WO2023155976A1

WO2023155976A1 - Tools, systems and methods for installing cable connectors

Info

Publication number: WO2023155976A1
Application number: PCT/EP2022/053691
Authority: WO
Inventors: Mahmoud Seraj; Manjunath GM; Daniel F. RIBEIRO; Curtis STIDHAM; Kathryn Marie Maher
Original assignee: Te Connectivity Solutions Gmbh
Priority date: 2022-02-15
Filing date: 2022-02-15
Publication date: 2023-08-24

Abstract

A method for installing an electrical connector on first and second electrical cables includes providing a connector installation tool including: a jaw system including opposed first and second jaws, the jaw system being configured to receive the electrical connector; and a clamping mechanism. The method further includes operating the clamping mechanism to clamp the first and second jaws onto at least one of the first and second electrical cables while the electrical connector is received in the jaw system; and thereafter clamping the electrical connector onto the first and second electrical cables while the electrical connector is received in the jaw system to thereby form an electrical connection between the first and second electrical cables.

Description

TOOLS, SYSTEMS AND METHODS FOR INSTALLING CABLE CONNECTORS

Field of the Invention

[0001] The present invention relates to connectors and methods for forming connections and, more particularly, to tools, systems and methods for connecting elongate electrical cables.

Background of the Invention

[0002] Electrical conductors often must be terminated or joined in various environments, such as underground or overhead. Such conductors may be, for example, high voltage electrical distribution or transmission lines. In order to form such connections, a connector may be employed. For example, in electrical power systems, it is occasionally necessary to tap into an electrical power line. One known system for tapping into an electrical power line is to use a tap connector for electrically connecting a main line electrical cable to an end of a tap line electrical conductor.

[0003] Insulation piercing (IPC) connectors are commonly used to form mechanical and electrical connections between insulated cables. Typically, an IPC connector includes metal piercing blades with sets of teeth on either end thereof. The piercing blades are mounted in housing members (e.g., along with environmental sealing components). The housing members are clamped about the insulated main and tap cables so that one set of teeth of a piercing blade engages the main cable and the other set of teeth of the piercing blade engages the tap cable. The teeth penetrate the insulation layers of the cables and make contact with the underlying conductors, thereby providing electrical continuity between the conductors through the piercing blade.

Summary of the Invention

[0004] According to some embodiments, a method for installing an electrical connector on first and second electrical cables includes providing a connector installation tool including: a jaw system including opposed first and second jaws, the jaw system being configured to receive the electrical connector; and a clamping mechanism. The method further includes operating the clamping mechanism to clamp the first and second jaws onto at least one of the first and second electrical cables while the electrical connector is received in the jaw system; and thereafter clamping the electrical connector onto the first and second electrical cables while the electrical connector is received in the jaw system to thereby form an electrical connection between the first and second electrical cables.

[0005] According to further embodiments, a connector installation tool for installing an electrical connector on first and second electrical cables includes a jaw system and a clamping mechanism. The jaw system includes opposed first and second jaws. The jaw system is configured to receive the electrical connector. The clamping mechanism is operable to clamp the first and second jaws onto at least one of the first and second electrical cables while the electrical connector is received by the jaw system.

[0006] According to further embodiments, a connection system for forming an electrical connection with first and second electrical cables includes an electrical connector and a connector installation tool. The connector installation tool includes a jaw system and a clamping mechanism. The jaw system includes opposed first and second jaws. The jaw system is configured to receive the electrical connector. The clamping mechanism is operable to clamp the first and second jaws onto at least one of the first and second electrical cables while the electrical connector is received by the jaw system

Brief Description of the Drawings

[0007] FIG. 1 is a top perspective view of a connection system according to some embodiments, with a main cable and a tap cable.

[0008] FIG. 2 is a connection pre-assembly formed using the main cable and the tap cable of FIG. 1 and an IPC connector forming a part of the connection system of FIG. 1.

[0009] FIG. 3 is a top perspective view of an IPC installation tool according to some embodiments and forming a part of the connection system of FIG. 1 clamped onto the connection pre-assembly of FIG. 2.

[0010] FIG. 4 is an enlarged, fragmentary, bottom perspective view of the IPC installation tool of FIG. 3 clamped onto the connection pre-assembly.

[0011] FIG. 5 is a front view of the IPC installation tool of FIG. 3 clamped onto the connection pre-assembly.

[0012] FIG. 6 is a cross-sectional view of the IPC installation tool of FIG. 3 clamped onto the connection pre-assembly, taken along the line 6-6 of FIG. 3. [0013] FIG. 7 is a side view of an electrical connection formed using the connection system of FIG. 1.

[0014] FIG. 8 is a top perspective view of an IPC connector forming a part of the connection system of FIG. 1 and a driver.

[0015] FIG. 9 is an exploded, top perspective view of the IPC connector of FIG. 8.

[0016] FIG. 10 is a cross-sectional view of the IPC connector of FIG. 8 taken along the line 10-10 of FIG. 8.

[0017] FIG. 11 is a side view of the IPC installation tool of FIG. 3 in an open position.

[0018] FIG. 12 is an enlarged, fragmentary, top perspective view of the IPC installation tool of FIG. 3 showing a lower jaw of the IPC installation tool.

