for receipt of a mains cable core strand; a palm extending from said barrel and defining a generally flat first face; a mounting aperture extending through said palm generally perpendicular to, and extending through, said first face; a first threaded aperture extending through a wall of said barrel into said first tunnel; [R:\LIBLL]687135nz.doc:gxt a first fastener threadingly received in said first threaded aperture, said first fastener having a leading end extendable into said first tunnel; a second tunnel for receipt of a first cable; a second threaded aperture intersecting said second tunnel; and a second fastener threadingly received in said second threaded aperture, said second fastener having a leading end extendable into said second tunnel.

Typically, said second tunnel is located in said palm and extends generally parallel to said first face, said second threaded aperture extending through a second face of said palm opposing said first face.

The second tunnel may be located between said mounting aperture and an end surface of said palm, said end surface extending between said first and second faces of said palm.

The cable terminal lug may further comprise: a third tunnel for receipt of a further cable; a third threaded aperture intersecting said third tunnel; and a third fastener threadingly received in said third threaded aperture, said third fastener having a leading end extendable into said third tunnel.

Typically, said third tunnel is located in said palm and extends generally parallel to said first flat face, said third threaded aperture extending through said second face of said palm.

The third tunnel may be located between said mounting aperture and said barrel. The cable terminal lug may further comprise a fourth tunnel for receipt of another cable, said fourth tunnel extending through said end surface of said palm and intersecting said second tunnel.

The second threaded aperture may intersect said fourth tunnel.

The cable terminal lug may further comprise: a fourth threaded aperture extending through said wall of said barrel into said first tunnel; and a fourth fastener threadingly received in said fourth threaded aperture, said fourth fastener having a leading end extendable into said first tunnel.

The cable terminal lug may further comprise: a fifth threaded aperture intersecting said second tunnel; and a fifth fastener threadingly received in said fifth threaded aperture, said fifth fastener having a leading end extendable into said second tunnel.

[R:\LIBLL]687135nz.doc:gxt INTELLECTUAL PROPERTY OFFICE OF N.Z. - 2 FEB 2005 —RECEIVED The cable terminal lug may further comprise: a sixth threaded aperture intersecting said third tunnel; and a sixth fastener threadingly received in said sixth threaded aperture, said sixth fastener having a leading end extendable into said third tunnel.

The first and fourth fasteners may be shear head bolts.

The second, third, fifth and sixth fasteners may be grub screws.

Each said fastener leading end may be convex.

The first tunnel may have a cross-sectional area of approximately 240 mm2. The second and third tunnels may each have a cross-sectional area of 10 approximately 50 mm .

Alternatively, the second and third tunnels may each have a cross-sectional area of 25 to 50 mm2.

The fourth tunnel may have a cross-sectional area of approximately 10 mm . There is further disclosed herein a method of forming a power distribution 15 connection comprising the steps of: inserting an end of a mains cable core strand into said first tunnel of a cable terminal lug as defined above; threading said first fastener into said first threaded aperture to thereby extend said first fastener leading end into said first tunnel into engagement with said mains cable 20 core strand; inserting an end of a first cable into said second, tunnel; and threading said second fastener into said second threaded aperture to thereby extend said second fastener leading end into said second tunnel into engagement with first cable.

The first cable may be a service cable, an earth cable or a cross-road cable.

The method may further comprise the steps of: inserting an end of a second cable into said third tunnel; and threading said third fastener into said third threaded aperture to thereby extend said third fastener leading end into said third tunnel into engagement with said second 30 cable.

The second cable may be a service cable or an earth cable.

The method may further comprise the steps of: inserting a lighting cable into said fourth tunnel prior to threading said first fastener into said first threaded fastener aperture, subsequent threading of said first [R:\LIB LL]687135nz.doc:gxt fastener into said first threaded aperture resulting in engagement of said first fastener leading end with both said first cable and said lighting cable.

