WO2000001035A2

WO2000001035A2 - Electrical cable connector and insert therefor

Info

Publication number: WO2000001035A2
Application number: PCT/US1999/014694
Authority: WO
Inventors: Albert Renaud Perrin; Roland Sion Timsit; Yue Jin Tan
Original assignee: The Whitaker Corporation
Priority date: 1998-06-30
Filing date: 1999-06-30
Publication date: 2000-01-06
Also published as: WO2000001035A3

Abstract

An electrical connector for electrically connecting a source wire and a tap wire. The invention relates to an electrical connector including a non-electrically conductive outer member, a non-electrically conductive inner member, and an electrically conductive insert that provides an electrical connection path between the wires. The outer member has a first inner recess that houses the tap wire and an opposing second inner recess that houses the source wire. The electrically conductive member is inserted between the tap wire and the source wire whereby the electrically conductive member provides an electrical connection between the source wire and the tap wire. The inner member is inserted or wedged within the outer member between portions of the electrically conductive insert contacting the tap wire and the source wire. The invention also provides embodiment for electrically connecting the source and tap wires which comprise insulated and uninsulated conductors.

Description

ELECTRICAL CABLE CONNECTOR AND INSERT THEREFOR

Background of the Invention

The present invention relates to an electrical connector for electrically connecting together a source wire and a tap wire. More specifically, the invention relates to an electrical connector including an outer member, an inner member, and a conductive insert that provides an electrical path between the connected wires. During the installation and maintenance of electrical distribution systems, such as those formed from distribution transformers or substations, it is necessary to connect respective pairs of lead wires. In order to construct a practicable electrical distribution system, it is further necessary to maintain solid mechanical retention of the wires, as well as a good electrical connection therebetween, despite typical electrical loading cycles that occur frequently in many operating conditions.

Conventional electrical cable connectors include a generally C-shaped member for electrically connecting lead wires with a wedge member, for example

U.S. Patent Number 5,567,186, issued on October 22, 1996, to Diniz et al. Typically, the C-shaped members are made by extruding a conductive material and blanking thereof followed by press forming and heat treating.

Manufacturing steps are necessary with a conductive material such as aluminum, a copper alloy, or a composite material in order to obtain the necessary material properties, such as strength, ductility and acceptably high electrical conductivity.

Similar manufacturing methods may also be necessary in order to produce the wedge members of these electrical connectors that are often made by casting.

These manufacturing processes are expensive, yet they are necessary in order to produce an electrical connector having a C-shape and wedge members.

Consequently, there exists a need for an electrical connector that is relatively inexpensive to produce. Electrical connectors having an electrically conductive piercing serrations, sometimes referred to herein as piercing members, penetrating means or means for piercing, for piercing the electrical insulation of electrical cables having an electrically conductive core therein so as to establish an electrical connection between conductors of different electrical cables are known and one such electrical connector is disclosed in U.S. Patent 5,842,893 ('893) issued December 1, 1998. The electrical connector of the '893 patent comprises a C-shaped receiver element, an intermediate member having opposed sections with piercing members running along opposed outwardly facing surfaces, and a wedge member that has dimensions so as to be inserted between the opposed sections and in so doing, forcing the piercing members through electrical insulation and into the cores of the different cables being electrical connected by the electrical connector of the '893 patent. It is desired that a more simplified electrical connector be provided, especially with regard to the piercing serration, and the method of manufacture thereof. It is further desired that the simplified electrical connector have features that render it more versatile. Further, it is desired to provide an electrical connector that accommodates both insulated and uninsulated cables.

Summary of the Invention

The present invention provides a novel electrical connector designed to satisfy the aforementioned needs. The invention embodies an electrical connector having an electrically conductive insert that provides an electrical connection path between a source wire and a tap wire. The conductive member is inserted within an outer, generally C-shaped, member between the source wire and the tap wire and an inner member is inserted within the conductive member. In this configuration the conductive member is responsible for electrically connecting the source and tap wires together, while the outer and inner members are responsible for providing the structual resistance to keep the combination together.

Accordingly, a benefit of the present invention is that the various functions of the electrical connector are divided among discrete components, allowing each component to be optimized for its particular function. More specifically, the conductive insert may be formed of a highly conductive material without consideration to its strength and expense since only a small amount of material is used in a non-structural capacity. The outer member may be formed of an inexpensive material with adequate strength to resist the expansive forces applied by the inner member, but without regard to conductivity. The inner member, likewise, need not be conductive but merely capable of withstanding the forces of being wedged within the outer member. By eliminating the need for constructing the outer member and the inner member from weaker materials, these components can be thinner thereby avoiding the need to be press-formed and/or heat treated to provide structure stability so as to prevent failure. This allows the outer and inner members to be constructed using inexpensive construction methods and inexpensive materials.

