CLIAMS:CLAIMS

What is claimed is:
1. A connector (100) for forming an electrical connection with an electrical conductor, the connector (100) comprising:
a first part (102) having multiple slots (104 and 106) adjacent to each other;
a second part (108) having multiple slots (110 and 112) identical to the slots (104 and 106) provided in the first part (102), the second part (108) configured to be clamped to the first part (102) in an inverted position such that the slots (110 and 112) on the second part (108) mate with the slots (104 and 106) on the first part (102) to form two channels (120 and 122) adjacent to each other, the channels (120 and 122) being configured for accommodating an electrical conductor each (124 and 126) for establishing electrical connection there between;
a pair of ingots (127 and 130) to be inserted through at least one socket (135, 137, 140 and 142) provided on each of the first part (102) and the second part (108) such the ingots (127 and 130) upon insertion lock the first part (102) to the second part (108) thereby forming a rigid structure; and
wherein the dimension of each of the slots (104 and 110) is less than the dimension of the conductor (124) that is to be accommodated, so as to import a desired clamping force.

2. The connector (100) of claim 1, wherein at least one of the slots (104, 106, 110 and 112) is structured to include mechanical deformation, coating or combination of both.

3. The connector (100) of Claim 1, wherein each of the first part (102) and the second part (108) are made of a metal selected from a group comprising copper, aluminum, silver, bronze and alloys thereof and the ingots (127 and 130) are made of a metal selected from a group comprising copper, aluminum, iron, silver, bronze and alloys thereof.

4. The connector (100) of Claim 1, wherein clamping of the first part (102) to the second part (108) is performed using an external clamping device.

5. A connector (100) comprising:
a first channel (120) for receiving a first electrical conductor (124) ;
a second channel (122) for receiving a second electrical conductor (126), the first channel (120) and the second channel (122) being formed using two one-piece metal members (102 and 108) upon mating the metal members (102 and 108);
a coupling means for coupling the metal members (102 and 108) so as to lock the movement of the metal members (102 and 108) and the conductors (124 and 126) with respect to each other; and
wherein the dimension of the channels (120 and 122) is less than the dimension of the conductors (124 and 126) that are to be accommodated, so as to import a desired clamping force.

6. The connector (100) of claim 5, wherein the coupling means comprises a pair of ingots (127 and 130) inserted through at least one socket (135, 137, 140 and 142) provided on each of the metal members (102 and 108).

7. The connector (100) of claim 5, wherein at least one of the slots (104, 106, 110 and 112) is structured to include mechanical deformation, coating or combination of both.

8. The connector (100) of claim 5, wherein the metal members (102 and 108) are said to be mated when concave portions (104 and 110), and (106 and 112) of the metal members (102 and 108) face each other.

9. The connector (100) of Claim 5, wherein each of the metal members (102 and 108) are made of a metal selected from a group comprising copper, aluminum, silver, bronze and alloys thereof and the ingots (127 and 130) are made of a metal selected from a group comprising copper, aluminum, iron, silver, bronze and alloys thereof.
,TagSPECI:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2003
COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)

Title of the Invention
“CONNECTOR FOR ELECTRICAL CONDUCTORS”
APPLICANT
Name: Raychem RPG Private. Limited.
Address: RPG House, 463, Dr. Annie Besant Road, Mumbai : 400 030, Maharashtra, India

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:-

CONNECTOR FOR ELECTRICAL CONDUCTORS

FIELD OF INVENTION

[0001] The present invention relates to connectors and more particularly to an electrical connector for connecting two conductors.

BACKGROUND OF THE INVENTION

[0002] Electrical conductors often need be terminated or joined in various environments, such as underground or overhead electrical network system. Such conductors may be a part of electrical transmission or distribution systems. In order to form such connections, a connector may be employed. One of the connectors used in overhead electrical network system is parallel groove connectors often referred to as PG connectors.

[0003] The PG connectors described in the prior art comprise multiple fastening devices depending on the size of the conductors and voltage range application. Major drawback of using such connectors includes excessive power loss occurring due to creep in the fastening devices. Further, application of inadequate or excessive force applied by an operator due to lack of skill, experience or guideline may cause physical damage and/or result in formation of inappropriate joint. This may further affect the performance of the connector and reliability of the electrical connections made.

[0004] Further, since the fastening devices are uncovered they often get corroded due to environmental exposure and tend to get loosened because of thermal cycles. This affects the reliability of the connector and in addition demands regular maintenance by skilled labor that is expensive and time consuming. This may further cause inconvenience to consumers as the power supply is discontinued during the time when the regular maintenance is carried out.

[0005] Hence there exists a long felt need for a connector that is efficient, low maintenance, reliable and easy to install.

