[0001] This invention relates to an insulation piercing connector assembly with a sealing
cap for covering an end of a cable positioned in the insulation piercing connector.
[0002] Insulation piercing connectors for tapping power from one cable to another typically
comprise a pair of insulated clamping housings with insulation piercing blades mounted
therein, the housings having a first set of teeth on one side thereof interconnected
with a second set of teeth on another side thereof, each side for connection to a
cable. Piercing of an outer insulation layer of the cables is effected by bolting
the connector clamping halves together. Such connectors are widely used and for example
shown in European patent 0 007 706, or in US 5,015,198, or FR 2 634 070. In the latter
two prior references, the clamping insulation piercing connector is provided on one
side thereof with an end cap that can be filled with sealing gel and which is received
over an end of a cable. In the latter application, the connector is used for tapping
off power from a continuous main conductor to a branch conductor (that commences at
the connector). In order to prevent ingress of fluid into the conductor strands of
the branch cable, and also to prevent exposure of live bare conductors, it is typical
to provide a cap over the end of branch cables. Typically, as in FR 2 634 070, the
end cap is fixed to the connector and the end of the cable is inserted into the connector
until abutment against the end cap. Subsequently, the clamping halves are bolted together
for the contacts to pierce through the cable outer insulation and connect with the
inner conducting strands thereof. By positioning the end cap securely on the connector
prior to insertion of the cable into the end cap, an easy and secure means of assembling
live cables to the connector is provided, and once assembled the end cap cannot be
lost or removed. The cable however needs to be inserted in the cable direction between
the connector jaws and into the end cap. Powerline cables are fairly stiff, and therefore
providing enough slack in the end cable for insertion into the connector (particularly
if the connector is fitted along another cable to be tapped) requires a fairly long
section of end cable. The latter thus means, for example, that a larger hole is required
where the cable is buried, increasing the costs of installing and maintaining power
lines.
[0003] It is an object of this invention to provide a sealed clamping connector that is
secure and that reduces the need for slack in cables to be interconnected thereby.
[0004] It would be desirable to provide a secure and easy means of connecting insulated
cables to insulation piercing clamping connectors that is more versatile. In particular,
it would be advantageous to enable clamping of cables with different configurations,
without requiring a different connector for each configuration. For example, it would
be advantageous to provide a secure and reliable insulation piercing clamping connector
that enables two cable ends to be connected together, the cable ends protected from
the environment and preventing exposure of live bare conductor ends.
[0005] Objects of this invention have been achieved by providing the connector assembly
according to claim 1. Disclosed herein is an electrical connector assembly comprising
an electrical insulation piercing connector having a pair of clamping halves or jaws,
at least one of the jaws comprising at least one insulation piercing terminal having
insulation piercing contacts for piercing through an outer insulation layer of an
electrical cable and contacting inner conducting strands thereof, the assembly further
comprising an end sealing cap insertable over an end of the cable wherein the end
sealing cap is adapted to be received between the clamping halves or jaws such that
the insulation piercing contacts pierce through the end sealing cap during clamping
connection to the cable. Advantageously therefore, the end sealing cap can be pre-mounted
to the cable end which may be inserted laterally (i.e. approximately orthogonally
to the direction of the cable) between the clamping jaws. The jaws are subsequently
clamped tightly together whereby the insulation piercing contacts pierce through the
end sealing cap and insulation of the cable for contacting the inner contacting strands.
The seal is thus securely held to the connector when the cable is terminated, and
provides safe operation by pre-assembly to the cable end thereby covering exposed
conductors at the cut-off end of the cable, and further enabling the sealed cable
end to be inserted between the clamping halves of the connector from the side rather
than in the cable direction such that little cable slack is required.
[0006] The connector assembly may further comprise one or more pre-clamping retention members
mountable on at least one of the clamping halves, for retaining the end sealing cap
and end cable to the connector prior to termination of the cable to the connector.
The end sealing cap and cable end can thus be inserted between the jaws of the connector
and held by the one or more retention devices thereto prior to clamping the jaws together.