In a preferred embodiment, the electrical connector comprises an outer member preferably having a generally C-shaped configuration, an inner member, and an electrically conductive insert that provide an electrical connection path between the source and tap wires. The outer member has a first inner recess that houses the tap wire and an opposing second inner recess that houses the source wire. The electrically conductive member is inserted between the tap wire and the source wire, whereby the conductive member provides an electrical connection between the source wire and the tap wire. The inner member is inserted or wedged within the outer member, whereby a first portion of the electrically conductive member is positioned between the inner member and the tap wire, and a second portion of the electrically conductive member is positioned between the inner member and the source wire. Preferably, the electrically conductive member includes a U-shaped, or C- shaped, portion located between the first portion and the second portion thereof. In this embodiment, the U-shaped, or C-shaped, portion of the conductive member may be compressed as the electrically conductive member is being inserted whereby the first portion and the second portion thereof are moved toward each other, thereby, facilitating the insertion of the electrically conductive member between the source wire and the tap wire. In other embodiments, the electrically conductive member has a fiat portion extending between the first portion and the second portion thereof. In this embodiment, the conductive member is snapped or locked into position on the inner member, and the resulting assembly may be inserted within the outer member. The electrically conductive member can be configured in a variety of different sizes and shapes using a variety of different manufacturing processes.

In other embodiments, electrical connector assemblies are provided for electrical connection between insulated and uninsulated conductors and do so with an implementation of at least one piercing serration. In one such embodiment, at least one piercing serration is provided on both the electrically conductive member and on the outer member, and in another embodiment at least one piercing serration is provided on each of opposing surfaces on one side of the electrically conductive member.

The electrical connector assembly of the present invention, in still another embodiment, provides for electrical connection between insulated conductors and does so with an implementation of a one-piece piercing member that is easily fabricated and yet provides a piercing function by cutting through the insulation of electrical conductors and establishing electrical connection therebetween. In another embodiment, an electrical connector assembly is provided for electrical connection between insulated and uninsulated conductors and does so with an implementation of a one-piece piercing member having piercing serrations on only one of its sides and that is easily fabricated.

The invention itself, together with further objects and advantages, may be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.

Brief Description of the Drawings

Figure 1 is a perspective view of an electrical connector according to the present invention depicting a source wire, a tap wire, an outer member, a conductive insert, and an inner member. Figure 2A is a cross-sectional end view of an outer member with a source wire and a tap wire inserted therein according to the present invention.

Figure 2B is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein according to the present invention and depicting a conductive insert being inserted between the wires. Figure 2C is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein and a conductive member inserted between the wires according to the present invention.

Figure 2D is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein, a conductive member inserted between the wires, and an inner member inserted therein according to the present invention.

Figure 3 is a schematic view of an assembled electrical connector according to the present invention depicting an electrical current flow path between a source wire and a tap wire.

Figure 4 is a cross-sectional end view of an outer member with a source wire and tap wire inserted therein, an alternative embodiment of a conductive member inserted between the wires, and an inner member inserted therein according to the present invention.

Figure 5 A is a cross-sectional end view of an inner member inserted within a conductive member thereby forming an assemblage according to a second embodiment of the present invention.

Figure 5B is a cross-sectional end view of an outer member with a source wire and a tap wire inserted therein according to a second embodiment of the present invention.

Figure 5C is a cross-sectional end view of an assemblage, including an inner member inserted within a conductive member, inserted within an outer member with a source wire and tap wire inserted therein according to a second embodiment of the present invention.

Figure 6 is a side view of an alternative embodiment of an inner member according to the present invention. Figure 7 is a perspective view of an alternative embodiment of a conductive member according to the present invention. Figure 8 is similar to Figure 1 except that the embodiment shown therein has piercing serrations to establish electrical connection between insulated and uninsulated conductors.

Figure 9 is similar to Figure 3 except that the embodiment shown therein is for the electrical connector of Figure 8.

Figure 10 is similar to Figure 8 except that the embodiment shown therein only has piercing serrations on the electrically conductive member for establishing electrical connection between insulated and uninsulated conductors.

Figure 11 is similar to Figure 4 except that the embodiment shown therein is for the electrical connector of Figure 10.

Fig. 12 is an exploded isometric view of the electrical connector assembly of the present invention;

Fig. 13 illustrates the receptacle member of Fig. 12partially cut away so as to illustrate piercing members thereof. Figs. 14(A) and 14(B) each illustrate a different embodiment of the receptacle element of Fig. 12 operatively cooperating with the tapered element and intermediate member for preferentially directing current flow between the cables and rigidly fixing the electrical connection of the cables.

Fig. 15 is an enlarged view of the intermediate member mated with the tapered member of the connector assembly of Fig. 1, as well as that of Fig. 6. Figs. 16(A), 16(B), 16(C), 16(D) and 16(E) illustrate sequential steps related to the practice of the present invention.

Figures 1 through 16 are presented by way of illustration and not limitation to depict the preferred embodiments of the present invention. Embodiments including the various aspects of the present invention will now be described in detail with reference to the accompanying drawings.

Detailed Description of the Preferred Embodiments

As depicted in Figure 1, the electrical connector 10 of the present invention for electrically connecting a tap wire 12 and a source wire 14 includes an outer member 20, an electrically conductive insert 30, and an inner member 50. The electrically conductive insert 30 provides an electrical connection path, identified by the letter C in Figure 3 to be described, between the tap wire 12 and the source wire 14.

Referring to Figures 1 and 2A, an embodiment of the outer member 20 has a generally C-shape configuration with a first inner recess 22, an opposing second inner recess 24, and a cavity 26 therebetween. The tap wire 12 is inserted within the first inner recess 22 and the source wire 14 is inserted within the second inner recess 24.

Since the outer member's conductivity is no longer a consideration, it may be formed of a stronger, less expensive material, thereby allowing less material to be used. In a preferred embodiment, the outer member is formed of a material having a Young's Modulus greater than that of the material of the conductive insert. More preferably, the material of the outer member 20 has a Young's Modulus no less than about 10,000,000 psi, even more, preferably, no less than about 20,000,000 psi, and, still even more preferably, no less than about 30,000,000 psi.