[0019] FIG. 13 is an enlarged, fragmentary, bottom perspective view of the IPC installation tool of FIG. 3 showing an upper jaw of the IPC installation tool.

[0020] FIG. 14 is a fragmentary, perspective view of an IPC installation tool according to further embodiments.

Description of Embodiments of the Invention

[0021] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0022] It will be understood that when an element is referred to as being "coupled" or "connected" to another element, it can be directly coupled or connected to the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly coupled" or "directly connected" to another element, there are no intervening elements present. Like numbers refer to like elements throughout.

[0023] In addition, spatially relative terms, such as "under", "below", "lower", "over", "upper" and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "under" or "beneath" other elements or features would then be oriented "over" the other elements or features.

Thus, the exemplary term "under" can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0024] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein the expression "and/or" includes any and all combinations of one or more of the associated listed items.

[0025] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of this disclosure and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0026] As used herein, "monolithic" means an object that is a single, unitary piece formed or composed of a material without joints or seams.

[0027] With reference to the figures, a connection system 20 according to embodiments of the present invention may be used to form a cable electrical connection 22 (FIG. 7). The connection system 20 includes an insulation piercing connector 200 (which may be referred to herein as an IPC, IP connector, or IPC connector), and a connector installation tool 100. The connector 200 can be used to form the electrical connection 22 (FIG. 12) including a pair of elongate conductor cables 12, 14 (e.g., electrical power lines) mechanically and electrically coupled by the connector 200. Generally, and as described in more detail below, a driver 26 (FIG. 8) may be used to secure the connector 200 on the cables 12, 14. [0028] The connector 200 is a multi-cable insulation piercing connector. The connector 200 may be adapted for use as a splice or tap connector for connecting an elongate electrical tap or feed cable 14 to an elongate main cable 12 of a utility power distribution system, for example. The connected cables 12, 14 may be other combinations of cables such as spliced cables.

[0029] With reference to FIG. 7, the second cable 14 may be an electrically conductive metal high, medium or low voltage cable or line having a generally cylindrical form in an exemplary embodiment. The first cable 12 may also be a generally cylindrical high, medium or low voltage cable line. The cable 14 includes a metal electrical conductor 14A surrounded by an insulation layer 14B. The cable 12 includes a metal electrical conductor 12A surrounded by an insulation layer 12B. One or more of the conductors 12A, 14A may be formed of multiple strands (e.g., parallel or twisted strands) as illustrated in the figures, or may be solid cylindrical conductors (solid wire). Multi-strand conductors may be easier to handle with better bending characteristics. Suitable materials for the conductors 12A, 14A may include aluminum or copper. The insulation layers 12B, 14B may be formed of a polymeric material such as PVC, polypropylene, polyethylene, or cross-linked polyethylene. The conductor 14A and the conductor 12A may be of the same wire gauge or different wire gauge in different applications and the connector 200 is adapted to accommodate a range of wire gauges for the conductor 14A and the conductor 12A. In some embodiments, the conductor 12A has a larger cross-sectional diameter than the conductor 14A. The cable 12 has a lengthwise axis E-E and the cable 14 has a lengthwise axis F-F (FIG. 1).

[0030] When installed on the first cable 12 and the second cable 14, the connector 200 provides electrical connectivity between the conductor 12A and the conductor 14A. This connection may be used to feed electrical power from the main conductor 12A to the tap conductor 14A in, for example, an electrical utility power distribution system. Or the connection may be used to feed electrical power to the main conductor 12A from a feed conductor 14A in an electrical power generation system, for example. The power distribution or generation system may include two or more main cables of the same or different wire gauge, and two or more tap or feed cables of the same or different wire gauge.

[0031] With reference to FIGS. 8-10, the IPC connector 200 includes a connector body assembly 210, a first pair of piercing conductors or blade members 252 (hereinafter, the “lower blade members”), a second pair of piercing conductors or blade members 254 (hereinafter, the “upper blade members”), seal members 260, cable end caps 262, end cap retainers 264 and a clamping or compression mechanism 270. The connector 200 has a longitudinal axis G-G (FIG. 10). The end caps 262 and the end cap retainers 264 are removable and are not shown in FIGS. 1-7.

[0032] The connector body assembly 210 includes a first or upper body member 220, and a second or lower body member 230.

[0033] The upper body member 220 includes a support portion 222 and a pair of laterally opposed legs or jaw portions 224, 225 extending laterally from the support portion 222 with respect to the connector axis G-G. The support portion 222 includes a bore 222A. The jaw portion 224 includes a cable groove or seat 224A. The jaw portion 225 includes a cable groove or seat 225A. The jaw portion 224 further includes, in the cable seat 224A, a pair of blade slots or seats 224B. The jaw portion 225 further includes, in the cable seat 225A, a pair of blade slots or seats 226B.

[0034] The lower body member 230 includes a support portion 232 and a pair of laterally opposed legs or jaw portions 234, 235 extending laterally from the support portion 232 with respect to the connector axis G-G. The support portion 232 includes a bore 232A. The jaw portion 234 includes a cable groove or seat 234A. The jaw portion 235 includes a cable groove or seat 235A. The jaw portion 234 further includes, in the cable seat 234A, a pair of blade slots or seats 234B. The jaw portion 235 further includes, in the cable seat 235A, a pair of blade slots or seats 236B.