The connector assembly can thus be easily handled for example to position the other
side of the clamping halves over another cable, whilst ensuring correct positioning
of the cables in the connector for correct termination thereof. The retention member
and end sealing cap may be further provided with interengaging shoulders that co-operate
to locate and position the clamping jaw with respect to the end of the cable, thereby
ensuring correct positioning during termination. The retention members may be movably
mounted to the connector, for example slidable in a direction approximately perpendicular
to the cable direction and towards on of the clamping jaws. The retention member provisionally
clamps the cable one of the clamping jaws of the connector. Ratchet teeth may be provided
along one or more sides or edges of the retention member for co-operation with complementary
teeth in a guide portion attached to the clamping jaw for receiving and guiding the
retention member, the interengaging teeth serving to maintain the retention member
in the provisional clamping position.
[0007] The end sealing cap may be made of an elastomeric material with a substantially cylindrical
body defining a cavity adapted to snugly or elastically fit over a length of the cable
end greater than the length of the connector (with regards to the cable direction).
Two or more end sealing caps may be provided as a single moulding whereby the end
sealing caps are breakably interconnected together such that different cable diameters
can be accommodated. Prior to utilisation, the end caps may for example be removably
attached to the connector.
[0008] Further advantageous aspects of the invention are set forth in the claims, or will
be apparent from the following description and drawings.
[0009] An embodiment of this invention will now be described by way of example with reference
to the figures in which;
figure 1 is a plan end view of an insulation piercing connector assembly about to
receive an end-cable over which is mounted an end sealing cap;
figure 2 is a perspective view of the connector assembly of figure 1, with the end
cable inserted between clamping halves or jaws of the connector;
figure 3 is a perspective view of the assembly of figure 2 with pre-termination retention
members of the assembly moved to the retaining position holding the end cable to the
connector;
figure 4 is a plan end view of the assembly of figure 3;
figure 5 is a perspective view of different size end sealing caps moulded together.
[0010] Referring to the figures, a connector assembly 1 comprises an insulation piercing
contact (IPC) connector 2 for interconnecting a first through-cable or end-cable (not
shown) to an end-cable 6. The through-cable may for example be a main cable, off which
electrical power is tapped to a branch, tap, or distribution cable 6 (hereinafter
"end-cable"). Alternatively, the IPC connector may interconnect two end-cables thereby
acting as a splice. Both cables are comprised of inner conducting strands surrounded
by an outer insulating layer. The IPC connector 2 is provided with a pair of opposed
clamping halves 11, 13, each comprising insulation piercing contacts for piercing
through the cable outer insulation layers and contacting the inner conducting strands.
Such connectors are generally well known in the art, and may for example be provided
with clamping halves comprising an insulative housing and contacts according to EP
0 007 706, FR 2 634 070, or US 5,015,198. The clamping halves 11, 13 are clamped together
by means of a bolt 14 centrally positioned between cable receiving sides 5, 7 of the
connector. As insulation piercing connectors are well known in the art, the IPC connector
2 will not be described in further detail except for the features relating to the
improvements thereof.
[0011] The assembly further comprises an end sealing cap 8 mountable over the end of the
end-cable 6, and a pre-termination retention device 4 mounted on the connector 2 for
holding the end cable and cap to the connector prior to electrical termination, as
will be described in more detail further on. The end cap 8 can be made of an elastomeric
material such as a silicon based rubber, or a flexible plastic material that is injection
moulded, and comprises a substantially cylindrical cavity 16 extending therethrough
for snugly receiving the cable end 6 therein through a cable receiving or open end
18 until abutment with an opposed closed end 20 (see figures 2 and 5). Proximate the
open end 18 the cavity 16 may be provided with a plurality of circumferential sealing
ribs 22 for providing a water tight seal against the cable 6. For caps made from a
supple elastic material such as rubber, the inner diameter of the cylindrical cavity
16 may be slightly smaller than the outer diameter of the cable such that elastic
compression of the sealing ribs 22 against the cable provides a tight seal. The elasticity
of a rubber sealing cap also enables a single sealing cap to be utilised for cables
of slightly different diameters.