Suitable materials include, for example, various steels (both carbon and stainless steel), cast iron, ceramic materials, polymeric materials, and composites. As used herein, the term "ceramic" refers to oxides, nitrides, carbides, borides and suicides of metals or semi-metals and combinations thereof, and includes, for example, silicon carbide, aluminum nitride, silicon nitride, aluminum oxide, tin oxide, titanium carbide, iron suicide, hafnium oxide and zirconium oxide, titanium oxide and dioxide, molybdenum disilicide, lithium aluminate, and ferrites. Polymeric materials include, for example, plastics, such as ABS, phenol- plastics, vinyl-plastics, and other polymers such as high-density polypropylenes, polyurethanes, and epoxies. Composites refer to polymeric materials in combination with other materials such as fiberglass and graphite. More preferably, the outer member is formed from steels such as plated/coated mild (known in the art) or stainless steel, or other similar materials which do not require complex forming or heat treating operations. The outer member 20 can be constructed by bending opposing free ends of the sheet of steel to form the first and second inner recesses, 22 and 24. The thickness of the sheet of steel used to form the outer member 20 can be less than that of an outer member 20 made of an aluminum alloy or a copper alloy. The thickness of the sheet of steel used to form outer member 20 should be as small as possible so as to reduce the amount thereof, and therefore the cost of materials used, and yet large enough to prevent cracking of the outer member 20 when it is fabricated, and later on when it is operationally forced into high pressure contact with the tap and source wires 12 and 14 respectively. The material used to form outer member 20 should also be strong and ductile enough to withstand the application of large bending and tensile forces without cracking or failing, and to ensure acceptable spring-back when used in an electrical connector contemplated by the practice of this invention.

The conductive member 30 is depicted in Figures 1, 2B, and 2C. In a preferred embodiment, the conductive member is formed of a material having a lower electrical resistence than said first material. More preferrably, the material has an electrical resistence less than about 10 microhm-cm, and even more preferably, less than about 5 microhm-cm. Suitable materials include, for example, copper, a copper alloy, aluminum, an aluminum alloy, and a bimetallic aluminum-copper material.

The conductive member 30 includes a first portion 32, a second portion 34, and a portion 36 between the first portion 32 and the second portion 34. The conductive member 30 also has bent portions 38 and 40 shown in Figure 2B. When the conductive member 30 is inserted within a cavity 26 of the outer member 20, as depicted in Figure 2C, the conductive member 30 has a cavity 42 (also shown in Figure 1) between the first portion 32 and the second portion 34. The first portion 32 includes a contact surface 33 that is generally arcuate in shape and is configured to abut and rest generally adjacent to the tap wire 12. The second portion 34 includes a contact surface 35 that is generally arcuate in shape and is configured to abut and rest generally adjacent to the source wire 14. Alternatively, the contact surfaces 33 and 35 may be configured using a variety of different shapes.

In one embodiment, portion 36 protrudes beyond the outer member 20 and is generally U-shaped, or C-shaped, as depicted in Figures 1-4. However, the present invention contemplates other protruding shapes, such as other arcuate shapes, and V-shapes that are able to perform a similar function as described below. The portion 36 is preferably configured such that when a force F is applied thereto, the first portion 32 moves toward the second portion 34 to facilitate the insertion of the conductive member 30 between the tap wire 12 and the source wire 14, one embodiment of which is depicted in Figure 2B. In the embodiment depicted in Figure 2B, the force F is applied in opposite directions to opposing bends, 38 and 40, of the portion 36. The electrically conductive member 30 of the present invention is made of a conductive material, such as copper, a copper alloy, aluminum, an aluminum alloy, a bimetallic aluminum-copper material, or other conductive material, for example, currently experimental conductive polymers. One method of manufacturing the electrically conductive member 30 is by stamping the conductive member 30 from a sheet of electrically conductive material and bending the resulting stamped piece of material to form the electrically conductive member 30. The conductive member 30 should have a thickness great enough to accommodate the full power range experienced by electrical connectors contemplated by the present invention. The conductive member 30 should also be configured and made of a material capable of withstanding bending of the portion 36 during insertion of the electrically conductive member 30 between the tap wire 12 and the source wire 14. The contact surfaces, 33 and 35, of the conductive member 30 provide an electrical connection between the tap wire 12 and the source wire 14. The conductive member 30 still provides a proper conductive path even when inserted in an inverted position.

