Compression formed connector for a composite conductor assembly used in transmission line installations and method of constructing the same

#The present invention relates generally to compression dead-end and compression joint connector assemblies. More particularly, the present invention discloses a compression connection assembly for use in both dead-end and mid-joint conductors, such as are further typically employed in transmission line installations, as well as a method for constructing such a connection assembly.

#Connector assemblies are generally known in the art and such as is are particularly used with high current transfer (power) cables utilized in conventional transmission line applications. Such conductor lines typically incorporate outer layers of such as high temperature aluminum strands, as well as inner layers or “core” of such as aluminum matrix composite wires. It is also known that this conductor core exhibits fairly significant longitudinal strength, on the order of 240 kips per square inch (ksi) while that the same time having limited (typically on the order of 20 ksi) transverse strength properties.

#In application, it is desirable to communicate the extending end of a given length of power cable, in both an insulated and effective current conducting fashion and such as to a succeeding and interconnecting length of cable. Alternatively, another conventionally known connection for such a current transfer line is to an insulator string associated with an overhead tower or transmission support structure and such as is conventionally known as a “dead-end” connection.

#FIG. 1 is a perspective illustration in partially exploded fashion of a compression dead end connector according to a first preferred embodiment of the present invention and which illustrates the steel tube with end attachable steel eye forging, as well as the aluminum insert for inserting into an opposite end of the steel tube;

#FIG. 2 is a succeeding perspective view according to the embodiment of FIG. 1, in which the aluminum sleeve is arrayed in end inserted fashion within the steel tube, and further illustrating in partially exploded fashion the manner of insertion of the transmission cable with both outer wire strands and inner composite core;

#FIG. 3 is a further succeeding perspective view, again in partially exploded fashion, and illustrating the axial end insertion of the assembled connector within an outer tubular body associated with the dead end connection;

#Referring now to the various figure illustrations, a compression connection assembly is illustrated for use in both dead-end and mid-joint conductors. As previously described, such joint and dead-end connections are further typically employed in transmission line installations and are particularly suited for use with composite conductors assemblies. As will also be described, the present invention additionally discloses a method for constructing such a connection assembly.

#Referring to FIGS. 1-3 and 7, a series of illustrations are shown of a compression dead end connector according to a first preferred embodiment 10 (see in particular completed assemblies in FIGS. 3 and 7) of the present invention. An elongated and interiorly hollow tube 12 is provided, the tube having a first end 14 and a second end 16 and a desired polygonal (hexagonal, circular, etc.) cross sectional shape. The tube 12 in the preferred embodiment is constructed of a suitable carbon steel material, however further may be constructed of any metallic and conductive material having specified rates of ductility and extrusion.

#The steel tube 12 according to the first preferred embodiment is configured for particular application to a dead-end connection, specifically such as which connects to an overhead tower or pole. The tube 12 includes such particular features as a selected interior diameter 18 (see cutaway portion in FIG. 1) and a plurality of spaced apart and accordion-like corrugations 20 extending along a selected axial length of the tube 12. Yet additional features include a heavy duty eyelet 22, such as a steel eye forging, integrally formed with and extending from the tube second end 16, as well as a felt washer 24 slidably engaged over the tube and inter-disposed between the spaced apart corrugations 20.