AU2007201734B2 - A mains-power connector assembly - Google Patents

Description

AUSTRALIA PATENTS ACT 1990 COMPLETE SPECIFICATION STANDARD PATENT A MAINS-POWER CONNECTOR ASSEMBLY The following statement is a full description of this invention including the best method of performing it known to me: A MAINS-POWER CONNECTOR ASSEMBLY 5 TECHNICAL FIELD The present invention generally relates to mains-power connectors which are suitable for use in electrical distribution systems. 10 BACKGROUND Mains power and electrical distribution connectors are commonly used for connecting mains power (e.g. 11OV, 240V, 415V, etc.) electrical cables together. In underground power distribution systems, for example, lengths of 15 sector cable are serially connected together (i.e. daisy chained) using mains power connectors which are located within protective "pillar" boxes. The cable may include a plurality of insulated cores, each carrying a respective phase of mains-power, with each core in turn comprising a plurality 20 of respective wire conductors. Alternatively, respective cables can be used which each carry a respective phase. During connection, the free ends of the cores to be connected are first stripped of their insulation and then fastened together using the connectors which apply force directly to the wire conductors. In use, the connectors and stripped ends of the core often have 25 exposed portions carrying power which, although shielded by the pillar boxes, present a safety hazard in the event of the pillar boxes being removed as a result of vandalism or an accident. Rain and moisture can also often penetrate the pillar boxes and undesirably result in the corrosion of the exposed portions. 30 The mains-power connectors are invariably replaced or reconfigured when changing the configuration of the power distribution system. In this event, the wire conductors which are forcibly engaged with the connectors often become damaged and fractured. Accordingly, the damaged ends of the cores often 2 need to be removed, and further outer insulation material stripped away when replacing or reconfiguring a connector. Each core is generally quite large and stiff, and can be quite difficult to manually strip of its outer insulation. 5 It is an object of the present invention to provide techniques which can be used to impede damage to electrical conductors during the replacement or reconfiguration of mains-power connectors in electrical distribution systems. Embodiments of the present invention impede exposed conductive portions 10 carrying power from being readily accessible about the mains-power connector. Further embodiments of the present invention impede the corrosion of the mains-power connector and the electrical conductors. 15 SUMMARY OF THE INVENTION According to one aspect of the present invention, there is provided a mains power connector assembly including: 20 a first terminal for terminating a first electrical conductor; a second terminal for terminating a second electrical conductor; and a mains-power connector for housing and connecting the terminals so that the first and second electrical conductors are electrically coupled together. 25 The power connector may include a body defining respective terminal passages for each receiving a respective terminal so that the terminals do not directly contact each other. The body may define a pair of sets of threaded terminal apertures, each set of terminal apertures including one or more 30 terminal apertures which extend from a corresponding terminal passage, each terminal aperture being threaded so as to receive a respective threaded fastener when fastening the terminal within the terminal passage.