BRIEF DESCRIPTION OF THE INVENTION

[0006] In one embodiment, a connector for forming an electrical connection with an electrical conductor is provided. The connector comprises a first part having multiple slots adjacent to each other, a second part having multiple slots identical to the slots provided in the first part, the second part configured to be clamped to the first part in an inverted position such that the slots on the second part mate with the slots on the first part to form multiple channels adjacent to each other, the channels being configured for accommodating an electrical conductor each for establishing electrical connection there between and a pair of ingots to be inserted through at least one socket provided on each of the first part and the second part such that the ingots upon insertion lock the first part to the second part thereby forming a rigid structure.

[0007] In another embodiment, a connector is provided that comprises a first channel for receiving a first electrical conductor, a second channel for receiving a second electrical conductor, the first channel and the second channel being formed using two one-piece metal members upon mating the metal members and a coupling means for coupling the metal members upon clamping so as to lock the movement of the metal members with respect to each other and thereby establishing electrical connection between the conductors.

[0008] Various other features and advantages of the invention will be made apparent from the following detailed description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Embodiments are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like reference numerals refer to similar elements and in which:

[0010] FIG. 1 shows a side view of a connector in an open position as described in one embodiment of the invention;

[0011] FIG. 2 shows an isometric view of the connector of FIG. 1 in a mated position; and

[0012] FIG. 3 shows a side view of the connector in FIG. 1, along with conductors, as described in one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0013] It shall be observed that system components described in accordance with exemplary embodiments have been represented by known symbols in the figures, showing only specific details that are relevant for an understanding of the present disclosure. Further, details that are readily apparent to those skilled in the art may not have been disclosed.

[0014] Turning now to FIG. 1, a connector 100 for forming an electrical connection with an electrical conductor is provided. The connector 100 comprises a first part 102 having multiple slots 104 and 106 adjacent to each other and a second part 108 having multiple slots 110 and 112 identical to the slots 104 and 106 provided in the first part 102.

[0015] The second part 108 is configured to be clamped to the first part 102 in an inverted position such that the slots 110 and 112 on the second part 108 mate with the slots 104 and 106 on the first part 102 to form two channels 120 and 122 adjacent to each other. In one embodiment channels 120 and 122 are parallel to each other. This is shown in FIG. 2.

[0016] Turning now to FIG. 3, the channels 120 and 122 are configured for accommodating an electrical conductor each, 124 and 126 respectively, for establishing electrical connection there between. The connector 100 further comprises a pair of ingots 127 and 130 to be inserted through at least one socket 135, 137, 140 and 142 provided on each of the first part 102 and the second part 108 such the ingots 127 and 130 upon insertion lock the first part 102 to the second part 108 thereby forming a rigid structure.

[0017] Though FIG. 1 shows each of the first part 102 and the second part 108 as having two slots each, 104 and 106, and 110 and 112 respectively, it is to be understood that the structure can be extended to include two or more slots in order to establish electrical connection between two or more electrical conductors.

[0018] Further, the size of slot 104, 106, 110 and 112 may vary depending on the size of the conductor that is to be accommodated. The size of the conductor in turn depends on the current carrying capacity of the respective conductor. Further, the conductor may be selected from a group comprising single strand, multi strand and a bus bar.

[0019] Further, in an additional embodiment, the surface of at least one slot 104, 106, 110 and 112 may be structured to include mechanical deformation, coating or combination of both. In one exemplary embodiment, the mechanical deformation can be one of knurling or teeth formation. Coating can be performed with a material having higher electrical conductivity when compared to the conductivity of the metal used for constructing the first part 102 and/or the second part 108. In one exemplary embodiment, the coating is performed using silver, gold or alloy thereof.

[0020] Further, knurling or teeth formation provided increases the contact area between the conductor 124 and the slots 104 and 110 and helps in establishing optimal contact between the slots 104 and 110 and the conductor 124 by increased surface contact area. The mechanical deformation and coating provided on the slots 104 and 110 help in reducing the surface contact resistance that in turn reduces the power loss occurring in the conductor 124 and hence increases the efficiency of the connector 100. Further, knurling or teeth formation provided on the slots 104 and 110 aids in removing oxidation that may have already formed on the conductor 124 prior to installation. This further increases the conductivity of the conductor 124 and consequently efficiency of the connector 100 is enhanced.

[0021] In one embodiment, the orientation of knurling or teeth formation may be such that it provides resistance against movement of the conductor 124 that is positioned over the slots 104 and 110 so as to mitigate accidental displacement of the conductor 124 due to external forces.

[0022] Though FIG. 1, FIG. 2 and FIG. 3 show the shape of the channels 120 and 122 and the conductors 124 and 126 to be circular, skilled artisans shall appreciate that each of the channels 120 and 122 and the conductors 124 and 126 may have different shapes, sizes, profiles and configurations. However, it is to be understood that the shape and size of the channels 120 and 122 and the conductors 124 and 126 are interdependent and are to be selected in a manner so as to maximize the contact area.

[0023] In one exemplary embodiment, when the shape of the channel 120 is selected to be circular, the shape of the conductor 124 is selected to be circular as well in order to maximize the contact area and therefore the conductivity.