The method may further comprise the steps of: inserting a further mains cable core strand into said first tunnel of a further cable terminal lug as defined above; threading said first fastener of said further cable terminal lug into said first threaded aperture of said further cable terminal lug to thereby extend said first fastener leading end of said further cable terminal lug into said first tunnel of said further cable terminal lug into engagement with said further mains cable core strand, positioning a bus bar between said palm of said cable terminal lug and said palm of said further cable terminal lug; extending a bolt through said mounting aperture of said cable terminal lug, an aperture provided in said bus bar and said mounting aperture of said further cable terminal lug; and threading a nut onto said bolt to thereby secure and engage said cable terminal lug, said bus bar and said further cable terminal lug.

Brief Description of the Drawings Preferred forms of the present invention will now be described by way of example with reference to the accompanying drawings, wherein: Figure 1 is a front elevation view of a power distribution connection according to the prior art.

Figure 2 is a perspective view of a cable terminal lug.

Figure 3 is an inverse plan view of the cable terminal lug of Figure 2.

Figure 4 is a side elevation view of the cable terminal lug of Figure 2.

Figure 5 is a front elevation view of a power distribution connection utilising the cable terminal lug of Figure 2 with a single mains cable core strand.

Figure 6 is a side elevation view of the power distribution connection of Figure .

Figure 7 is a front elevation view of a power distribution connection utilising the two cable terminal lugs of Figure 2 with two mains cable core strands.

Figure 8 is a side, elevation view of the power distribution connection of Figure 7.

[R:\LIBLL]687135nz.doc:gxt 6 Figure 9 is a front elevation view of a power distribution connection utilising four cable terminal lugs of Figure 2 with four mains cable core strands.

Figure 10 is a side elevation view of the power distribution connection of Figure 9.

Figure 11 is a front elevation view of a power distribution connection utilising an alternate cable terminal lug with a single mains cable core strand.

Figure 12 is a side elevation view of the power distribution connection of Figure 11.

Figure 13 is a front elevation view of a power distribution connection utilising 10 two cable terminal lugs with two mains cable core strands and a cover assembly.

Figure 14 is a side elevation view of the power distribution connection of Figure 13.

Figure 15 is a perspective view of the front portion of a cover assembly.

Detailed Description of the Preferred Embodiments Referring particularly to Figures 2 to 4, a cable terminal lug 100 has a barrel 101 and a palm 102 extending from the barrel 101. The barrel defines a first tunnel 103, best depicted in Figure 3, which is sized to receive a mains cable core strand 2. Here the tunnel 103 has a cross-sectional area, as viewed in the inverse plan view of Figure 3, of approximately 240 mm2 such that it can neatly receive a typical 240 mm2 cable core 20 strand 2. The tunnel 103 has a depth of the order of 60 mm, terminating in a blind end face immediately below the palm 102.

The palm 102 defines a generally flat first face 104 and a second face 105 opposing the first face 104. The second face 105 will also typically be generally flat. An end surface 106 extends between the first and second faces 104, 105 of the palms at the 25 end of the palm 102. First and second side walls 107, 108 extend between the first and second faces 104, 105 of the palm along respective sides thereof. A mounting aperture 109, here having a diameter of approximately 12 mm, extends through the palm 102 generally perpendicular to, and extending through, the first and second faces 104, 105. A first threaded aperture 110 extends through a wall of the barrel 101 into the 30 first tunnel 103. A first fastener 111 is threadingly received in the first threaded fastener aperture 110. Upon threading the first fastener 111 into the first threaded fastener aperture 110, the convex leading end 11 la of the first fastener 111 extends into the first tunnel 103 for engagement with a cable core strand 2 inserted into the first tunnel 103.

[R:\LIB LLJ687135nz.doc:gxt 7 The first fastener 111 may be a shear head bolt, designed such that the head of the bolt shears upon exceeding a pre-determined torque load, thereby preventing overtorquing of the shear head bolt. The first fastener 111 is provided with an alien key type drive socket 111b.