The inner member 50 depicted in Figures 1 and 2D may be formed of the same material of the outer member since strength and expense are primary concerns over conductivity. As depicted in Figures 1 and 2D, an inner member 50 is preferably slightly tapered for ease of insertion within the cavity 42 of the electrically conductive member 30, although a taper is not essential to proper operation of the present invention. A leading end 52 (best seen in Figure 1) of the inner member 50 that enters the cavity 42 first is narrower than trailing end 54 of the inner member 50. Opposing sides, 56 and 58, of the inner member 50 are shaped to abut the first portion 32 and the second portion 34, respectively, of the conductive member 30. The inner member 50 is dimensioned so as to fit snugly within the cavity 42 (best seen in Figure 2D) of the conductive member 30 such that the first portion 32 and the second portion 34, more particularly surfaces 33 and 35 respectively, of the conductive member 30 are pressed against the tap wire 12 and the source wire 14, respectively, thereby causing a good electrical interconnection to be made therebetween. As discussed above, for the outer member 20, a benefit of the present invention is that it allows the inner member 50 to be constructed using a variety of different methods and a variety of different materials, such as aluminum, aluminum alloys, copper, copper alloys, brass, plated/coated mild or stainless steel, other types of steel, a bimetallic material, plastics, ceramics, polymers, or other similar materials. This allows the inner member 50 to be constructed using inexpensive construction methods and inexpensive materials. The inner member 50 can be constructed of non-electrically conductive materials having poor electrical conductivity or no conductivity at all since the conductive member 30 is being used to electrically connect the tap wire 12 to the source wire 14. As used herein, the terms non-conductive material and non-electrically conductive material are meant to mean non-highly electrically conductive material, e.g. , steel, or electrical insulative material, e.g., non-conductive polymer or ceramic material. Consequently, the outer member and the inner members may be made from material such as various forms of relatively inexpensive steel or other materials such as polymers and ceramics. The inner member 50 is preferably made from a spring, a spring device or a resilient material. The springy inner member 50 is preferably made from sheet, plate, or other metal or material structure.

The inner member 50 may be configured to be inserted within the cavity 42 by an explosively-driven or power actuated portable tool, such as an AMP ACT^® tool supplied by AMP Incorporated of Harrisburg, Pennsylvania. Alternatively, the inner member 50 may be configured to be inserted within the cavity 42 by bolting or other mechanical driving tool.

Figures 2A-2D depict a method of electrically connecting a tap wire 12 to a source wire 14. Figures 2 A depicts the first step that includes positioning the tap wire 12 and the source wire 14 within opposing recesses, 22 and 24, respectively, of the outer member 20. Figure 2B depicts the step of inserting the conductive member 30 between the tap wire 12 and the source wire 14. As depicted in Figure 2B, one method of inserting the conductive member 30 includes using a force, indicated as F, to compress the U-shaped portion 36 so as to move the first portion 32 toward the second portion 34, thereby, facilitating the insertion of the conductive member 30 between the tap wire 12 and the source wire 14.

Alternatively, the conductive member 30 may be slid into position between the tap wire 12 and the source wire 14.

Figure 2C depicts the conductive member 30 as being inserted between the tap wire 12 and the source wire 14. And finally, as depicted in Figure 2D, the inner member 50 is inserted within the outer member 20 whereby the first portion 32 of the conductive member 30 is positioned between the inner member 50 and the tap wire 12 and a second portion 34 of the conductive member 30 is positioned between the inner member 50 and the source wire 14.

Figure 3 is a schematic view of an assembled electrical connector 10 according to the present invention depicting an electrical current flow path, indicated by the letter C, flowing between the source wire 14, the conductive member 30, and the tap wire 12. In various embodiments of the present invention where conductive material is used to make the outer member 20 and/or the inner member 50, some or all of the electrical current may flow through one or both of those conductive members.

Figure 4 is a cross-sectional end view of an outer member 20 with a source wire 14 and tap wire 12 inserted therein, an alternative embodiment of a conductive member 130 inserted between the wires, and an inner member 50 inserted therein according to the present invention. As depicted in Figure 4, the first portion 132 and a second portion 134 of the conductive member 130 can be constructed using a variety of dimensions. The first and second portions, 132 and 134, depicted in Figure 4 are elongated relative to those depicted in Figure 3, for example. The first and second portions 132 and 134 could also be constructed so as to be shorter than those depicted in Figure 3. The present invention contemplates a limitless variety of sizes, shapes, and configurations for all of its members.

Figures 5A-5C depict an alternate method of electrically connecting a tap wire 212 to a source wire 214, as contemplated by the present invention. Figure 5 A depicts a step that includes positioning a conductive member 230 on an inner member 250 to form an assemblage. Opposing sides, 256 and 258, of the inner member 250 abut the first portion 232 and the second portion 234, respectively, of the conductive member 230. Figure 5B includes positioning the tap wire 212 and the source wire 214 within opposing recesses, 222 and 224, respectively, of an outer member 220. The steps depicted in Figures 5 A and 5B can be performed in the opposite order if so desired. Figure 5C depicts the step of inserting the assemblage including the conductive member 230 and the inner member 250 between the tap wire 212 and the source wire 214 whereby the first portion 232 of the conductive member 230 is positioned between the inner member 250 and the tap wire 212 and a second portion 234 of the conductive member 230 is positioned between the inner member 250 and the source wire 214. In Figures 5A-5C an alternative embodiment of the conductive member 230 is depicted wherein the portion 236 of the conductive member 230 is flat, rather than U-shaped as in the first embodiment described with reference to Figures 1-4. In the embodiment of Figures 5A-5C the portion 236 preferably does not protrude beyond the outer member 220. Figure 6 depicts a side view of an alternative embodiment of a conductive inner member 350 according to the present invention. This embodiment is particularly well suited for use with the method depicted in Figures 5A-5C. In this embodiment of Figure 6, the inner member 350 includes stops 353 and 355 located on either end of side 356, and stops 357 and 359 located on the other ends of side 358. The stops, 353, 355, 357, and 359, allow the conductive member 220 to be locked in place on the inner member 350 using anyone of a variety of methods. Examples of the methods used to lock the conductive member 220 on the inner member 350 is by snapping it thereon, sliding it in place thereon, or using bendable tabs on either the inner member 350 or on the conductive member 220. For example, the stops, 353, 355, 357, and 359, can be configured as bendable tabs to further help to prevent the conductive member 220 from sliding off of the inner member 350 as the leading end 352 of the inner conductive member 350 is forced within the outer member 220 with end 354 following thereafter.