[0035] The jaw portion 224 and the jaw portion 234 define a first or main side cable receiving slot 211A therebetween. The jaw portion 225 and the jaw portion 235 define a second or tap side cable receiving slot 21 IB therebetween.

[0036] The body members 220, 230 may be formed of any suitable material. According to some embodiments, the body members 220, 230 are formed of a polymeric material. In some embodiments, the polymeric material is selected from the group consisting of polyamide (PA) 6.6, PA 6.6 reinforced with glass fibers or talc, polycarbonate, or polycarbonate blend. The body members 220, 230 may be formed using any suitable technique. According to some embodiments, the body members 220, 230 are molded. According to some embodiments, the each of the body members 220, 230 is monolithic and unitarily formed. [0037] The compression mechanism 270 includes a bolt 272, and a torque control member in the form of a nut 276. A washer 277 may be provided between the nut 276 and the upper body member 220. However, other types of compression mechanisms may be used for the compression mechanism 270. For example, the compression mechanism may include an inclined surface device operable to provide mechanical advantage, for example.

[0038] The bolt 272 may be a carriage bolt and includes a threaded shank 272A, and a head 272B.

[0039] In some embodiments and as shown, the nut 276 is a shear nut including a shear head 276 A, a base portion 276B, a shear or breakaway section 276C coupling the portions 276A and 276B, and a tubular, internally threaded connecting section 276D extending from the base portion 276B to the breakaway section 276C.

[0040] The bolt 272 extends through the bores 222A, 232A and is axially constrained by the bolt head 272B and the body member 230. The nut 276 is rotatably mounted on the bolt 272 and is axially constrained by the body member 220. The bores 222A, 232A may be round, or elongated, so that the upper connector body can rock as it is torqued down against two conductors with different outer diameters.

[0041] The axial spacing distance D4 (FIG. 10) between the cable seats 224A, 234A and 225A, 235A can be varied. The body member 220 can slide up and down the bolt 272 relative to the lower body member 230 another along a slide axis B-B. Accordingly, the heights of the slots 211 A, 21 IB can be independently varied.

[0042] In use, the shear head 276A of the nut 276 is engaged by a driver and forcibly rotated thereby. The shear head 276A may be faceted or otherwise shaped to mate with the tool. The nut 276 is thereby rotated relative to the axially and bolt 272, which may be rotationally constrained by a tool or an anti-rotation feature or mechanism of the connector 200. This causes the bolt 272 to translate up through the nut 276, which slides or translates the body portions 220 and 230 together (in respective converging directions) along the slide axis B-B. The shear head 276A will shear off from the base portion 276B at the breakaway section 276C when subjected to a prescribed torque. The base portion 276B may be faceted or otherwise configured to mate with a tool to enable loosening of the nut 276 to permit removal of the connector 200 from the cables. [0043] According to some embodiments, the bolt 272 and the nut 276 may be formed of any suitable materials, such as steel (e.g., galvanized steel or stainless steel), aluminum alloy, plastic or zinc alloy.

[0044] Each lower blade member 252 is mounted in one of the blade slots 236B for movement with the upper body member 230. Each lower blade member 252 includes a body or base 252A having laterally opposed ends. Each end is provided with an integral cable engagement or insulation piercing feature 252B. Each insulation piercing feature 252B includes a plurality of serrations or teeth 252C separated by slots and having terminal points. The points of the teeth 252C may collectively lie on an arc generally corresponding to the profile of the arcuate outer surface of the corresponding cable conductor 12A, 14A.

[0045] Each upper blade member 254 is mounted in one of the blade slots 226B for movement with the upper body member 220. Each main blade member 254 includes a body or base 254A having axially opposed ends. Each end is provided with an integral cable engagement or insulation piercing feature 254B. Each insulation piercing feature 254B includes a plurality of serrations or teeth 254C separated by slots and having terminal points. The points of the teeth 254C may collectively lie on an arc generally corresponding to the profile of the arcuate outer surface of the corresponding cable conductor 12A, 14A.

[0046] The blade members 252, 254 are affixed in their respective blade seats such that the teeth 254C of the blade members 254 face the teeth 252C of the blade members 252.

[0047] According to some embodiments, the width of each blade member 252, 254 is at least ten times its thickness. According to some embodiments, the thickness of each the blade member 252, 254 is in the range of from about 0.05 and 0.125 inch.

[0048] The blade members 252, 254 may be formed of any suitable electrically conductive material. According to some embodiments, the blade members 252, 254 are formed of metal. According to some embodiments, the blade members 252, 254 are formed of aluminum, aluminum alloy, or copper and may be galvanized. The blade members 252, 254 may be formed using any suitable technique. According to some embodiments, each blade members 252, 254 is monolithic and unitarily formed. According to some embodiments, each of the blade member 252, 254 is extruded and cut, stamped (e.g., die-cut), cast and/or machined.