3 The first and second conductors may each be power supply conductors. The body may further define one or more load conductor passages for each receiving a respective load conductor. The body may define respective threaded load conductor apertures each extending from a corresponding load 5 conductor passage, each load conductor aperture being threaded so as to receive a respective threaded fastener when fastening the load conductor within the load conductor passage. The body may be integrally formed from aluminium or other like conductive material. The connector may further include one or more socket fittings for each being received within a respective 10 load conductor passage. The connector may further include one or more plugs for each engaging with a respective socket. The connector may further include a plurality of threaded fasteners for fastening the terminals with the connector. Each fastener may be a shear 15 fastener having a head from which a threaded conductive shaft extends, the head defining a recess such that a tip of the head can be separated from the fastener by shearing. Preferably, the tip is hexagonal in shape. The head may include an insulated base. The head may be integrally formed from nylon or other like insulation material. 20 The connector may further include an insulator defining a space in which the body can be located. In use, the space may be sealed so as to impede the ingress of water or moisture. The insulator may define a pair of tubes for each receiving a respective electrical conductor. The connector may include a pair 25 of threaded caps for each engaging with a respective tube. The insulator may include one or more other tubes for each engaging with a respective fastener. The insulator may be integrally formed from resilient material. The resilient material may be polyethylene. 30 Each terminal may include a barrel defining one or more threaded apertures for each receiving a respective threaded shaft. Each terminal may define a retention formation for retaining the barrel within the connector in use. The retention formation may include a channel. The barrel may be integrally formed from aluminium. The barrel may define a tunnel having a circular 4 segment or other shaped cross section for receiving the conductor. Each conductor may be a respective core of a sector cable, have a circular cross section or have a cross section of any other shape. The tunnel may be closed at one end. 5 The connector assembly may further include a third terminal for terminating with a third conductor wherein the connector can connect with the third terminal so that each of the conductors are electrically coupled together. 10 According to a further aspect of the present invention, there is provided a mains-power connector assembly including: a pair of couplers for each coupling with a respective electrical conductor; and a mains-power connector defining one or two passages in which the 15 couplers can be received and for connecting the couplers so that the electrical conductors are electrically coupled together. Each coupler may include a terminal for terminating a respective electrical conductor. 20 According to a further aspect of the present invention, there is provided a mains-power connector for connecting a pair of electrical terminals, the mains power connector including: a conductor body defining respective passages for each receiving a 25 respective one of the terminals; and a pair of fasteners for each fastening a respective terminal to the conductor body to thereby connect the terminals. Preferably, the connector further includes an insulator defining a space for 30 receiving the body. According to a further aspect of the present invention, there is provided an electrical terminal or coupler for a mains-power conductor, the terminal or coupler defining: 5 a tunnel for receiving the conductor; and one or more threaded apertures each extending from the tunnel and for receiving a respective threaded fastener to thereby fasten the conductor within the tunnel. 5 According to a further aspect of the present invention, there is provided a method for coupling a first electrical conductor to a second electrical conductor using a mains-power connector, the method including the steps of: terminating each conductor with a respective terminal; 10 housing each terminal within the mains-power connector; and connecting the terminals using the mains-power connector so that the first and second electrical conductors are electrically coupled together. The step of terminating may involve the step of screwing a respective 15 threaded shaft into each terminal. The step of screwing may involve the step of shearing the shaft. The step of connecting may involve the step of screwing a threaded fastener of the connector so as to connect each terminal with the connector. 