Figure 7 depicts a perspective view of an alternative embodiment of a conductive member 430 according to the present invention. In this embodiment a portion 436 between a first portion 432 and a second portion 434 is narrow. Any variety of sizes, shapes, or configurations can be used for the conductive member. For example, the portion between the first portion 432 and the second portion 434 can simply be a wire or cable electrically connecting the first portion and the second portion, or it can have cut-outs, slot, holes, etc. The first and second portions 432 and 434, respectively, can be of any size, shape or configuration as well. For example, the first and second portions 432 and 434, respectively, can be constructed in a variety of lengths and do not need to be the same length as the outer member. Alternate embodiments of the present invention are contemplated by the practice of the present invention wherein the outer member and/or the inner member are constructed of or coated with a non-conductive, insulating material, such as rubber, plastic, ceramic or other similar materials. Similarly, in order to protect outside objects from damage due to the conductive member overheating from high levels of current running therethrough, an insulation coating may be placed over the portion between the first portion and the second portion. The outer member, the conductive member, and the inner member may also be coated with a corrosion resistant coating in order to protect them from the environment. It should be noted that the conductive member can be coated, especially at the bond line (known in the art) in a bimetallic conductive member; however, the electrical contact surfaces should be bare, or uncoated so as to provide electrical conductance thereat.

It should now be appreciated that the present invention provides a conductive member that provides a current path between a tap wire and a source wire. The electrically conductive member of the present invention eliminates the need for the outer member and the inner member to be made from expensive electrically conductive materials. Therefore, the outer member and the inner member can be constructed of a variety of materials.

In addition to the embodiments of Figures 1-7 that provide for electrical connections between uninsulated conductors and, the present invention also provides embodiments that provide for electrical connections between insulated conductors and uninsulated conductors and may be described with reference to Figures 8-11.

Figure 8 illustrates an electrical connector 500 comprising a C- shaped outer member 502 similar to the C-shaped inner member 20 of Figure 1 except that it has at least one piercing serration 504 located along its inner wall and facing the insulated conductor 12' having an insulative covering 12A. The electrical connector 500 further comprises the inner member 20 of Figure 1 and an electrically conductive member 506 which is similar to the electrically conductive member 42 of Figure 1 except that it has at least one piercing serration 506 located on its outer wall 32 and facing the insulated conductor 12' . The piercing serration 504 of the outer member 502 and the piercing serration 508 of the conductive member 506 are both suitable for piercing the electrical insulation 12A of the electrical cable 12' . The outer member 502 operatively cooperates with the conductive member 56 as well as with the inner member 50 which may be further described with reference to Figure 9 which illustrates an embodiment which provides for satisfactory electrical connections between cables 12' and 14.

Figure 9 is quite similar to Figure 3, but illustrates the embodiment of Figure 8 rather than Figure 3 illustration of the embodiment of Figure 1. The piercing serrations 504 and 508 are preferably arranged to be in alignment with each other and with both 504 and 508 piercing the insulation 12A of the electrical cable 12' . Further, the inner member 50 is wedged into the conductive member 506. The embodiment of Figure 9 captures the electrical cable 12' between the piercing serrations 504 and 506, so as to fix the cable 12' in a stationary position. In the embodiment of Figure 9, electrical current need not pass through the outer member 506 and the inner member 50, but rather current only needs to pass from one cable 12' to the other cable 14 by conduction only through the conductive member 506 and is shown therein by both path C . In the embodiment of Figure 9, the piercing serration 504 need not conduct electricity. Instead, the piercing serration 508 penetrates through the conductor insulation 12A to make mechanical contact with the conductor 12' . This provides mechanical support directly to the metal conductor 12' . Such mechanical support, coupled with the mechanical support provided by piercing member 504 of the outer member 502, minimizes mechanical support by the insulation 12A of the cable 12' . This, in turn, eliminates mechanical flow of the insulation material during service, particularly if the conductor temperature becomes elevated. More particularly, direct mechanical support by the insulation material 12A of the cable 12' is to be avoided since the insulation material 12 A flows particularly if the cable 12' temperature becomes elevated, or if the interface with the cable 12' allows mechanical support by the insulation sleeve making up the insulation 12A. Flow of insulation material 12A would lead to loss of mechanical load at the electrical interfaces in the cables 12' and 14, thus leading to a potential degradation of the connector performance.

More particularly, the piercing serration-to-metal conductor 12' contact provided by the piercing serrations 504 and 508 biting into the electrical conductor 12' should be used to provide the desired mechanical load bearing function so as to avoid degradation of the connector performance. A further embodiment having the benefits of the embodiment of Figures 8 and 9 may be described with reference to Figures 10 and 11 for an embodiment 510.

The embodiment 510 of Figure 10 includes the outer member 20 and the inner member 50 (previously described) and a conductive member 512 having at least one piercing serration, but preferably at least two serrations 514 and 516 oppositely disposed from each other on the same side of the conductive member 512, that is, on the side of conductive member 512 that is arranged to come into contact with the insulative covering 12A of the conductor 12'. The conductive member 512 has the same electrical characteristics as those of conductive member 506 of Figure 8 and, also as those of the conductive member 30 of Figure 1. The conductive member 512 may be further described with reference to Figure 11.