[0049] The connector installation tool 100 has a proximal end 102A, an opposing distal end 102B, a longitudinal axis L-L (FIG. 11), a first lateral axis M-M (perpendicular to the axis L-L; FIG. 5), and a second lateral axis N-N (perpendicular to the axes L-L and M- M; FIG. 11). The tool 100 includes a clamping mechanism 110 and a jaw system 140. The jaw system 140 includes a first jaw 150 and a second jaw 170. The jaws are referred to herein as the lower jaw 150 and the upper jaw 170; however, it will be appreciated that the relative positions of the jaws 150, 170 may be reversed in use. As discussed in more detail below, the jaw system 140 defines a connector pocket, cradle, or seat 143 configured to receive and hold the IPC connector 200.

[0050] The clamping mechanism 110 can be operated to place the tool 100 in each of an open position (as shown in FIGS. 1 and 11) and a closed position (as shown in FIGS. 3-6). In the open position, the jaws 150, 170 are spaced apart from one another a first distance DI (FIG. 11), and in the closed, locked position, the jaws 150, 170 are spaced apart a second distance D2 (FIG. 5) that is less than the first distance DI. Closing the tool 100 relatively displaces one or both jaws 150, 170 toward the other along the axis N-N in directions CL-CL (FIG. 5). Opening the tool relatively displaces one or both of the jaws 150, 170 away from one another along the axis N-N in directions the opposite directions OP-OP. The jaws 150, 170 define a front opening 145 when in the open position.

[0051] In some embodiments, the clamping mechanism 110 is a locking clamp mechanism that can be operated to place the tool 100 in each of the open position (FIG. 11) and the closed position (FIG. 1) such that the tool 100 is locked in the closed position.

[0052] In some embodiments, the locking clamp mechanism 110 is an automatic locking clamp mechanism that locks the tool 100 in the closed position when handles (e.g., handles 114 and 118 as discussed below) are pushed toward one another a sufficient amount without requiring the operator to execute an additional locking step (e.g., engage a locking device).

[0053] In some embodiments, the locking clamp mechanism 110 is an over-center clamp mechanism. In some embodiments, the over-center clamp mechanism is configured as known for locking pliers. The illustrated locking clamp mechanism 110 may be configured and operate generally as disclosed in U.S. Patent No. 7,472,632 to Engvall et al., for example.

[0054] While the locking clamp mechanism 110 is shown and described herein, other configurations and types of locking clamp mechanisms may be employed instead, in accordance with embodiments of the technology. In some embodiments, the clamping mechanism is a non-locking clamp mechanism (c.g, such that the operator must hold the handles 114, 118 together to maintain the jaws 150, 170 in the closed position). In some embodiment, the clamping mechanism may be any suitable mechanism for applying a clamping load to the jaws, such as a single pivot pin pliers or scissors-type mechanism.

[0055] With reference to FIG. 6, the illustrated locking clamp mechanism 110 includes a first or upper arm 112, a second or lower arm 116, a movable jaw member 120, a link 122, a biasing spring 124, a release mechanism 130, and an adjustment mechanism 134. The adjustment mechanism 134 includes an adjustment screw 136. The release mechanism 130 includes a release lever 132.

[0056] The upper jaw 170 is secured to a distal end 112A of the upper arm 112. The lower jaw 150 is secured to a distal end 120A of the movable jaw member 120. The upper arm 112 has a first or upper handle 114 at its proximal end. The lower arm 116 includes a movable handle 118. The movable jaw member 120 is pivotably connected to the upper arm 112 by pivot pin Pl. The movable jaw member 120 is pivotably connected to the lower arm 116 by pivot pin P2. The link 122 is pivotably connected to the lower arm 116 by a pivot pin P3. The end of link 122 abuts the end of screw 136 such that as the screw 136 is translated in the upper arm 112, the end of link 122 is also translated in upper arm 112. The proximal end of the link 122 forms a fourth pivot point P4 with the distal end of the screw 136. The spring 124 applies a bias which tends to separate the handles 114 and 118 from one another and open the jaws 150 and 170.

[0057] In some embodiments, when the locking clamp mechanism 110 is in the open position (FIG. 11), the pivot points P1-P4 are arranged as a polygon. When the locking clamp mechanism 110 is in the closed, locked position as shown in FIG. 6, the pivots P2, P3 and P4 are substantially in a straight line where pin P3 is slightly over-center, toward upper arm 112, of a line between the pivots P2 and P4. The link 122 is prevented from moving closer to the upper handle 112 because the link 122 presses against the lower arm 116.

[0058] The lower jaw 150 extends forwardly from the distal end 120A of the movable jaw member 120. The lower jaw 150 may be integrally formed with the movable jaw member 120 or separately formed and rigidly affixed to the movable jaw member 120 (e.g., by welding or a fastener).

[0059] With reference to FIG. 12, the lower jaw 150 forms a first or lower cradle 152 to receive the connector 200 and the cables 12, 14. The lower jaw 150 includes laterally opposed front cable engagement features 166 and laterally opposed rear cable engagement features 168. The front cable engagement features 166 define channels 166A to receive the cable 12 along a channel axis Cl-Cl (FIG. 3). The rear cable engagement features 168 define channels 168A to receive the cable 14 along a channel axis C2-C2.

[0060] The lower jaw 150 also includes a lower connector seat 153. The lower connector seat 153 is defined by opposed side walls 158, an end or bottom support 160, a rear locator feature 162, and a front locator feature 164. The connector seat 153 includes a main slot 154 and a reduced lower slot 156.