[0024] The electrical connector 100 is assembled by placing the first part 102 and the second part 108 in superimposed relation such that concave portions 104 and 110, and 106 and 112, are facing each other. Such an alignment forms two adjacent channels 120 and 122. This is termed as mating. The size of the slot 104 for example is less than the size of the conductor 124 that is accommodated within the slot 104. The ratio of difference between the inner dimension of the slot 104 and outer dimensions of the conductor 124 varies based on the size and shape of the conductor 124.

[0025] This difference between the inner dimension of the slot 104 and the outer dimension of the conductor 124 is reduced upon clamping the first part 102 to the second part 108 to form a clamped unit. The difference in the dimension between the slot 104 and the conductor 124 is maintained so as to import sufficient clamping force. The clamping of the first part 102 to the second part 108 is performed using an external clamping device.

[0026] Subsequently, the ingots 127 and 130 are inserted on both sides of the clamped unit in order to hold together the first part 102 and the second part 108 and the conductors 124 and 126 there between.

[0027] In one embodiment, each of the slots 104, 106, 110 and 112 can be configured for accommodating conductors of various dimensions particularly the conductors whose dimensions are considerably less than the inner dimension of the slots 104, 106, 110 and 112. One or more buffers (not shown) having a shape matching with that of the conductor 124 and the slot 104 can be inserted in the interstice between the conductor 124 and the slot 104 so as to make the slot 104 capable of accommodating conductor 124. The number, shape and size of the buffers (not shown) inserted may vary based on the size and shape of the slot 104 and the conductor 124 and the difference in inner dimension of the slot 104 and the outer dimension of the conductor 124

[0028] In one embodiment, each of the first part 102 and the second part 108 are made of a metal selected from a group comprising copper, aluminum, silver, bronze and alloys thereof and the ingots 127 and 130 are made of a metal selected from a group comprising copper, aluminum, iron, silver, bronze and alloys thereof.

[0029] In another embodiment, a connector 100 is described that comprises a first channel 120 for receiving a first electrical conductor 124 and a second channel 122 for receiving a second electrical conductor 126. The first channel 120 and the second channel 122 are formed using two one-piece metal members 102 and 108 upon mating the metal members 102 and 108.

[0030] The metal members 102 and 108 are said to be mated when concave portions 104 and 110, and 106 and 112 of the metal members 102 and 108 face each other. The metal members 102 and 108 are then clamped using the external clamping device. The clamping exerts a fairly uniform pressure on the electrical conductors 124 and 126. This rules out application of uneven pressure on the electrical conductors 124 and 126 that may damage the electrical conductors 124 and 126.

[0031] The connector 100 further comprises a coupling means for coupling the metal members 102 and 108 upon clamping so as to lock the movement of the metal members 102 and 108 with respect to each other. The coupling means comprises a pair of ingots 127 and 130 inserted through at least one socket 135, 137, 140 and 142 provided on each of the metal members 102 and 108.

[0032] The channels 120 and 122 are configured for accommodating the conductors 124 and 126, and the ingots 127 and 130 are configured for holding the metal members 102 and 108. The ingots 127 and 130 are covered inside the sockets 135, 137, 140 and 142 and hence the possibility the ingots 127 and 130 being exposed to moisture or water is less. This avoids the ingots 127 and 130 from getting corroded. This in turn reduces the need for maintenance.

[0033] Further, each of the metal members 102 and 108 is made of a metal selected from a group comprising copper, aluminum, silver, bronze and alloys thereof and the ingots 127 and 130 are made of a metal selected from a group comprising copper, aluminum, iron, silver, bronze and alloys thereof.

[0034] In one preferred embodiment, the metal members 102 and 108 are made of aluminum and the ingots 127 and 130 are made of stainless steel.

[0035] The connector 100 described herein is efficient as it eliminates the usage of fastening devices such as bolts and screws in order to clamp the connector 100. Power loss occurring due to creep in the fastening devices is thus eliminated.

[0036] Further, eliminating the usage of fastening devices forgoes need for performing frequent maintenance and thus makes the connector 100 operator proof and maintenance proof. This enhances the reliability and longevity of the connector 100.

[0037] Further, eliminating the need for fastening device facilitates speedy installation of the connector 100 and therefore the connector 100 neither requires skilled labor nor specific guidelines for installation.

[0038] The ingots 127 and 130 used for connecting the members 102 and 108 are covered by the sockets 135, 137, 140 and 142. This avoids exposure of the ingots 127 and 130 to the external environment thereby avoiding risk of corrosion.

[0039] The connector 100 described in various embodiments herein is configured for connecting multiple overhead electrical conductors. However, the application of the connector 100 can be extended to other areas for example in establishing electrical and mechanical coupling of multiple members.

[0040] It will be appreciated by those skilled in the art that the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the invention is indicated by the appended claims rather than the foregoing description and all changes that come within the meaning and range and equivalence thereof are intended to be embraced therein.