Figure 11 is quite similar to that of Figure 4 except that Figure 11 illustrates the conductive member 512 as having piercing serrations 514 and 516 that capture the conductor 12' . As seen in Figure 11 , the piercing serrations 514 and 516 along with the conductive member 512 establish the electrical path C" between conductors 12' and 14. Each of the piercing serrations 514 and 516 penetrates through the conductor insulation 12A to make mechanical contact with the conductor metal 12' . Such mechanical support, coupled with the mechanical support provided the outer member 50, minimizes mechanical support by the insulation 12A of the cable 12' . This, in turn, eliminates mechanical flow of the insulation material during service, particularly if the conductor temperature becomes elevated in a manner as described for Figure 10.

Figs. 12-16 show an alternate embodiment of the piercing members and conductive insert of the present invention. More specifically, Fig. 12 shows a connector assembly 610 for connecting together electrically conductive conductors 612 and 614 each having an insulation covering 616 and each having an electrically conductive core 618 which may comprise a plurality of electrical conductors. The electrical connector assembly 610 of the present invention finds utilization for existing power sources that require the establishment of electrical continuity between the two electrical conductors such as those shown as cables 612 and 614. The electrical connector assembly 610 comprises a receptacle element 620, a tapered element 622, and a one-piece intermediate member 624 which is of particular importance to the present invention.

The receptacle element 620 has two ears 626 each of which has a channel 628 suitable for partially enclosing a respective electrically conductive conductors 612 and 614. The receptacle element 620 has a front end 630 and a rear end 632 and is contoured so as to converge from the front end 630 toward the rear end 632 with the width of receptacle element 620 correspondingly decreasing therebetween. The receptacle element 620 may have piercing serrations 634 which may be further described with reference to Fig. 172.

Fig. 12 illustrates the receptacle element 620 as being partially cut away so as to more clearly show the piercing serrations 634 as being located along at least one, but preferably both channels 628. The receptacle element 620 for the embodiment of Fig. 172, and also Fig. 15 to be described, may have at least one but preferably more than one piercing serration 634. The piercing serration 634, as well as the piercing member for the intermediate member 624 to be described, may have different shapes and may be arranged in one or more rows.

The tapered element 622, shown in Fig. 12, has two concave side walls 633, a front end 636, and a rear end 638. The tapered element 622 is contoured so as to converge from the front end 636 toward the rear end 638 with the width of the tapered element 622 corresponding by decreasing therebetween. The tapered element 622 is dimensioned so as to be inserted into the one-piece intermediate member 624.

The one-piece intermediate member 624 is dimensioned so as to be situated between the receptacle element 620 and the tapered element 622. The one-piece intermediate member 624 having edges, a front end 642, a rear end 644 and cable engaging sections 640 with outwardly facing surfaces. The one-piece intermediate member 624 is contoured so as to converge from the front end 642 to the rear end 644 with the width of the one-piece intermediate member 624 correspondingly decreasing therebetween. The oppositely disposed cable-engaging sections 640 have edges that are dimensioned so as to be complementary to and capable of accepting the edges 633 of the tapered member 622.

The oppositely disposed cable-engaging sections 640 have end portions that are folded inwardly toward each other and away from the outwardly facing surfaces to form movable sections 641. Each movable section 641 includes at least one piercing serration 646 and at least one slot 648 preferably arranged in parallel with and in alignment with the at least one piercing member 646. The cable engaging sections 640 are folded so that the at least one-piercing member 646 fits into the at least one slot 648 as shown in Fig. 1. The piercing serration 646 of the intermediate member 624 is suitable for piercing the electrical insulation 616 of the electrical cables 612 and 614, so as the piercing serration 634 of the receptacle element 620 of Fig. 172, the piercing serration 646 makes electrical contact with the electrically conductive cores 618 of the cables 612 and 614. The intermediate member 624 operatively cooperates with the receptacle element 620 as well as with the tapered member 622 which may be further described with reference to Figs. 14(A) and 14(B) which illustrate embodiments which provide for satisfactory electrical connections with cables 612 and 614. Both of the embodiments of Figs. 14(A) and 14(B) utilize the receptacle element 620 of Fig. 12 having the piercing members 63'4. The serrations 634 are preferably arranged to be in alignment with the piercing members 646 of the intermediate member 624 with the piercing serrations 634 and 646 both piercing the insulation 616 of the respective electrical cables 612 and 614. Further, the tapered member 622, shown in cross-hatched, is wedged into the intermediate member 624. Both of the embodiments of Figs. 14(A) and 14(B) capture the electrical cables 612 and 614 between the piercing serrations 634 and 646 of the receptacle element 620 and the intermediate member 624, respectively, so as to fix the cables 612 and 614 in a stationary position. In the embodiment of Fig. 14(A), electrical current need not pass through the receptacle element 620 and the tapered element 622, but rather current only needs to pass from one cable 612 to the other cable 614 by conduction only through the intermediate member 624. In the embodiment of Fig. 14(A) the piercing serration 634 need not conduct electricity. Instead, the piercing serration 634 penetrates through the conductor insulation 616 to make mechanical contact with the conductor metal body 618.