[0061] With reference to FIG. 13, the upper jaw 170 extends forwardly from the distal end 112A of the upper arm 112. The upper jaw 170 may be integrally formed with the upper arm 112 or separately formed and rigidly affixed to the upper arm 112 (e.g., by welding or a fastener).

[0062] The upper jaw 170 forms a second or upper cradle 172 to receive the connector 200 and the cables 12, 14. The upper jaw 170 includes laterally opposed front cable engagement features 176 and laterally opposed rear cable engagement features 178. The front cable engagement features 176 define channels 176A to receive the cable 12 along a channel axis C3-C3 (FIG. 3). The rear cable engagement features 178 define channels 178A to receive the cable 14 along a channel axis C4-C4.

[0063] The upper jaw 170 includes an upper connector slot or seat 173. The upper jaw 170 also includes opposed upper connector locator tabs 175.

[0064] The tool 100 may be formed of any suitable material(s). In some embodiments the tool 100 is formed of metal and, in some embodiments, is formed of steel.

[0065] The connector installation system 20 can be used as follows in accordance with methods of the present invention to form the electrical connection 22. Generally, the connector 200 is mounted on the cables 12, 14 using the tool 100. Thereafter, the connection 22 is formed by installing the connector 200 on the cables 12, 14.

[0066] The connector 200 is set such that sufficient spacing is provided between the blade members 252, 254 to permit the cables 12 and 14 to be easily slid into the slot 211 A and the slot 21 IB, respectively (e.g., as shown in FIG. 10). If necessary, the compression mechanism 270 of the connector 200 is loosened or opened to permit the jaw portions 224, 234 and 225, 235 (and thereby the blade members 252, 254) to be separated.

[0067] The cable 12 (with the insulation layer 12B covering the conductor 12A) is inserted in or between the cable grooves 224A, 234A and the cable 14 (with the insulation layer 14B covering the conductor 14A) is inserted in or between the cable grooves 225A, 235A, as shown in FIG. 2. The cables 12, 14 can be axially or laterally inserted into the slots defined between the jaws. In other methods, only the cable 12 is installed in the connector 200 at this time, and the cable 14 is installed in the connector 200 after the connector 200 is mounted in the tool 100 as described below. This alternative procedure may be used when the connector 200 is being secured to a terminal end of the cable 14 rather than a pass-through section of the cable 14. The cable 12 (and the cable 14, if installed) and the connector 200 (not yet clamped onto the cable(s)) together form a connection pre-assembly 23 (FIG. 2).

[0068] If not already opened and sized as needed, the tool 100 is opened to the appropriate size to slide over and clamp onto the connection pre-assembly 23. The tool 100 is opened by pulling the handles 114, 118 apart. The screw 136 can be manually rotated to adjust the spacing D2 between the jaws 150, 170 in the closed position of the tool 100.

[0069] The tool 100, in its open position, is then slid onto the connection pre-assembly 23. The connector 200 is received through the front opening 145 and into the region between the lower jaw seat 153 and the upper jaw seat 173. The connector 200 may be inserted substantially fully into one or both of the upper and lower seats 153, 173. The cable 12 is aligned with the channels 166A, 176A. The cable 14 is aligned with the channels 168A, 178A. The cables 12, 14 may be inserted into the lower channels 166A, 168A or into the upper channels 176A, 178A.

[0070] During this step and the following steps, the front opening 145 and/or a rear opening 148A and side openings 148B (FIG. 3) defined between the jaws 150, 170 may assist the operator in viewing the connection pre-assembly 23 to ensure proper alignment between the connection pre-assembly 23 and the jaws 150, 170.

[0071] With the tool 100 positioned about the connection pre-assembly 23 as described, the tool 100 is then closed about the connection pre-assembly 23 by forcing the handles 114, 118 toward one another. As a result, the jaw seats 153, 173 of the jaws 150, 170 combine to form a connector seat 143 holding the connector 200, and the jaws 150, 170 clamp onto one or both of the cables 12, 14. The channels 166A, 176A combine to form a front cable slot 147A that receives the cable 12 (FIG. 4). The channels 168A, 178A combine to form a rear cable slot 147B that receives the cable 14. The cable slot 147A has a lengthwise axis Sl-Sl, and the cable slot 147B has a lengthwise axis S2-S2 (FIG. 3). [0072] Because the sizes and positions of the front cable locator features 166 are fixed relative to the sizes and positions of the rear cable locator features 176, the engagement between the jaws 150, 170 and the cables 12, 14 will depend on the relative outer diameter (OD) sizes of the cables 12 and 14. For some OD combinations of cables 12, 14, the jaws 150, 170 will clamp onto (i.e., apply a clamping load) the cable 12 and not the cable 14. For some OD combinations of cables 12, 14, the jaws 150, 170 will clamp onto the cable 14 and not the cable 12. For some OD combinations of cables 12, 14, the jaws 150, 170 will clamp onto both cables 12, 14. In some embodiments, the rear cable locator features 168, 178 will constrain movement of the cable 14 even though the jaws 150, 170 are not clamped onto the cable 14. Likewise, in some embodiments, the front cable locator features 166, 176 will constrain movement of the cable 12 even though the jaws 150, 170 are not clamped onto the cable 14.