[0012] A plurality of end sealing caps 8, 8' as shown in figure 5, may be provided with
the connector assembly 1 for use with different cable sizes, whereby to provide an
economical connector assembly the different end sealing caps 8, 8' may be moulded
together such that they are integrally attached via bridging portions 24 and connected
to the bridging portions 24 via thin breakable portions 26 such that the desired end
cap may be broken off for use in the assembly, as shown for example in figure 2. The
sealing caps may be fixable provisionally to the connector by means of the hole 25
received in the stud 27 on the connector.
[0013] The end cap may also be made of a less resilient material such as a plastic, and
for example partially filled with a sealing gel or grease that prevents the ingress
of moisture by filling any hollow spaces within the cavity 16 when the cap is mounted
on the cable.
[0014] The end sealing cap is further provided with retaining walls 28, 29 proximate the
or open end 18 and closed end 20 respectively, the retaining walls 28, 29 in the form
of circular flanges defining retention shoulders 30, 31 extending radially from the
elongate cylindrical body portion 32 of the sealing cap. The retention shoulders 30,
31 are in this embodiment spaced apart by a distance (D) that is greater than the
length (L) of the IPC connector 2 (in the direction (C) of the cable 6) between opposed
end faces 34, 35 of the connector. The retaining walls 28, 29 thus serve to locate
and position the cable end assembled to the sealing cap 8 with respect to the connector,
and in particular with respect to the insulation piercing contact teeth 9 thereof.
[0015] Prior to termination the end sealing cap 8 is thus slipped over the end of the cable
8 until abutment of the severed end of the cable against the closed end 20 of the
sealing cap, and subsequently inserted between the clamping halves or jaws 11, 13
on one side (for example the second side 7 as shown in figure 2) of the connector
2. Insertion of the assembled sealing cap 8 and cable 6 is effected in a direction
approximately perpendicular to the cable direction (C) as indicated by the orthogonal
direction (T) shown in figure 1. Lateral insertion of the cable end 6 between the
jaws 11, 13 whilst ensuring effective sealing and enhanced operator safety, enables
the cable to be terminated in confined spaces where there is little available cable
slack (in comparison to conventional sealed IPC connections where the cable is inserted
in the cable direction (C) a sealing cap protruding beyond an end of the connector).
[0016] As the cable 6 needs to be interconnected to another cable that is received on the
first side 5 of the connector, it is advantageous to provisionally hold the connector
and cable end together prior to tightening the bolt 14, which is effected by the retention
members 4. Whilst two retention members are provided in the embodiment shown in figures
2-4, one retention member 4 mounted to one of the connector jaws 11 at either end
34, 35 respectively thereof may be provided. The retention member 4 comprises a retainer
plate 38 movably received through a guide 40 securely attached to a support 39 extending
from one of the clamping jaws 13 of the connector. In this embodiment, the support
39 and guide 40 are integrally formed with the housing of the lower clamping jaw 13.
The guide 40 has a cavity extending therethrough for guiding the retainer plate 38
in the direction of movement (V) thereof which is orthogonal to a plane formed by
the cable direction (C) and direction of insertion (T) of the cable end into the connector.
The retainer plate 38 is provided with a pair of flexible extensions 41 that extend
from an actuation end 42 to a retaining end 44 of the plate, the ends 42, 44 at opposed
ends of the retainer plate 38 with respect to the vertical direction (V) as viewed
with respect to figure 1. Each extension 41 is provided with a plurality of teeth
46 on an outer edge thereof that are co-operable with teeth on respective inner edges
of opposed sides of the guide 40 for retaining the retention plate 38 in the guide
40. In particular, the teeth 46 prevent the retaining plate 38 from being raised out
of the retaining position shown in figure 3, which is achieved y depressing the retainer
plate 38 (for example by manually pushing down the actuation end 42) until the opposed
oblique clamping surfaces 48 of the retention end 44 clamp the cylindrical body portion
32 against the lower clamping jaw 13. The elasticity of the extensions 41 enable the
retainer plate 38 to be depressed into the retaining position shown in figure 3 with
the teeth 46 engaging co-operating teeth in the guide 40 like a ratchet.