This provides mechanical support directly to the metal conductor body 618. Such mechanical support, coupled with the mechanical support provided by piercing member 646 of the intermediate member 624, minimizes mechanical support by the insulation 616 of the cables 612 and 614. This, in turn, eliminates mechanical flow of the insulation material during service, particularly if the conductor temperature becomes elevated. More particularly, direct mechanical support by the insulation material 616 of the cables 612 and 614 is to be avoided since the insulation material 616 flows particularly if the conductor 618 temperature becomes elevated, or if the interface with the cables 612 and 614 allows mechanical support by the insulation sleeve making up the insulation 616. Flow of insulation material 616 would lead to loss of mechanical load at the electrical interfaces in the cables 612 and 614, thus leading to a potential degradation of the connector performance. More particularly, the piercing serration-to-metal conductor 618 contact provided by the piercing sercations 634 and 646 biting into the electrical conductors 618 should be used to provide the desired mechanical load bearing function so as to avoid degradation of the connector performance. In the embodiment of Fig. 14(A), the current flowing in direction 650 may also pass through the tapered element 622 if the tapered element 622 is selected to be of an electrically conductive material in a manner as to be described hereinafter.

In the embodiment of Fig. 14(B), electrical current need not pass through the intermediate member 624 and tapered element 622, but rather current only needs to pass from one cable 612 to the other cable 614 by conduction only through the receptacle element 620 as shown by directional arrow 652. In the embodiment of Fig. 14(B) the piercing senation 646 need not conduct electricity. Instead, the piercing senation 646 penetrates through the conductor insulation 616 to make mechanical contact with the conductor metal body 618. This provides mechanical support directly to the metal conductor body 618. Such mechanical support, coupled with the mechanical support provided by piercing member 634 of the receptacle element 620, minimize mechanical support by the insulation 616 of the cables 612 and 614. This, in turn, eliminates mechanical flow of the insulation material during service, particularly if the conductor temperature becomes elevated in a manner as described for Fig. 14(A). Fig. 14(A) is an embodiment wherein the receptacle element 620 is of non-electrically conductive material so that the electrical connection provided by the operative cooperation of the intermediate member 624 and the receptacle element 620 cause the cunent to flow between the cores 618 of the electrical cables 612 and 614 by way of the intermediate member 624 comprised of electrically conductive material as indicated by directional anows 650. As used herein, the terms non-conductive material and non-highly electrically conductive material are meant to mean non-highly electrically conductive material, e.g., steel or electrically insulative material, e.g. , non-conductive polymer or ceramic material. For the embodiment of Fig. 14(A), the tapered member 622 may carry current if it is selected to be of a electrically conductive material and, conversely, may not carry cunent if it is selected to be of a non-electrically conductive material.

Fig. 14(B) illustrates an embodiment wherein the receptacle element 620 is comprised of an electrically conductive material and the intermediate member 624 is comprised of an insulating material. For such a combination, the current flows through the receptacle element 620 and is indicated by directional arrows 652.

The embodiments of Figs. 14(A) and 14(B) allow for different combinations of the materials selected for the receptacle element 620, the tapered element 622 and the intermediate member 624. More particularly, these embodiments allow one combination of the receptacle element 620 and the intermediate member 624 both being of the electrically conductive material, wherein the cunent path is provided by both the intermediate member 624 illustrated by directional anows 650 and also by the receptacle element 620 indicated by directional arrow 652. Another combination wherein the tapered member 622 is of an electrically conductive material allows the current (flow 650) to pass through the tapered element 622. Similarly, the embodiment of the Fig. 14(A) allows for the intermediate member 624 to be of the conductive material and the receptacle element 620 to be of a non-electrically conductive material. Again, the tapered element 622 of Fig. 14(A) may be selected to be an electrically conductive material so as to share the cunent flow with the intermediate member 624. Similarly, the embodiment of Fig. 14(B) allows for the receptacle element 620 to be of an electrically conductive material and the intermediate member 624 to be of an insulating material.

In operation, the tapered element 622 has its two concave side walls 143 inserted under the concave cable-engaging sections 640 and when the tapered element 622 receives a sufficient mechanical force, the tapered element 622 is driven into the intermediate member 624 thereby causing the piercing serrations 646 to pierce the electrical insulation 616 of both the cables 612 and 614 and into the electrically conductive cores 618 thereof and may be further described with reference to Fig. 15. Fig. 15 illustrates one of cable-engaging sections 640 having a concave surface and also illustrates the piercing members 646 being lodged within and spaced apart by the slots 648. Furthermore, Fig. 15 illustrates the tapered element 622 under the cable-engaging section 640 and the concave side wall 633 of the tapered element 622 snugly against the shown cable-engaging section 640. In operation the tapered element 622 is driven by into the intermediate member 624 in direction 654A causing the tapered element 622 to be moved upward in direction 654B which, in turn, causes the piercing members 646 to be urged outwardly, piercing the electrical insulation 616 of the cables 612 and 614. Although not shown in Fig. 15, it can be seen with reference to Figs. 14(A) and 14(B) that as electrical cables 612 and 614 are raised upward by the insertion of tapered element 622 and the piercing serrations 634 of the receptacle element 620 of the embodiment of Fig. 12 are driven into the insulation 616 and then into the electrical cores 618 of the electrical cables 612 and 614. The intermediate member 624 is a one-piece device which is of particular importance to the present invention. The one-piece intermediate member 624 may be fabricated in accordance with the practice of the present invention which may be further described with reference to Figs. 16(A), 16(B), 16(C), 16(D) and 16(E).