20 The method may further involve the step of sealing the connector so as to impede water and moisture from entering the connector. BRIEF DESCRIPTION OF THE DRAWINGS 25 Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding 30 Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows: Figure 1 is a partially exploded perspective view of a mains-power connector assembly in accordance with a first embodiment of the present invention; 6 Figure 2a is a plan view of the mains-power connector assembly of Figure 1; Figure 2b is a side cross sectional view through the line A-A of Figure 2a; 5 Figure 3 is a partially exploded perspective view of a mains-power connector assembly in accordance with a second embodiment of the present invention; Figure 4a is a plan view of the mains-power connector assembly of Figure 3; 10 Figure 4b is a side cross sectional view through the line B-B of Figure 4a; Figure 5a is a perspective view of a mains-power connector assembly in accordance with a third embodiment of the present invention; 15 Figure 5b is a partially exploded perspective view of the mains-power connector assembly of Figure 5a; Figure 6a is a plan view of the mains-power connector assembly of Figure 5a; 20 Figure 6b is a side cross sectional view through the line C-C of Figure 6a; Figure 7a is a perspective view of a mains-power connector assembly in accordance with a fourth embodiment of the present invention; 25 Figure 7b is a partially exploded perspective view of the mains-power connector assembly of Figure 7a; Figure 8a is a perspective view of a body of the connector assembly of Figure 30 1; Figure 8b is a perspective view of a body of the connector assembly of Figure 3; 7 Figure 8c is a perspective view of a body of the connector assembly of Figure 5a; Figure 8d is a perspective view of a body of the connector assembly of Figure 5 7a; Figure 9a is a perspective view of a terminal of the connector assembly of Figure 3 or Figure 7b; 10 Figure 9b is a perspective view of a terminal of the connector assembly of Figure 1 or Figure 5b; Figure 9c is a perspective view of an alternative terminal to that of Figure 9a; and 15 Figure 9d is a perspective view of an alternative terminal to that of Figure 9b. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 20 According to a first embodiment of the present invention, there is provided a mains-power connector assembly 2a as shown in Figures 1 and 2. The connector assembly 2a includes a pair of terminals 16a for each terminating a respective insulated core 26 of a cable. The connector assembly 2a also includes a mains-power connector 4a for housing and connecting the pair of 25 terminals 16a so that the pair of cores 26 are electrically coupled together. Each terminal 16a can be readily removed from the connector 4a during the replacement or reconfiguration of the connector. A detailed description of components of the connector assembly 2a is provided below. 30 Turning firstly to Figure 8a, the connector 4a includes an aluminium extruded body 32a which defines a pair of respective terminal passages 34a, 34b for each receiving a respective terminal 16a. The body 32a effectively forms a housing for housing the terminals 16a. The terminals 16a do not directly contact each other. The body 32 defines a pair of threaded terminal apertures 8 35, with each aperture 35 extending from a corresponding terminal passage 34. Each terminal aperture 35 is threaded so as to receive the threaded shaft 12a of a terminal bolt 6a (Figure 1) when fastening the terminal 16a within the terminal passage 34. 5 As discussed in detail below, each terminal 16a terminates a respective core 26 of a cable and effectively carries mains-supply power in use. The body 32a also defines a quartet of load conductor passages 36 for each receiving a respective load conductor carrying power to a load. The body 32a also defines 10 respective threaded load conductor apertures 37 each extending from a corresponding load conductor passage 36. Each load conductor aperture 37 is threaded so as to receive a respective threaded shaft 12b of a load conductor bolt 6b (Figure 1) when fastening a load conductor within the load conductor passage 36. 15 Turning to Figure 1, each load conductor may include a socket 38 of the connector 4a which is received within a corresponding load conductor passage 36. Each socket 38 is clamped within a corresponding load conductor passage 36 using a corresponding load conductor bolt 6b. The 20 connector 4a may further include a quartet of internally threaded or ribbed plugs or caps 40 for each engaging with a respective socket 38. Each cap 40 can slide along a respective load cable which supplies power from the connector 4a to a load and also forms a watertight seal. 25 The terminal bolts 6a and load conductor bolts 6b referred to above are of like construction, however, the terminal bolts have a threaded shaft 12a of greater diameter than the threaded shafts 12b of the load conductor bolts 6b. Accordingly, the diameter of the terminal apertures 35 is greater than the diameter of the load conductor apertures 37 defined in the body 32a (Figure 30 8a). Each bolt 6a, 6b is a shear fastener having an insulator head 10 from which the threaded conductive shaft 12 extends. As can best be seen in Figure 2b, the head defines a recess 9 so that the hexagonal tip at the free end of the 9 head 10 can be separated from the bolt 6 by shearing. The head 10 also includes an insulated base 14 which defines an annular well in which a ribbed cylinder 48 of an insulator cover 44 can be snugly fitted. 