A second tunnel 112 is provided for receipt of a cable, typically either a service cable 12 or earth cable 14, and has a cross-sectional area of approximately 50 mm2. The second tunnel 112 may alternatively receive a cross-road cable that is used to supply mains power to a cable terminal lug in a power distribution unit on the opposing side of the road, thereby avoiding the need to run mains cables along both sides of the road. If 10 only service cables 12 or earth cables 14 are to be received in the second tunnel 112, the second tunnel may have a smaller cross-sectional area of approximately 25 mm2, given that service and earth cables are typically smaller than cross-road cables.

The second tunnel 112 is located in the palm 102 and extends generally parallel to the first face 104 between the first and second side walls 107, 108 of the palm 102. 15 The second tunnel 112 may open onto both the first and second side walls 107, 108, allowing the cable to be inserted from either side, or may have one blind end. Here the second tunnel 112 is located between the mounting aperture 109 and the palm end surface 106. A second threaded aperture 113 extends through the palm second face 105 and intersects the second tunnel 112. A second fastener 114 is threadingly received in the second threaded aperture 113. Threading the second fastener 114 into the second fastener aperture 113 extends the convex leading end 114a of the second fastener 114 into the second tunnel 112 for engagement with a cable 12, 14 inserted into the second tunnel 112. The second fastener 114 may be in the form of a grub screw/set screw, and is provided with an alien key type drive socket 1146.

A third tunnel 115 is provided for receipt of another cable, again typically either a service cable 12 or earth cable 14, and has a cross-sectional area of approximately 50 mm2. Again, the third tunnel 115 may receive a cross-road cable. If cross-road cables will not be received in the third tunnel 115, it may have a smaller cross-sectional area of ■j approximately 25mm . The third tunnel 115 is located in the palm 102 and extends 30 generally parallel to the first face 104 between the first and second side walls 107, 108 of the palm 102. The third tunnel 115 may open onto both the first and second side walls 107, 108, allowing the cable to be inserted from either side, or may have one blind end. Here the third tunnel 115 is located between the mounting aperture 109 and the barrel 101. A third threaded aperture 116 extends through the palm second face 105 and [R:\LIB LL]687135nz.doc:gxt 8 intersects the third tunnel 115. A third fastener 117 is threadingly received in the third threaded aperture 116. Threading the third fastener 117 into the third aperture 116 extends the convex leading end 117a of the third fastener 117 into the third tunnel 115 for engagement with a cable 12, 14 inserted into the third tunnel 115. The third fastener 117 5 is here identical to the second fastener 114, being a grub screw/set screw with an alien key type drive socket 117b.

To comply with local regulations, each of the first, second and third tunnels 103, 112 and 115 is provided with a further threaded aperture and fastener to ensure a more robust connection of any cables inserted into the tunnels, each cable being engaged by 10 two fasteners.

Accordingly, the cable terminal lug 100 includes a fourth threaded aperture 118 extending through the wall of the barrel 101 into the first tunnel 103. A fourth fastener 119, in the form of a shear head bolt identical to the first fastener 111, is threadingly received in the fourth threaded aperture 118. Threading of the fourth fastener 119 into the 15 fourth threaded fastener 119 extends the leading end 119a of the fourth fastener into the first tunnel 103 for engagement with a mains cable core strand 2 inserted into the first tunnel 103. The fourth threaded aperture 118 and fourth fastener 119 are radially and axially offset from the third threaded aperture 110.

A fifth threaded aperture 120 extends through the palm second face 105 and 20 intersects the second tunnel 112. A fifth fastener 121, identical to the second fastener 114, is threadingly received in the fifth threaded aperture 120. Threading the fifth fastener 121 into the fifth threaded 112 aperture 120 extends the convex leading end 121a of the fifth fastener into the second tunnel for engagement with a cable 12, 14 inserted into the second tunnel 112.