[0073] In some embodiments, the connector seat 143 is sized and configured relative to the connector 200 such that the connector 200 is substantially immobilized along the side- to-side axis M-M and along the fore-aft axis L-L within the jaws 150, 170. Some play or tolerance may be permitted along the axes M-M and L-L (e.g., in the range of from about +/- 1 mm to +/- 2 mm). Movement of the connector 200 is also limited along the axis N-N by the bottom support 160 and the locator tabs 175, but one or both of the connector parts 220, 230 is able to slide relative to the jaws 150, 170.

[0074] In some embodiments, when one or both of the cables 12, 14 is/are clamped between the jaws 150, 170 and increasing force is applied to the handles 114 and 118, the forces generated on the linkage cause the link 122 to pivot and the linkage begins to straighten and the effective length of the linkage between pivots P2 and P4 increases. As the effective length of the linkage increases, increasing force must be applied to the handles 114 and 118 to move the linkage to the over-center locked position. This force is transmitted through the locking clamp mechanism 110 to the cable(s) 12, 14 to increase the clamping force generated by the jaws 150, 170 on the cable(s) 12, 14. Once the tool 100 is locked, the over-center condition of the pivots P2, P3 and P4 ensures that the jaws 150, 170 remain engaged with or about the cables 12, 14.

[0075] In some embodiments, the locking clamp mechanism 110 is configured and set such that, as the clamping mechanism 110 is closed, the mechanism passes through a point of tightest clamping and, as the clamping mechanism 110 is closed further into the final locked position, the jaws 150, 170 release slightly. The locking clamp mechanism 110 maintains a persistent spring load or bias on the cable(s) 12, 14 such that the handles 1114, 118 must be pulled apart by the operator to release the clamping pressure. Therefore, the jaws 150, 170 will remain clamped on or about the cable(s) 12, 14 without requiring the operator to hold the tool closed.

[0076] Advantageously, the tool 100 is configured to receive and hold the main cable 12 at the tool’s front end. In some instances, the main cable 12 will run alongside another main cable. This configuration of the tool 100 enables the operator to position the handles 114, 118 facing away from the other main cable. The cable 12 is received in and extends through the front cable slot 147A. The cable 14 is received in and extends through the rear cable slot 147B. The jaw system 140 maintains the cables 12, 14 in side-by-side, parallel relation.

[0077] With the tool 100 clamped about the connection pre-assembly 23, the connector 200 is then tightened or installed on the cables 12, 14. More particularly, the nut 276 is then driven to compress the compression mechanism 270 along the slide axis B-B and thereby drive the jaws 224, 234 and 225, 235 together along a clamping axis parallel to the slide axis B-B. The nut 276 is driven until a prescribed torque is applied. The shear nut 276 is driven via the shear head 276A until a prescribed torque is applied, whereupon the shear head 276A will break off at the shear section 276C, thereby helping to ensure that the proper load is applied to the blade members 252, 254, 256.

[0078] As a result, the insulation piercing features 252B, 254B of the opposed pairs of the blade members 252, 254 are driven to converge on and capture the cables 12, 14 therebetween. More particularly, the teeth 252C, 254C of each blade member 252, 254 are forced through the insulation layer 12B and into mechanical and electrical contact with the conductors 12A, 14A. The teeth 252C, 254C embed in the insulation layers 12B, 14B and make electrical and mechanical contact or engagement with the conductors 12A, 12B. In the foregoing manner, the connector 200 is operatively connected to the cables 12, 14 and the conductors 12A, 14A are electrically connected to one another without stripping the insulation layers 12B, 14B.

[0079] According to some embodiments, the teeth 252C, 254C embed in the conductors 12A, 14A. According to some embodiments, the teeth 252C, 254C embed into the conductors 12 A, 14A a distance of at least about 0.5 mm. [0080] In the foregoing manner, the connection 22 (FIG. 7) is formed. The blade members 252, 254 provide electrical continuity (i.e., a path for electrical current flow) between the conductors 12A, 14A of the cables 12, 14. The connector 200 mechanically secures the cables 12, 14 relative to one another.

[0081] Once the connection 22 has been formed, the tool 100 is removed from the connector 200 and the cables 12, 14. The operator opens the tool 100 and separates the jaws 150, 170 by applying a force to displace the handles 114, 118 away from one another. The release lever 132 can be operated to push the handles 114, 118 apart to unlock the locking clamp mechanism 110.

[0082] Once the connection 22 has been constructed as described above, an enclosure may be installed on the connection 22 and the cables 12, 14. For example, a sealant filled enclosure as disclosed in U.S. Published Patent Application No. 2020/0006869 to Newman may be installed about the connection.

[0083] The installation tool 100, system 20, and methods can provide several advantages are conventional tools and methods for installing electrical connectors and especially for installing IPC connectors. When the tool 100 is clamped on the cables 12, 14 with the connector 200 received in the jaw system 140, the tool 100 substantially fixes or limits the axial position of the connector 200 relative to the cables 12, 14 along the lengthwise cables axes E-E, F-F. The tool 100 also substantially fixes the positions of the connector 200 and the cables 12, 14 along the tool axis L-L so that proper spacing is maintained between the cables 12, 14, the axis E-E of the cable 12 is substantially aligned with the axis Sl-Sl of the front cable slot 147A, and the axis F-F of the cable 14 is substantially aligned with the axis S2-S2 of the rear cable slot 147B. The jaw system 140 may also constrain the connector 200 against tilting or rotating relative to the cables 12, 14. Thus, the installation tool 100 can hold the cables 12, 14 and the connector 200 in proper alignment for installation without requiring the operator to hold these components in place while of the connector 200 is being driven to form the connection.

