Connection enclosure assemblies, connector systems and methods for forming an enclosed connection between conductors

Patent metadata

Field	Value
Publication number	US-10840615-B2
Application number	US-201916453513-A
Country	US
Kind code	B2
Filing date	Jun 26, 2019
Priority date	Jun 28, 2018
Publication date	Nov 17, 2020
Grant date	Nov 17, 2020

Abstract

An enclosed connection system for mechanically and electrically connecting first and second cables, the cables each including an elongate electrical conductor covered by an insulation layer, includes an insulation piercing connector and an enclosure. The insulation piercing connector includes at least one electrically conductive piercing member and a clamping mechanism. The clamping mechanism is configured and operable to force the at least one piercing member through the insulation layers of the first and second cables and into electrical engagement with the conductors of the first and second cables such that the conductors of the first and second cables are electrically connected to one another through the at least one piercing member. The enclosure is configured to receive and cover the connection and to protect the insulation piercing connector.

First claim

That which is claimed is:

1. An enclosed connection system for mechanically and electrically connecting first and second cables each including an elongate electrical conductor covered by an insulation layer, the enclosed connection system comprising:
a) an insulation piercing connector including:
at least one electrically conductive piercing member; and
a clamping mechanism configured and operable to force the at least one piercing member through the insulation layers of the first and second cables and into electrical engagement with the conductors of the first and second cables to form a connection including the insulation piercing connector and the first and second cables wherein the conductors of the first and second cables are electrically connected to one another through the at least one piercing member; and

b) an enclosure configured to receive and cover the connection and to protect the insulation piercing connector;
wherein:
the enclosure includes first and second cover members defining first and second cover member cavities, respectively, and being pivotally connected by a hinge;
the first and second cover members are relatively pivotable about the hinge between an open position to receive the connection and a closed position wherein the first and second cover members define an enclosure cavity to contain the connection such that the insulation piercing connector is encapsulated in the first and second cover members; and
the enclosed connection system includes:
a main latch mechanism including:
a first latch feature forming a part of the first cover member; and
a second latch feature forming a part of the second cover member; and

a safety latch mechanism including:
a safety latch member pivotally connected to the first cover member by a second hinge, the safety latch member including a first safety latch feature; and
a second safety latch feature on the second cover member;

wherein:
the first and second latch features are configured to interlock with one another when the first and second members are placed in the closed position; and
the safety latch member is configured to pivot about the second hinge from a ready position to a safety latching position after the first and second cover members are placed in the closed position; and
in the safety latching position, the first and second safety latch features are interlocked with one another.

2. The enclosed connection system of claim 1 wherein the enclosure includes a flowable sealant disposed in at least one of the first and second cover members to provide a seal about the insulation piercing connector.

3. The enclosed connection system of claim 2 wherein the sealant is a gel.

4. The enclosed connection system of claim 2 wherein the enclosure includes a first flowable sealant disposed in the first cover member cavity and a second flowable sealant disposed in the second cover member cavity;
wherein the enclosure is configured such that the insulation piercing connector will displace the first and second sealants when the first and second cover members are moved from the open position to the closed position about the insulation piercing connector.

5. The enclosed connection system of claim 4 wherein the first and second sealants are first and second gels adapted to be elongated and elastically deformed in the closed position when the insulation piercing connector is disposed in the enclosure cavity.

6. The enclosed connection system of claim 4 wherein:
the insulation piercing connector has a connector volume;
the first and second sealants include first and second voids, respectively, defined therein to receive the insulation piercing connector, the first and second voids having a first void volume and a second void volume, respectively; and
the sum of the first void volume and the second void volume is less than the connector volume.

7. The enclosed connection system of claim 6 wherein the sum of the first void volume and the second void volume is between about 60 and 100 percent of the connector volume.

8. The enclosed connection system of claim 4 wherein:
the first cover member includes an integral sealant retention flange projecting above an upper surface of the first sealant;
the second cover member includes an integral sealant retention groove positioned below an upper surface of the second sealant and containing a portion of the second sealant; and
when the first and second cover members are moved from the open position to the closed position about the insulation piercing connector, the sealant retention flange will enter the sealant retention groove and embed in the second sealant in the sealant retention groove to form a seal at the interface between the first and second cavities.

9. The enclosed connection system of claim 4 wherein:
the first cover member includes:
a first port extension forming a part of the first cover member cavity;
a first strain relief slot; and
a first openable port wall located between the first port extension and the first strain relief slot;

the second cover member includes:
a second port extension forming a part of the second cover member cavity;
a second strain relief slot; and
a second openable port wall located between the first port extension and the first strain relief slot; and

when the first and second cover members are in the closed position:
the first and second port extensions combine to form a cable port;
the first and second strain relief slots combine to form a strain relief opening;
the first and second port walls partition the cable port from the strain relief opening;
the enclosure is configured to receive the first cable such that the first cable extends from the insulation piercing connector in the enclosure cavity, through the cable port, through the first and second port walls, and through the strain relief opening;
the first and second port walls inhibit flow of the first and second flowable sealants from the cable port toward the strain relief opening; and
the strain relief opening is configured to receive a portion of the first cable to provide strain relief for the first cable.

10. The enclosed connection assembly of claim 2 wherein at least one of the first and second cover members includes a plurality of integral ribs configured to enhance adhesion between the sealant and the cover member.

11. The enclosed connection system of claim 1 wherein the enclosure includes:
a conductor port configured to receive the first conductor therethrough; and
a frangible port wall extending across the conductor port.

12. The enclosed connection system of claim 1 wherein the enclosure cavity has a shape that substantially conforms to a shape of the insulation piercing connector.

13. The enclosed connection system of claim 1 wherein at least one of the first latch feature and the second latch feature includes a curved latch finger.

14. The enclosed connection system of claim 1 wherein the first safety latch feature includes a ramped cam surface that forces the first and second cover members together as the safety latch member is pivoted into the safety latching position.

15. A method for forming an enclosed connection assembly about first and second cables each including an elongate electrical conductor covered by an insulation layer, the method comprising:
a) providing an insulation piercing connector including:
at least one electrically conductive piercing member; and
a clamping mechanism configured and operable to force the at least one piercing member through the insulation layers of the first and second cables and into electrical en

Assignees

• Te Connectivity Corp

Inventors

• Newman John Anthony

Classifications

• Y02E10/50

  Photovoltaic [PV] energy · CPC title

• H01R4/2445 Primary

  the contact members having additional means acting on the insulation or the wire, e.g. additional insulation penetrating means, strain relief means or wire cutting knives · CPC title

• H01R4/2408 Primary

  actuated by clamping screws · CPC title

• H01R13/5216

  characterised by the sealing material, e.g. gels or resins · CPC title

• H02G15/013

  Sealing means for cable inlets (inlets for cables filled with, or surrounded by, gas or oil H02G15/32) · CPC title