5 Turning to Figure 9b, each terminal 16a includes an integrally formed aluminium barrel 18a which defines a pair of threaded apertures 20 for each receiving a respective threaded shaft 23 (Figure 1). The barrel 18a defines a tunnel 24a having a segment cross section for receiving the complementarily shaped bundle of wires 28 extending from the core 26 of a sector cable. The 10 tunnel 24a may or may not be closed at one end. During termination of the core 26, the bundle of wires 28 are inserted in the tunnel 24a and the threaded shafts 23 are each screwed tight so that the bundle of wires 28 is firmly clamped between the shafts 23 and the barrel 18a. Typically, enough torque is applied to the threaded shafts 23 so that they shear within the 15 apertures 20, below the outer surface of the barrel 18a. Each terminal 16a is sized so as to fit within a terminal passage 34 so that the terminal 16a is housed within the connector 4a. Each terminal 16a defines a continuous channel 22 which circumscribes the terminal 16a. In use, the shaft 20 12a of a terminal bolt 6a is engaged in the channel 22 so as to impede the axial movement of the barrel 18a, thereby retaining the barrel 18a within the terminal passage 34 and connector 4a. Any rotation of the terminal 16a within the terminal passage 34 is impeded by the inherently stiff properties of the core 26 to which it is fastened. Each terminal 16a effectively forms a type of 25 coupler for electrically coupling a conductor core 26 to the connector 4a. The connector 4a further includes an insulator cover 44a which surrounds the conductive body 32a. The insulator cover 44a may be integrally formed from polyethylene, rubber or other like resiliently extensible material and defines an 30 internal space in which the body 32a can be located. The insulator cover 44a defines a pair of ribbed cylinders 46 for each receiving a respective core 26. Each ribbed cylinder 46 is located in register with a respective terminal passage 34 of the body 32 and, during assembly, is stretched so as to permit the passage of a terminal 16 into the terminal passage 34. The connector 4a 10 also includes a pair of internally threaded or ribbed caps 30 for each engaging with a respective threaded cylinder 46 so as to from a water tight seal. Each cap 30 can slide along a core 26 and also forms a water tight seal with the core 26. 5 The insulator cover 44a also includes a quartet of ribbed cylinders 48 for each engaging with a respective bolt 6 so as to form a water tight seal. Each ribbed cylinder 48 snugly fits into the annular well defined by the insulated base 14 of the bolt 6. 10 Once the connector assembly 2a is assembled, the conductive body 32a, terminals 16a, bundles of wires 28, shafts 12 of the bolts 6, and conductive components of the sockets 38 and caps 40 are all housed within an insulator shield so that no live (power) portions of the connector assembly are exposed. 15 These conductive components are at approximately the same voltage potential. The insulator shield is defined by the insulation of the cores 26, the caps 30, the insulation cover 44a, the nylon heads of the bolts 6, and the outer plastic covers of the sockets 38 and caps 40. 20 In addition, a water tight interface exists between: each cap 40 and socket 38 pair, the sockets 38 and the insulator cover 44a, each cap 30 and cylinder 46 pair, and each base 14 and cylinder 48 pair. Accordingly, the ingress of water and moisture into the connector 4a is impeded so that the corrosion of the live metallic portions housed within the insulator shield is impeded. 25 A method for coupling a pair of electrical cores 26 together using the mains power connector 4a is now described in detail. Firstly, the method includes the step of terminating each core 26 with a 30 respective terminal 16a. The insulation sheath at the end of each core 26 is stripped so as to expose the bundle of wires 28. Each bundle of wires 26 is then passed into a corresponding tunnel 24a of a terminal 16a and the threaded shafts 23 are engaged in their corresponding threaded apertures 20. The shafts 23 are screwed into place so that the portion of the shaft 23 11 remaining in the aperture 20 is below the outer surface of the terminal 16a. This may be achieved by the shaft shearing at a pre-determined torque. Each bundle of wires 28 is firmly clamped in a tunnel 24a between the threaded shafts 23 and a barrel 18a. 5 Next, the method includes the step of housing each terminal 16a within a passage 34 of the body 32a by locating the terminals 16a in corresponding