[0084] The procedure for installing the connector on the cables 12, 14 using the tool 100 can be revised, depending on the configuration of the cables to be connected and/or the installer’s preference. In accordance with a second or modified procedure, the connector 200 is mounted in the jaw seats 153, 173 of the open tool 100. The tool 100 (with the connector 200 therein) may then be partially closed around the connector 200. The tool 100, with the connector 200 mounted therein, is then mounted on the cable 12 such that the cable 12 is received in the cable locator features 166. As a result, the cable 12 is received in the connector cable grooves 224A, 234A. The tool 100 may be held closed (e.g., by hand) on the cable 12 without fully actuating the locking clamp mechanism 110 into its locking position. With the connector 200, tool 100, and cable 12 in this position, the cable 14 is then inserted into the connector cable grooves 225A, 235A to form the connection pre-assembly 23. The tool 100 is then fully clamped and locked onto the connection pre-assembly 23 as described above. With the tool 100 clamped about the connection pre-assembly 23, the connector 200 is then tightened or installed on the cables 12, 14 to form the connection as described above.

[0085] In accordance with a further procedure, the cable 12 or the cable 14 is mounted in the connector 200 prior to mounting the connector 200 in the tool, and the other cable 14 or 12 is then mounted in the connector 200 while the connector 200 is mounted in the tool 100 but before lock clamping the tool 100 onto one or both of the cables 12, 14.

[0086] The cable channels 166A, 168A, 176A, 178A may have different shapes than shown in the figures. For example, in some embodiments one or more of the channels 166A, 168A, 176A, 178A have a V-shaped profile rather than a U-shaped profile.

[0087] The tool 100 may be sized and configured to accommodate a range of sizes of connectors 200 and cables 12, 14. In some embodiments, the tool 100 is configured to install the connector 200 on main cables 12 having a size in the range of from about 20 mm to 25 mm, and tap cables 14 having a size in the range of from about 6 mm to 9 mm.

[0088] With reference to FIG. 14 a tool 300 according to further embodiments is shown therein. The tool 300 is constructed and operated in the same manner as the tool 100, except as follows. The tool 300 may be particularly well-suited for installing an IPC connector 200 on a main cable 12 and a tap cable 14 having a relatively small outer diameter (e.g., less than 3 mm).

[0089] The tool 300 differs from the tool 100 in that the tool 300 does not include rear cable locator features corresponding to the rear cable locator features 168, 178 or upper front cable locator features 176. The jaws 350, 370 of the tool 300 instead have planar walls 354, 374 on their rear ends so that the view of and access to the rear jaw region is less obstructed.

[0090] In other embodiments, an installation tool and method as described herein may be used to install a different type of electrical connector in place of an IPC connector 200. Such other type of electrical connector may be an IPC connector of a different design or a non-insulation piercing connector. [0091] The tool 300 may be sized and configured to accommodate a range of sizes of connectors 200 and cables 12, 14. In some embodiments, the tool 300 is configured to install the connector 200 on main cables 12 having a size in the range of from about 3 mm to 5.5 mm, and tap cables 14 having a size in the range of from about 2 mm to 3 mm.

[0092] According to some embodiments, the connector installation tool (e.g., the tool 100 or the tool 300) and the connector (e.g., the IPC connector 200) are pre-configured or packaged as a matched kit. However, the connector installation tool and the connector need not be provided as a kit. For example, the connector installation tool may be provided independently as a tool to install connectors separately provided by the end user.

[0093] According to some embodiments, the cables 12, 14 are power transmission conductors. According to some embodiments, the cables 12, 14 are aerial power transmission conductors. According to some embodiments, the cable 12 is a main line electrical conductor cable and the cable 14 is a tap line electrical conductor cable.

[0094] The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the invention.

Claims

THAT WHICH IS CLAIMED IS:

1. A method for installing an electrical connector on first and second electrical cables, the method comprising: providing a connector installation tool including: a jaw system including opposed first and second jaws, the jaw system being configured to receive the electrical connector; and a clamping mechanism; operating the clamping mechanism to clamp the first and second jaws onto at least one of the first and second electrical cables while the electrical connector is received in the jaw system; and thereafter clamping the electrical connector onto the first and second electrical cables while the electrical connector is received in the jaw system to thereby form an electrical connection between the first and second electrical cables.

2. The method of Claim 1 wherein: the clamping mechanism includes a locking clamp mechanism; and operating the clamping mechanism to clamp the first and second jaws onto at least one of the first and second electrical cables includes operating the locking clamp mechanism to releasably lock the first and second jaws onto the at least one of the first and second electrical cables.

3. The method of Claim 1 including, after clamping the electrical connector onto the first and second electrical cables: operating the clamping mechanism to release the first and second jaws from the first and second electrical cables; and thereafter removing the connector installation tool from the electrical connection.