A sixth threaded aperture 122 extends through the palm second face 105 and intersects the second tunnel 115. A sixth fastener 123, identical to the third fastener 117, is threadingly received in the sixth threaded aperture 122. Threading the sixth fastener 123 into the sixth threaded aperture 122 extends the convex leading end 123a of the sixth fastener 123 into the third tunnel 115 for engagement with a cable 12,14 inserted into the 30 third tunnel 115.

The cable terminal lug 100 may be provided with a fourth tunnel 124 extending through the end surface 106 of the palm 102 and intersecting the second tunnel 112. The fourth tunnel here has a cross-sectional area of approximately 10 mm2, specifically for receipt of a small lighting cable 15. The fourth tunnel 124 is positioned such that it [R:\L1B LL]687135nz.doc:gxt 9 intersects with the second threaded aperture 113. Threading of the second fastener 114 into the second threaded aperture 113 extends the leading end 114a of the second fastener 114 into both the second tunnel 112 and the fourth tunnel 124, enabling engagement with cables inserted into both tunnels.

Each of the fasteners 111, 114, 117, 119, 121, 123 is formed of tin plated brass.

The barrel 101 and palm 102 are integrally machined from conductive aluminium. Referring to Figures 5 and 6, a power distribution connection involving a single mains cable core strand 2 is achieved by inserting the end of the mains cable core strand (after having stripped any sheathing from the end portion) into the first tunnel 103 of a cable 10 terminal lug 100. The cable terminal lug is 100 is rotated for any required alignment. The first and fourth fasteners 111, 119 are then threaded into their respective threaded apertures 110, 118 so as to engage the mains cable core strand 2 with the fastener leading ends 111a, 119a. The first and fourth fasteners 111, 119 are threaded into their apertures by way of an alien key engaging the drive sockets 111b, 119b. Engagement of the 15 convex leading ends 111a, 119a of the first and fourth fasteners with the mains cable core strand 2 provides a secure mechanical and electrical connection between the mains cable core strand 2 and the cable terminal lug 100. Whilst the first tunnel 103 is designed to terminate a 240 mm2 mains cable core strand 2, the connection is range-taking in that cable core strands with a cross-sectional area down to approximately 185 mm2 can still be 20 securely terminated in the first tunnel 103.

The stripped end of a service cable 12 is then inserted into the second tunnel 112 of the cable terminal lug 100. The second and fifth fasteners 114, 121 are then threaded into their respective threaded apertures 113, 120 so as to engage the service cable 12 with the fastener leading ends, 114a, 121a. Engagement of the convex leading ends 114a, 25 121a of the second and fifth fasteners with the service cable 12 provides a secure mechanical and electrical connection between the service cable 12 and the cable terminal lug 100.

The stripped end of an earth cable 14 is then inserted into the third tunnel 115 of the cable terminal lug 100. The third and sixth fasteners 117, 123 are then threaded into 30 their respective threaded apertures 116, 122 so as to engage the earth cable 14 with the fastener leading ends 117a, 123a. Engagement of the convex leading ends 117a, 123a of the third and sixth fasteners with the earth cable 14 provides a secure mechanical and electrical connection between the earth cable 14 and the cable terminal lug 100.

[R:\LIBLL]687135nz.doc:gxt Alternative to the above, the earth cable 14 could be inserted into the second tunnel 112 with the service cable 12 being inserted into the third tunnel 115.

Whilst the second and third tunnel 112, 115 are designed to terminate service, earth or cross-road cables up to 50 mm2 (for tunnels having a cross-sectional area of 5 50 mm2), the connections are range-taking in that cables with a cross-sectional area down to approximately 16 mm2 can still be securely terminated in the second and third tunnels 112, 115.