passages 34. Each cylinder 46 is stretched so as to allow the ingress of a terminal 46 and then resumes its natural state, whereafter each cap 30 is 10 engaged with a corresponding cylinder 46. In this manner, each terminal 16a is housed within the mains-power connector 4a. The method then involves the step of connecting the terminals 16a using the mains-power connector 4a so that the pair of cores 26 are electrically coupled 15 together. In this manner, a pair of terminal bolts 6a are each engaged and screwed within a respective terminal aperture 35 of the body 32a so as to electrically connect each terminal 16a with the connector 4a. The tip of each shaft 12a engages within a respective channel 22 of the terminal 16a. An electrical circuit is thereby sequentially formed between a first one of the cores 20 26, a first one of the terminals 16a, the body 32a of the connector 4a, a second one of the terminals 16a, and a second one of the cores 26 so as to thereby electrically couple the cores 26 together. A quartet of load conductors inserted through the sockets 38 are each 25 clamped within a respective load conductor passage 36 of the body 32a using the load conductor bolts 6b. A quartet of caps 40 each fitted to a respective load cable 42 can then be engaged with the sockets 38. The connector 4a is thereby sealed so as to impede water and moisture from entering the connector. 30 In the event that the connector 4a needs to be changed or reconfigured, the terminals 16a can be readily removed from the connector 4a after release of the terminal bolts 6a. The terminals 16a can then be engaged within another connector 4a or located in a different terminal passage 34. The bundle of 12 wires 28 remains secure within the terminal 16a and is not stressed or damaged when engaging and disengaging the terminals 16a within passages 34 using the terminal bolts 6a. In the ensuing embodiments described below, various reference numerals in 5 the figures correspond to like features having like reference numerals previously described in relation to the first embodiment. According to a second embodiment of the present invention, there is provided a mains-power connector assembly 2b as shown in Figures 3 and 4. The 10 connector assembly 2b includes an extruded body 32b as shown in Figure 8b. The extruded body 32b defines a pair of terminal passages 34 in which terminals 16b shown in Figure 9a can pass and be received. A pair of threaded terminal apertures 35 extends from each terminal passage 34. A pair of terminal bolts 6a engage with each terminal 16b to provide improved 15 retention of the terminals 16b in the passages 34. An insulator cover 44b surrounds the body 32b. According to a third embodiment of the present invention, there is provided a mains-power connector assembly 2c as shown in Figures 5 and 6. The 20 connector assembly 2c includes an extruded body 32c as shown in Figure 8c. The extruded body 32c defines a first terminal passage 34a, a second terminal passage 34b and a third terminal passage 34c. A respective terminal 16a (Fig. 9b) is engaged in each passage 34 so that the three cores 26 coupled to the terminals 16a are electrically coupled together. A single 25 terminal aperture 35 extends from each terminal passage 34. An insulator cover 44c surrounds the body 32c. According to a fourth embodiment of the present invention, there is provided a mains-power connector assembly 2d as shown in Figure 7. The connector 30 assembly 2d includes an extruded body 32d as shown in Figure 8d. The extruded body 32d defines a first terminal passage 34a, a second terminal passage 34b and a third terminal passage 34c. A respective terminal 16b (Fig. 9a) is engaged in each passage 34 so that the three cores 26 coupled to the terminals 16b are electrically coupled together. A pair of threaded terminal 13 apertures 35 extends from each terminal passage 34. A pair of terminal bolts 6a engage with each terminal 16b to provide improved retention of the terminals 16b in the passages 34. An insulator cover 44d surrounds the body 32d. 5 Figure 9c shows a terminal 16c having a tunnel 24b of circular cross section and which can be used in place of the terminal 16b of the second and fourth embodiments. Figure 9d shows a terminal 16d having a tunnel 24b of circular cross section 10 and which can be used in place of the terminal 16a of the first and third embodiments. A person skilled in the art will appreciate that many embodiments and variations can be made without departing from the ambit of the present 15 invention. In the first embodiment, the terminal passages 34a, 34b were separated by a wall of the body 32a. In an alternative embodiment, the wall may be broken or removed so that the pair of terminals 16a are provided in a single passage 34. 20 In this manner, the pair of terminals 16a may directly contact each other. In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or 25 described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Claims (25)

