Two-material separable insulated connector

• US 8,109,776 B2
• Filed: 02/27/2008
• Issued: 02/07/2012
• Est. Priority Date: 02/27/2008
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Hughes, David Charles, Augustia, Thomas, Makal, John Mitchell, Gebhard, Michael John Sr.
• Primary Examiner(s): LE, THANH TAM T
• Application Number:
  US12/072,647
• Publication Number:
  US 20090215299A1
• Time in Patent Office: 1,441 Days
• Field of Search: 439/181, 439/445, 439/921, 439/89, 439/281, 439/282, 174/84.R, 174/DIG.8
• US Class Current: 439/282
• CPC Class Codes: B29C 45/1676 using a soft material and a rigid material, e.g. making articles with a sealing part
• CPC Class Codes: B29K 2023/16 EPM, i.e. ethylene-propylene copolymers; EPDM, i.e. ethylene-propylene-diene copolymers; EPT, i.e. ethylene-propylene terpolymers
• CPC Class Codes: B29L 2031/36 Plugs, connectors, or parts thereof
• CPC Class Codes: H01R 13/46 Bases; Cases
• CPC Class Codes: H01R 13/504 different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
• 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 43/18 for manufacturing bases or cases for contact members
• CPC Class Codes: Y10S 439/921 Transformer bushing type or high voltage underground connector
• CPC Class Codes: Y10T 29/49002 Electrical device making

Abstract

Stiff and soft materials each provide certain advantages when used in the manufacture of separable insulated connectors, such as elbow and T-body connectors. Utilizing a shell or an insert that includes one section made from a stiff material and one section made from a soft material can provide a separable insulated connector that capitalizes on the advantages associated with both types of materials. The stiff materials and soft materials can be placed strategically on the shell or insert of the separable insulated connector to maximize the advantages of each material. For example, the stiff material can be used to form a section of the separable insulated connector where strength and durability is most desirable, and conversely, the soft material can be used to form a section of the connector where flexibility is desirable.

Claims

1. A separable insulated connector, comprising:

an external shell for grounding said connector, wherein said shell comprises at least one of a conductive material and a semi-conductive material, wherein said shell comprises

a first portion comprising a first material,

a bushing entrance for connection to an energy distribution component, the bushing entrance comprising at least a part of said first portion,

a second portion comprising a second material that is more flexible than said first material, and

a cable entrance for receiving a cable, the cable entrance comprising at least a part of said second portion;

an insert disposed within said external shell, wherein said insert comprises at least one of a conductive material and a semi-conductive material, wherein said insert is a faraday cage; and

insulating material directly disposed between said external shell and said insert such that an interior surface of the external shell covers substantially an entire outer surface of the insulating material, wherein said insulating material is non-conductive, wherein said insulating material prevents a voltage breakdown between said shell and said insert.

2. The separable insulated connector of claim 1, wherein said first material comprises a mixture comprising ethylene propylene dienemonomer rubber and carbon black, and

wherein said second material comprises a mixture comprising ethylene propylene dienemonomer rubber and carbon black.

3. The separable insulated connector of claim 1, wherein said separable insulated connector comprises an elbow connector.

4. The shell of claim 1, wherein said separable insulated connector comprises a T-body connector.

5. The separable insulated connector of claim 1, wherein said first portion abuts said second portion.

6. The separable insulated connector of claim 1, wherein said first portion overlaps with said second portion.

7. The separable insulated connector of claim 1, wherein said first material has a tensile stress measurement from about 1% to about 15% higher than a tensile stress measurement of said second material.

8. The separable insulated connector of claim 1, wherein said first material has an elongation measurement from about 1% to about 40% lower than an elongation measurement of said second material.

9. The separable insulated connector of claim 1, wherein said first material has a durometer measurement from about 5% to about 25% higher than a durometer measurement of said second material.

10. The separable insulated connector of claim 1, wherein said first material has a modulus measurement from about 10% to about 60% higher than a modulus measurement of said second material at a 50%, 75%, and 100% elongation percentage.

11. A separable insulated connector, comprising:

an external shell for grounding said connector, wherein said shell comprises at least one of a conductive material and a semi-conductive material;

a single insert disposed within said external shell, wherein said insert comprises

a first portion comprising a first semi-conductive material, and

a second portion comprising a second semi-conductive material that is more flexible than said first material, wherein said insert is a faraday cage; and

insulating material directly disposed between said external shell and said insert, wherein said insulating material is non-conductive, wherein said insulating material prevents a voltage breakdown between said shell and said insert.

12. The separable insulated connector of claim 11, wherein said first material comprises a mixture comprising ethylene propylene dienemonomer rubber and carbon black,

wherein said second material comprises a mixture comprising ethylene propylene dienemonomer rubber and carbon black, and

wherein said semi-conductive insert comprises a conductive or semi-conductive material.

13. The separable insulated connector of claim 11, wherein said semi-conductive insert is configured to be inserted within a shell for said separable insulated connector.

14. The separable insulated connector of claim 11, wherein said separable insulated connector comprises an elbow connector.

15. The semi-conductive insert of claim 11, wherein said separable insulated connector comprises a T-body connector.

16. The separable insulated connector of claim 11, wherein said semi-conductive insert comprises a faraday cage.

17. A separable insulated connector, comprising:

an external shell for grounding said connector, wherein said shell comprises at least one of a conductive material and a semi-conductive material;

a semi-conductive insert disposed within said external shell, wherein said semi-conductive insert is a faraday cage; and

insulating material directly disposed between said external shell and said semi-conductive insert such that an interior surface of the external shell covers substantially an entire outer surface of the insulating material, wherein said insulating material is non-conductive, wherein said insulating material prevents a voltage breakdown between said shell and said insert,

wherein at least one of said external shell, said semi-conductive insert, and said insulating material comprises a first portion, a bushing entrance for connection to an energy distribution component, the bushing entrance comprising at least a part of said first portion, a second portion, and a cable entrance for receiving a cable, the cable entrance comprising at least a part of said second portion,

wherein said first portion comprises a first material, and

wherein said second portion comprises a second material that is more flexible than said first material.

18. The separable insulated connector of claim 17, wherein said insulating material comprises ethylene propylene dienemonomer rubber.

19. The separable insulated connector of claim 17, wherein said insulating material is bonded to said shell and said insert.

20. The separable insulated connector of claim 17, wherein said first material comprises a mixture comprising ethylene propylene dienemonomer rubber and carbon black,

wherein said second material comprises a mixture comprising ethylene propylene dienemonomer rubber and carbon black, and

wherein said insert comprises a semi-conductive material.

21. The separable insulated connector of claim 17, wherein said separable insulated connector comprises an elbow connector.

22. The separable insulated connector of claim 17, wherein said separable insulated connector comprises a T-body connector.

23. The separable insulated connector of claim 17, further comprising:

a cable adapter; and

a probe;

wherein said cable adapter is located in said second portion, and

wherein said probe is located in said first portion.