Method of manufacturing a dual interface separable insulated connector with overmolded faraday cage

• US 8,056,226 B2
• Filed: 02/25/2008
• Issued: 11/15/2011
• Est. Priority Date: 02/25/2008
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Kadow, Mark Clifford, Gebhard, Michael John Sr., Hughes, David Charles
• Primary Examiner(s): Banks; Derris H
• Assistant Examiner(s): Kue; Kaying
• Application Number:
  US12/072,193
• Publication Number:
  US 20090211089A1
• Time in Patent Office: 1,359 Days
• Field of Search: 439/89, 439/511, 439/921, 439/181, 439/606, 439183-185, 439/137, 439/148, 439/604, 439/736, 29883-884, 264/272.12
• US Class Current: 29/883
• CPC Class Codes: H01R 11/18 End pieces terminating in a probe
• CPC Class Codes: H01R 13/53 Bases or cases for heavy duty; Bases or cases for high voltage with means for preventing corona or arcing
• CPC Class Codes: H01R 31/08 Short-circuiting members for bridging contacts in a counterpart
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: Y10T 29/49211 of fused material
• CPC Class Codes: Y10T 29/49217 by elastic joining
• CPC Class Codes: Y10T 29/4922 with molding of insulation

Abstract

A dual interface separable insulated connector comprising a faraday cage molded over a bus bar for use in an electric power system and a method of manufacturing the same are provided. The faraday cage can be disposed within a semi-conductive shell. The configuration of the separable insulated connector can provide for easier bonding between the faraday cage and insulating material. Additionally, the configuration can eliminate or reduce the need to coat the bus bar with an adhesive agent and to smooth the metal bus bar to remove burrs, other irregularities, and sharp corners from the bar. Manufacturing the dual interface separable insulated connector can include molding a semi-conductive rubber faraday cage over a conductive bus bar, inserting the faraday cage into a shell, and injecting insulating material between the faraday cage and shell.

Claims

1. A method of manufacturing a separable insulated connector, comprising the steps of:

manufacturing a faraday cage with a conductive bus bar disposed therein;

injecting a first rubber in a liquid state into a first mold for a shell of the dual interface separable insulated connector;

curing the first rubber;

inserting the faraday cage into the shell;

injecting a first insulating material in a liquid state into the shell; and

curing the first insulating material,

wherein the first rubber comprises semi-conductive rubber.

2. The method of claim 1, wherein the step of manufacturing a faraday cage with a conductive bus bar disposed therein comprises the steps of:

coupling a first set of mandrels to the conductive bus bar;

placing the conductive bus bar in a second mold for the faraday cage;

injecting a second rubber in a liquid state into the second mold such that the second rubber surrounds the conductive bus bar and at least a portion of the mandrels; and

curing the second rubber, thereby forming a faraday cage,

wherein the second rubber comprises semi-conductive rubber.

3. The method of claim 2, further comprising the steps of:

removing the faraday cage from the second mold;

replacing the first set of mandrels with a second set of mandrels after the rubber has been cured;

placing the faraday cage in a third mold;

injecting a second insulating material in a liquid state into the third mold; and

curing the second insulating material.

4. The method of claim 3, further comprising the steps of:

removing the faraday cage from the third mold after the second insulating material has been cured;

removing the second set of mandrels; and

coupling a third set of mandrels to the conductive bus bar.

5. The method of claim 2, wherein the first rubber comprises semi-conductive rubber,

wherein the second rubber comprises semi-conductive rubber, and

wherein the first insulating material comprises rubber.

6. The method of claim 1, wherein the step of inserting the faraday cage into the shell comprises the steps of:

making an incision in the shell to create an opening in the shell;

inserting the faraday cage through the opening; and

sealing the opening.

7. The method of claim 1, wherein the first mold is configured such that the shell comprises two pieces after the first rubber has been cured, and

wherein the step of inserting the faraday cage into the shell comprises the steps of inserting the faraday cage into the two pieces of the shell and bonding the two pieces together, thereby enclosing the faraday cage within the shell.

8. The method of claim 1, further comprising the steps of:

manufacturing at least one insulating sleeve; and

attaching the at least one insulating sleeve to the shell.

9. The method of claim 8, wherein the at least one insulating sleeve comprises rubber.

10. The method of claim 1, wherein the first mold comprises a pulling eye section, and

wherein the pulling eye section has a shape of a pulling eye.

11. The method of claim 10, further comprising placing an insert in the pulling eye section prior to injecting the first rubber in a liquid state into the first mold.

12. The method of claim 1, wherein the step of injecting a first insulating material in a liquid state into the shell comprises the steps of:

opening an injection port on the shell;

injecting the first insulating material through the injection port; and

closing the injection port.