4. The method of Claim 1 including, prior to operating the clamping mechanism to clamp the first and second jaws onto at least one of the first and second electrical cables: mounting the first electrical cable in the electrical connector to form a connection pre-assembly; and mounting the connection pre-assembly in the jaw system.

5. The method of Claim 1 wherein, when the first and second jaws are clamped onto at least one of the first and second electrical cables, the first and second electrical cables extend side-by-side and substantially parallel to one another, and the electrical connector extends between the first and second electrical cables.

6. The method of Claim 1 wherein the electrical connector is an insulation piercing (IPC) connector.

7. The method of Claim 1 wherein: the IPC connector includes a compression mechanism; and clamping the electrical connector onto the first and second electrical cables includes operating the compression mechanism to clamp the electrical connector onto the first and second electrical cables while the electrical connector is received in the jaw system.

8. The method of Claim 1 wherein: the first jaw defines a jaw seat; and the method includes mounting the electrical connector in the jaw seat prior to operating the clamping mechanism to clamp the first and second jaws onto at least one of the first and second electrical cables.

9. The method of Claim 8 wherein: the second jaw defines a second jaw seat; and when the first and second jaws are clamped onto at least one of the first and second electrical cables, the first and second jaw seats together form a connector seat containing the electrical connector.

10. The method of Claim 8 wherein: at least one of the first and second jaws includes an integral cable engagement feature defining a channel; and clamping the first and second jaws onto at least one of the first and second electrical cables includes clamping the at least one of the first and second electrical cables with the cable engagement feature and in the channel.

11. The method of Claim 1 wherein the clamping mechanism includes first and second opposed handles operable to close and open the first and second jaws.

12. The method of Claim 1 wherein the jaw system is configured such that, when the first and second jaws are clamped onto at least one of the first and second electrical cables, the jaw system: prevents or limits movement of the electrical connector along a first lengthwise cable axis of the first electrical cable and along a second lengthwise cable axis of the second electrical cable; prevents or limits movement of the electrical connector along a tool axis perpendicular to the first and second lengthwise cable axes and extending through the first and second electrical cables; and permits movement of the electrical connector along a connector axis perpendicular to the first and second lengthwise cable axes and perpendicular to the tool axis to facilitate clamping of the electrical connector onto the first and second electrical cables to form the electrical connection.

13. A connector installation tool for installing an electrical connector on first and second electrical cables, the connector installation tool comprising: a jaw system including opposed first and second jaws, the jaw system being configured to receive the electrical connector; and a clamping mechanism operable to clamp the first and second jaws onto at least one of the first and second electrical cables while the electrical connector is received by the jaw system.

14. The connector installation tool of Claim 13 wherein: the clamping mechanism includes a locking clamp mechanism; and the locking clamp mechanism is operable to releasably lock the first and second jaws onto the at least one of the first and second electrical cables.

15. The connector installation tool of Claim 13 wherein the jaw system is configured to receive a connection pre-assembly including the electrical connector and the first electrical cable pre-mounted in the electrical connector.

16. The connector installation tool of Claim 13 configured to clamp the first and second jaws onto at least one of the first and second electrical cables such that the first and second electrical cables extend side-by-side and substantially parallel to one another, and the electrical connector extends between the first and second electrical cables.

17. The connector installation tool of Claim 13 wherein the electrical connector is an insulation piercing (IPC) connector.

18. The connector installation tool of Claim 13 wherein: the first jaw defines a jaw seat; and the connector installation tool is configured to receive the electrical connector in the jaw seat prior to operating the clamping mechanism to clamp the first and second jaws onto at least one of the first and second electrical cables.

19. The connector installation tool of Claim 18 wherein: the second jaw defines a second jaw seat; and when the first and second jaws are clamped onto at least one of the first and second electrical cables, the first and second jaw seats together form a connector seat containing the electrical connector.

20. The connector installation tool of Claim 18 wherein: at least one of the first and second jaws includes an integral cable engagement feature defining a channel; and the cable engagement feature is configured to clamp the at least one of the first and second electrical cables in the channel when the first and second jaws are clamped onto the at least one of the first and second electrical cables.

21. The connector installation tool of Claim 13 wherein the clamping mechanism includes first and second opposed handles operable to close and open the first and second jaws.

22. The connector installation tool of Claim 13 wherein the jaw system is configured such that, when the first and second jaws are clamped onto at least one of the first and second electrical cables, the jaw system: prevents or limits movement of the electrical connector along a first lengthwise cable axis of the first electrical cable and along a second lengthwise cable axis of the second electrical cable; prevents or limits movement of the electrical connector along a tool axis perpendicular to the first and second lengthwise cable axes and extending through the first and second electrical cables; and permits movement of the electrical connector along a connector axis perpendicular to the first and second lengthwise cable axes and perpendicular to the tool axis to facilitate clamping of the electrical connector onto the first and second electrical cables to form the electrical connection.

23. A connection system for forming an electrical connection with first and second electrical cables, the connection system comprising: an electrical connector; and a connector installation tool including: a jaw system including opposed first and second jaws, the jaw system being configured to receive the electrical connector; and a clamping mechanism operable to clamp the first and second jaws onto at least one of the first and second electrical cables while the electrical connector is received by the jaw system.

24. The method of Claim 23 wherein the electrical connector is an insulation piercing (IPC) connector.