1. A mains-power connector assembly including: a first terminal for terminating a first electrical conductor; a second terminal for terminating a second electrical conductor; and a mains-power connector for housing and connecting the terminals so that the first and second electrical conductors are electrically coupled together.

2. A connector assembly as claimed in claim 1, wherein the connector includes a body defining respective terminal passages for each receiving a respective terminal to thereby house the terminals within the connector.

3. A connector assembly as claimed in claim 2, wherein the body defines a pair of sets of terminal apertures, each set including one or more terminal apertures which extend from a corresponding terminal passage, each terminal aperture being threaded so as to receive a respective threaded fastener when fastening the terminal within the terminal passage.

4. A connector assembly as claimed in claim 2, further including the first and second conductors wherein each conductor is a power supply conductor.

5. A connector assembly as claimed in claim 4, wherein the body further defines one or more load conductor passages for each receiving a respective load conductor.

6. A connector assembly as claimed in claim 5, wherein the body defines respective threaded load conductor apertures each extending from a corresponding load conductor passage, each load conductor aperture being threaded so as to receive a respective threaded fastener when fastening the load conductor within the load conductor passage. 15

7. A connector assembly as claimed in claim 5, wherein the connector includes one or more socket fittings for each being received within a respective load conductor passage.

8. A connector assembly as claimed in claim 1, wherein the connector includes a plurality of threaded fasteners for fastening the terminals with the connector.

9. A connector assembly as claimed in claim 1, wherein the connector includes an insulator defining a space in which the body can be located.

10. A connector assembly as claimed in claim 9 wherein, in use, the space is sealed so as to impede the ingress of water or moisture.

11. A connector assembly as claimed in claim 9, wherein the insulator defines a pair of tubes and the connector includes a pair of threaded caps for each engaging with a respective tube.

12. A connector assembly as claimed in claim 9, wherein the insulator includes one or more tubes for each engaging with a respective fastener.

13. A connector assembly as claimed in claim 9, wherein insulator is integrally formed from resilient material.

14. A connector assembly as claimed in claim 1, wherein each terminal includes a barrel defining one or more threaded apertures for each receiving a respective threaded shaft.

15. A connector assembly as claimed in claim 14, wherein each terminal defines a retention formation for retaining the barrel within the connector in use.

16. A connector assembly as claimed in claim 1, further including a third terminal for terminating a third conductor wherein the connector can connect 16 with the third terminal so that each of the conductors are electrically coupled together.

17. A mains-power connector assembly including: a pair of couplers for each coupling with a respective electrical conductor; and a mains-power connector defining one or two passages in which the couplers can be received and for connecting the couplers so that the electrical conductors are electrically coupled together.

18. A connector assembly as claimed in claim 17, wherein each coupler includes a terminal for terminating a respective electrical conductor.

19. A mains-power connector for connecting a pair of electrical terminals, the mains-power connector including: a conductor body defining respective passages for each receiving a respective one of the terminals; and a pair of fasteners for each fastening a respective terminal to the conductor body to thereby connect the terminals.

20. A connector as claimed in claim 19, further including an insulator defining a space for receiving the body.

21. An electrical terminal or coupler for a mains-power conductor, the terminal or coupler defining: a tunnel for receiving the conductor; and one or more threaded apertures each extending from the tunnel and for receiving a respective threaded fastener to thereby fasten the conductor within the tunnel.

22. A method for coupling a first electrical conductor to a second electrical conductor using a mains-power connector, the method including the steps of: terminating each conductor with a respective terminal; housing each terminal within the mains-power connector; and 17 connecting the terminals using the mains-power connector so that the first and second electrical conductors are electrically coupled together.

23. A method as claimed in claim 22, further including the step of sealing the connector so as to impede water or moisture from entering the connector.

24. A connector assembly as claimed in any one of claims 1 to 18, and substantially as herein described with reference to the accompanying drawings.

25. A connector as claimed in claim 19 or claim 20, and substantially as herein described with reference to the accompanying drawings. Dated this 18 th day of April 2007 SICAME AUSTRALIA PTY LTD by my attorneys Eagar & Buck Patent and Trade Mark Attorneys