If required, a lighting power cable 15 may be terminated by inserting the stripped end of the lighting power cable 15 into the fourth tunnel 124 of the cable terminal lug 100 10 prior to threading the second fastener 114 into the second threaded aperture 131.

Subsequent threading of the second fastener 114 into the second threaded aperture 113 results in engagement of the second fastener leading end 114a with both the service cable 12 and the lighting power cable 15, securing both cables. Again the fourth tunnel 124 is range-taking, accepting cables between 4 mm2 and 10 mm2.

Referring to Figures 7 and 8, a power distribution connection utilising two mains cable core strands 2 is achieved by connecting both mains cable core strands 2 to a cable terminal lug 100 in the manner described above, with the cable terminal lugs 100 being aligned with the first face 104 of the palms 102 aligned parallel and facing each other. Service cables 12, an earth cable 14 and lighting power cables 15 may be terminated to 20 either of the cable terminal lugs 100 in the manner described above. The two cable terminal lugs 100 are connected by way of an aluminium bus bar 9 positioned between the palms 102 of the cable terminal lugs 100. A bolt 8 is extended through the mounting apertures 109 of the cable terminal lugs 100 and a corresponding aperture provided in the bus bar 9. A nut 11 is then threaded onto the free end of the bolt 8 to secure and engage 25 the cable terminal lugs 100 and the bus bar 9.

Referring to Figures 9 and 10, a power distribution connection involving four mains cable core strands 2 may similarly be achieved utilising four cable terminal lugs 100 and an elongate bus bar 9' having two apertures, each for receiving a bolt 8 passing through the mounting apertures 109 of aligned cable terminal lugs 100. 30 Referring to Figures 11 and 12, an alternate version of the cable terminal lug 100 is depicted which includes a fifth tunnel 125 arranged parallel to and directly above the third tunnel 115 so as to provide greater flexibility and capacity for creating cable connections. In this arrangement, the second tunnel 112 has a cross-sectional area of 50 mm2 specifically for accepting a cross-road cable 16, whilst the third and fifth tunnels [R:\LIBLL]687135nz.doc:gxt 11 115, 125 each have a cross-sectional area of 25 mm2 for receiving the smaller earth and service cables 14, 12. Cables are retained within the fifth tunnel 125 by way of threaded fasteners 126, 127 in the same manner as for the third tunnel 115.

To further simplify the process of forming a power distribution connection with cable terminal lugs 100 as described above, the power distribution connection may be mounted within a cover assembly so as to avoid the need to apply heat shrink tubing to the terminal lug barrel 101 and adjacent portion of mains cable core strand 2. The need for a heat gun for shrinking the heat shrink tubing is thus dispensed with. A power distribution connection formed of two mains power cables 1 terminated with cable terminal lugs 100, as per those of Figures 11 and 12, housed within a cover assembly 200 is depicted in Figures 13 and 14. The cover assembly 200 is formed of front and rear cover portions 201, 202. The cover assembly front and rear portions 201, 202 are mounted onto the assembled terminal lugs 100 from opposing sides. The cover assembly portions 201, 202 are then mutually fastened to each other by way of fasteners 203 extending through aligned apertures 204 provided on each corner of each of the cover assembly portions 201, 202. Each of the cover assembly portions 201, 202 is provided with two semi cylindrical openings at the base thereof which, when the two cover assembly portions 201, 202 are fastened together, define a cylindrical opening through which the mains power cables 1 extend. The cover assembly 200 is mounted on the power distribution connection once the mains power cables 1 have been terminated and the terminal lugs 100 interconnected, but prior to connecting various secondary cables such as surface cables 12, earth cables 14, lighting power cables 15 or cross-road cables 16 to the terminal lugs 100.