[0017] The retention end 44 of each retainer plate 38 engages the sealing cap body 32 adjacent
the respective retaining shoulders 30, 31 of the sealing cap in order to retain the
end cable 6 and sealing cap 8 securely to the connector, particularly in the cable
direction (C).
[0018] In view of the oblique (inwardly tapered and partially arcuate) surfaces 48 at the
retention end 44, the sealing cap body 32 is tightly clamped against the end cable
6 at the locations of the retaining plates 38, particularly since the cap is made
of a flexible material, thereby ensuring a secure grip of the end cable 6 to the assembly
prior to termination. The cable 6 and sealing body 32 are "wedged" between the pair
of resilient extensions 41.
[0019] It may be noted that the extensions 41 extend from the actuation end 42 substantially
as cantilever beams provided with hollow portions 50 to increase the flexibility thereof
whilst providing a robust extension with a sufficiently large clamping edge 48. The
assembled end cable and sealing cap provisionally retained to the connector in the
pre-termination position shown in figure 3, can thus be handled by an operator for
positioning another cable on the other side of the connector without concern about
the need to position two cables simultaneously. This also ensures that when the bolt
14 is tightened and the clamping halves are moved together, the cables are correctly
positioned between the insulation piercing contacts 9. The insulation piercing contact
teeth of the connector are provided with a sufficient height to penetrate through
the body 32 of the sealing cap and subsequently through the insulation of the cable
for contacting the inner conductor core of the cable. As the body 32 of the sealing
cap may be of a relatively thin compressible material, the insulation piercing teeth
of standard connectors typically have a sufficient depth for piercing through the
seal cap and insulating layer of the cable.
1. An electrical connector assembly (1) comprising an electrical insulation piercing
connector (2) having a pair of clamping halves or jaws (11, 13), at least one of the
jaws comprising at least one insulation piercing terminal having insulation piercing
contacts (9) for piercing through an outer insulation layer of an electrical cable
(6) and contacting inner conducting strands thereof, the assembly further comprising
an end sealing cap (8) insertable over an end of the cable (6), wherein the end sealing
cap (8) is adapted to be received in a direction transverse (T) to a direction (C)
of the cable between the clamping halves (11, 13) such that the insulation piercing
contacts (9) pierce through the end sealing cap (8) during connection to the cable.
2. The assembly of claim 1 wherein end sealing cap (8) is provided with at least one
retaining wall (28, 29) for locating the end sealing cap with respect to the connector
(2) in the cable direction (C).
3. The assembly of claim 2 wherein the sealing cap comprises at least a pair of said
retaining walls (28, 29) separated by a distance (D) for positioning proximate or
adjacent respective opposed ends (34, 35) of the connector with regards to the cable
direction (C).
4. The assembly of claim 2 or 3 wherein the sealing cap retaining walls (28,29) are in
the shape of discs extending radially from a cylindrical body portion (32) of the
sealing cap, thereby defining opposed retention shoulders (30, 31) respectively.
5. The assembly of any one of the preceding claims wherein the assembly comprises a retention
member (4) comprising a guide (40) securely fixed to one of the clamping jaws (13)
and receiving a retaining plate (38) that is movable from a cable receiving position
where the sealing cap (8) and end cable (6) can be inserted between the jaws (11,
13) of the connector to a retaining position where the cable and sealing cap are retained
and positioned against said one of the clamping jaws (13) prior to termination of
the connector.
6. The assembly of the preceding claim wherein the retaining plate (13) comprises at
least one flexible extension (41) having teeth (46) along an outer edge thereof co-operable
with complementary teeth in the retaining guide (40) for holding the retaining plate
(38) in the cable receiving and retaining positions respectively.
7. The assembly of any one of the preceding claims wherein the connector comprises a
pair of retention members (4) positioned respectively adjacent opposed ends (34,35)
of the connector with regards to the cable direction (C).
8. The assembly of any one of the preceding claims wherein a plurality of end sealing
caps (8, 8') for receiving cables of different diameters are integrally moulded together
via break away bridging portions (24).