Loadbreak connector assembly which prevents switching flashover

A method for forming a loadbreak bushing insert comprising the steps of:

• forming an insulative housing having an axial bore therethrough, the housing including a first end section being dimensioned to be sealed in a bushing well, a second end section being dimensioned for insertion into a power cable elbow connector and a mid-section being radially larger than the first and second end sections;
• molding an interface shell from a low coefficient of friction plastic, the shell having a sleeve portion being dimensioned to be fitted over at least a substantial portion of the second end section of the housing;
• and
• bonding the interface shell over at least a substantial portion of the second end section of the housing.

A loadbreak bushing insert comprising:

• an insulative housing having an axial bore therethrough, the housing including a first end section being dimensioned to be sealed in a bushing well, a second end section being dimensioned for insertion into a power cable elbow connector and a mid-section being radially larger than the first and second end sections;
• a conductive member positioned within the axial bore of the housing;
• and
• an interface shell molded from a low coefficient of friction plastic and having a band portion provided on the mid-section, adjacent the second end section, of the housing and a sleeve portion provided on at least a substantial portion of the second end section of the housing for reducing frictional forces between the loadbreak bushing insert and a power cable elbow connector upon connection and disconnection therebetween, the band portion including a vent, whereby upon disconnection of a power cable elbow connector from the loadbreak bushing insert, a cavity is formed therebetween, said cavity being exposed to ambient air pressure via said vent thereby substantially preventing formation of a vacuum within said cavity.

In combination:

• a power cable elbow connector including a conductor receiving end and a loadbreak bushing insert receiving end, the elbow connector further including a conductive member extending from the cable receiving end to the bushing insert receiving end, the bushing insert receiving end including an open end portion having an elbow cuff therearound;
• a loadbreak bushing insert comprising:
• an insulative housing having an axial bore therethrough, the housing including a first end section being dimensioned to be sealed in a bushing well, a second end section being dimensioned for insertion into said open end portion of said bushing insert receiving end of said power cable elbow connector and a mid-section being radially larger than the first and second end sections;
• a conductive member positioned within the axial bore of the housing;
• and an interface shell molded from a low coefficient of friction plastic and having a sleeve portion provided on at least a substantial portion of the second end section of the housing for reducing frictional forces between the loadbreak bushing insert and the power cable elbow connector upon connection and disconnection therebetween;
• and
• a loadbreak bushing well including a well housing having an interior surface defining an open chamber for receiving therein the first end section of the loadbreak bushing insert.

An electrical connector assembly comprising:

• an insulative housing having an axial bore therethrough, the housing including a first end section being dimensioned to be sealed in a first mating connector, a second end section being dimensioned for insertion into a second mating connector and a mid-section being radially larger than the first and second end sections;
• a conductive member positioned within the axial bore of the housing;
• and
• an interface shell molded from a low coefficient of friction plastic and having a sleeve portion provided on at least a substantial portion of at least one of the first and second end sections of the housing for reducing frictional forces between the electrical connector assembly and at least one of the first and second mating connectors upon connection and disconnection therebetween.

A method for forming a separable electrical connector comprising the steps of:

• forming a first insulative housing;
• forming a second insulative housing having an axial bore therethrough, the second housing including a first end section being dimensioned for insertion into said first insulative housing;
• separately molding an interface shell from a low coefficient of friction plastic, the shell having a sleeve portion being dimensioned to be fitted over at least a substantial portion of the first end section of the housing;
• and
• bonding the interface shell over at least a substantial portion of the first end section of the housing.