To enable such secondary cables to be connected to the terminal lugs 100, various apertures are provided in both the front and/or rear cover assembly portions 201, 202. As depicted in Figure 15, cross-road cable entry apertures 206 are provided toward the top of the face of the front cover assembly portion 201, aligned with the second tunnel 112 of each terminal lug 100, enabling a cross-road cable (or other type of cable as desired) to be passed through the cover assembly 200 and into the terminal lug second tunnel 112. For power distribution connections utilising the mains cables 1 and associated terminal lugs 100 only, the rear cover portion will typically have no cross-road cable entry apertures. Threaded fastener apertures 207 are provided on the side wall of each of the cover assembly portions 201, 202 toward the top thereof and aligned with the second and fifth threaded fastener apertures 113, 120 of the terminal lugs 100. An alien [R:\LIB LL]687135nz.doc:gxt 12 key can thus be passed through the apertures 207 in the cover assembly to drive the threaded fasteners 114, 121 into engagement with a cable located in the terminal lug second tunnel 112.

Further cable access apertures 208 are provided in the face of the front cover 5 assembly portion 201, and aligned with the third and sixth tunnels 115, 125 of the terminal lugs 100 enabling the service or earth cables 12, 14 to be passed through the cover assembly and into the third and sixth tunnels 115, 125. Again, for power distribution connections utilising two mains cables and two terminal lugs 100, no further cable access apertures are provided in the face or the rear cover assembly portion 202. to Further threaded fastener apertures 209 are provided in the side walls of the cover assembly portions 201, 202 to again allow access to the threaded fasteners 117, 123, 126 and 127 intersecting with the third and sixth tunnels 115, 125 so as to drive the fasteners into engagement with cables located in those tunnels.

Where three or four mains cables 1 and associated terminal lugs 100 are being 15 used to form a power distribution connection, alternate forms of the rear cover assembly portion having cable access apertures to suit the connection may be utilised.

[R:\LlBLL]687135nz.doc:gxt

Claims (22)

13 The claims defining the invention are as follows:

1. A cable terminal lug comprising: a barrel defining a first tunnel for receipt of a mains cable core strand; a palm extending from said barrel and defining a generally flat first face; a mounting aperture extending through said palm generally perpendicular to, and extending through, said first face; a first threaded aperture extending through a wall of said barrel into said first tunnel; a first fastener threadingly received in said first threaded aperture, said first fastener having a leading end extendable into said first tunnel; a second tunnel for receipt of a first cable; a second threaded aperture intersecting said second tunnel; and a second fastener threadingly received in said second threaded aperture, said second fastener having a leading end extendable into said second tunnel.

2. The cable terminal lug of claim 1 wherein said second tunnel is located in said palm and extends generally parallel to said first face, said second threaded aperture extending through a second face of said palm opposing said first face.

3. The cable terminal lug of either of claims 1 and 2 wherein said second tunnel is located between said mounting aperture and an end surface of said palm, said end surface extending between said first and second faces of said palm.

4. The cable terminal lug of any one of claims 1 to 3 wherein said cable terminal lug further comprises: a third tunnel for receipt of a further cable; a third threaded aperture intersecting said third tunnel; and a third fastener threadingly received in said third threaded aperture, said third fastener having a leading end extendable into said third tunnel.

5. The cable terminal lug of claim 4 wherein said third tunnel is located in said palm and extends generally parallel to said first flat face, said third threaded aperture extending through said second face of said palm.

6. The cable terminal lug of either of claims 4 and 5 wherein said third tunnel is located between said mounting aperture and said barrel.

7. The cable terminal lug of any one of claims 4 to 6 wherein said cable terminal lug further comprises a fourth tunnel for receipt of another cable, said fourth [R:\LIBLL]687135nz.doc:gxt r 14 tunnel extending through said end surface of said palm and intersecting said second tunnel.

8. The cable terminal lug of claim 7 wherein said second threaded aperture intersects said fourth tunnel. 5

9. The cable terminal lug of any one of claims 1 to 10 wherein said cable terminal lug further comprises: a fourth threaded aperture extending through said wall of said barrel into said first tunnel; and a fourth fastener threadingly received in said fourth threaded aperture, said fourth 10 fastener having a leading end extendable into said first tunnel.

10. The cable terminal lug of any one of claims 1 to 9 wherein said cable terminal lug further comprises: a fifth threaded aperture intersecting said second tunnel; and a fifth fastener threadingly received in said fifth threaded aperture, said fifth 15 fastener having a leading end extendable into said second tunnel.

11. The cable terminal lug of any one of claims 4 to 10 wherein said cable terminal lug further comprises: a sixth threaded aperture intersecting said third tunnel; and a sixth fastener threadingly received in said sixth threaded aperture, said sixth 20 fastener having a leading end extendable into said third tunnel.

12. The cable terminal lug of claim 9 wherein said first and fourth fasteners are shear head bolts.

13. The cable terminal lug of claim 4 wherein said second and third fasteners are grub screws. 25

14. The cable terminal lug of any one of claims 1 to 13 wherein each said fastener leading end is convex.

15. A method of forming a power distribution connection utilising a cable terminal lug as defined in any one of claims 1 to 14 comprising the steps of: inserting an end of a mains cable core strand into said first tunnel; 30 threading said first fastener into said first threaded aperture to thereby extend said first fastener leading end into said first tunnel into engagement with said mains cable core strand; inserting an end of a first cable into said second tunnel; and [R-.\L!BLL]687135nz.doc:gxt INTELLECTUAL PROPERTY 0FFICI OF N.Z. -2 FEB 2005 RECEIVED 15 threading said second fastener into said second threaded aperture to thereby extend said second fastener leading end into said second tunnel into engagement with first cable.

16. The method of claim 15 wherein said first cable is a service cable, earth cable or cross-road cable.

17. The method of either of claims 15 and 16 wherein said cable terminal lug is as defined in any one of claims 4 to 8 and said method further comprises the steps of: inserting an end of a second cable into said third tunnel; and threading said third fastener into said third threaded aperture to thereby extend said third fastener leading end into said third tunnel into engagement with said second cable.

18. The method of claim 17 wherein said second cable is a service cable or an earth cable.

19. The method of either of claims 17 and 18 wherein said cable terminal lug is as defined in either of claims 7 and 8 and said method further comprises the steps of: inserting a lighting cable into said fourth tunnel prior to threading said first fastener into said first threaded fastener aperture, subsequent threading of said first fastener into said first threaded aperture resulting in engagement of said first fastener leading end with both said first cable and said lighting cable.

20. The method of any one of claims 15 to 19 wherein said method further comprises the steps of: inserting a further mains cable core strand into said first tunnel of a further cable terminal lug as defined in any one of claims 1 to 14; threading said first fastener of said further cable terminal lug into said first threaded aperture of said further cable terminal lug to thereby extend said first fastener leading end of said further cable terminal lug into said first tunnel of said further cable terminal lug into engagement with said further mains cable core strand, positioning a bus bar between said palm of said cable terminal lug and said palm of said further cable terminal lug; extending a bolt through said mounting aperture of said cable terminal lug, an aperture provided in said bus bar and said mounting aperture of said further cable terminal lug; and [R:\LIBLL]687135nz.doc:gxt INTELLECTUAL PROPERTY OF N.Z. - 2 FEB 2005 R CP r i\/p 16 threading a nut onto said bolt to thereby secure and engage said cable terminal lug, said bus bar and said further cable terminal lug.

21. The method of claim 20 further comprising the step of mounting a cover assembly over said cable terminal lug and said further cable terminal lug.

22. A cable terminal lug substantially as hereinbefore described with reference to Figures 2 to 4 or Figures 11 and 12 of the accompanying drawings. Cable Accessories (Australia) Pty. Ltd. By the Attorneys for the Applicant SPRUSON & FERGUSON Per: [R:\LIB LL]687135nz.doc:gxt