The method of the present invention for forming the intermediate member 624 is initiated by providing a plate 656 having alternate embodiments shown in 16(A) and 16(B), with the embodiment Fig. 16(A) being prefened and the plate

656 of each embodiment being comprised of an electrically conductive material for use with the anangement of Fig 14(A), or of an insulating material for use with the anangement of Fig. 14(B).

As seen in Fig. 16(A), the plate 656 has penetrating means 646 and slots 648 previously described with reference to Figs. 61-4. The plate 656 further has oppositely disposed top and bottom portions 658 and 60, respectively, having unequal lengths. The plate 656 further has oppositely disposed side portions 62 and 64 with edge portions thereat that extend upward, at an acute angle, from the bottom portion 60. The plate 656 further comprises at least one piercing senation, but preferably more than one (e.g., four (4)) piercing senation 646 formed in at least one edge portion (See Fig. 16(B)), but preferably at both edge portions 62 and 64 (See Fig. 16(A)). The plate 656 of Fig. 16(B) provides for a further embodiment of the present invention to be further described hereinafter with reference to Figs. 6-8(B). The plate 656 further has at least one slot 648, but preferably at least four slots 648, separated from the at least piercing senation 646 by a predetermined distance and parallel with and in alignment with the at least one piercing senation 646.

Fig. 16(C) is a view which illustrates the slots 646, and the edge portions 62 and 64 each having a piercing senation 646 at the outermost edge thereof. Fig. 16(D) illustrates the three bending steps involved with forming the one-piece intermediate member 624 of the present invention. More particularly, Fig. 16(D) illustrates the bending of the plate 656 at two first predetermined locations 66 each relative to the respective edge portions so as to form first curved portions 68. The plate 656 is then bent at two second predetermined locations 70 each relative to the edge portions 62 and 64 so as to form second curve portions 72. The bending is continued so that the plate 656 is bent at two third predetermined locations 74 relative to the edge portions so as to form third curved portions 76 allowing the piercing senation 646 to be raised upward in the directions indicated by directional arrows 78.

Fig. 16(E) illustrates the condition of plate 656 after its piercing senation 646 are gripped and raised upward in directions 78 (Fig. 16(D)) and continuing in the same direction until the piercing senation 646 are inserted into the respective slots 648. After this is accomplished, the separation between the first and second curved portions 68 and 72 (See Fig. 16(D)) forms a concave surface therebetween indicated by the wire-engaging sections 640 movable sections 641 disposed inwardly therefrom. Alternatively, movable sections 641 may be angled sufficiently at curved portion 72 that piercing serration 646 are recessed within or inwardly from slots 648 until being assembled to the cables and urged outwardly by tapered element 622 as shown in Fig. 15.

It should now be appreciated that the connector assemblies of Figures 8-11 provide good electrical connections and rigid mechanical support for insulated and uninsulated conductors.

It should be further appreciated that the connector of the present invention can be used throughout the electrical power distribution system. The connectors can cover primary distribution networks including connections and taps from a high power grid, through to connecting secondary grids for subdivisions made up of houses and industrial areas.

Of course, it should be understood that a wide range of changes and modifications could be made to the prefened embodiment described above. It is therefore intended that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims, and equivalents thereof.

Claims

What is claimed is:

1. An electrical connector for electrically connecting a first wire and a second wire, said electrical connector comprising: an outer member formed of a first material having a first inner recess and an opposing second inner recess, said first inner recess adapted for housing the first wire and said second inner recess adapted for housing the second wire; an inner member formed of the first material or a second material and positioned within said outer member; a conductive insert formed of a third material and adapted to extend from a first portion between the first wire and said inner member to a second portion between the second wire and said inner member such that said conductive insert provides an electrical connection between the first wire and the second wire; and wherein the Young's Modulus of said first material is greater than that of said third material.

2. The electrical connector of claim 1 , wherein the Young's Modulus of said first material is greater than that of a low-resistence, electrical conductors selected from the group consisting of copper, a copper alloy, aluminum, an aluminum alloy, and a bimetallic aluminum-copper material.

3. The electrical connector of claim 1 , wherein said first material has a Young's Modulus no less than about 10,000,000 psi.

4. The electrical connector of claim 3, wherein said first material has a Young's Modulus no less than about 20,000,000 psi.

5. The electrical connector of claim 4, wherein said first material has a Young's Modulus no less than about 30,000,000 psi.

6. The electrical connector of claim 1, wherein said first material is selected from the group consisting of steel, iron, ceramic materials, and polymeric materials.

7. The electrical connector of claim 1, wherein said inner member is formed from said first material

8. The electrical connector of claim 1, wherein said inner member is formed from said second material, said second material being more malleable than said first material.

9. An electrical connector for electrically connecting a first wire and a second wire, said electrical connector comprising: an outer member formed of a first material having a first inner recess and an opposing second inner recess, said first inner recess adapted for housing the first wire and said second inner recess adapted for housing the second wire; an inner member formed of the first material or a second material and positioned within said outer member; a conductive insert formed of a third material and adapted to extend from a first portion between the first wire and said inner member to a second portion between the second wire and said inner member such that said conductive insert provides an electrical connection between the first wire and the second wire; and wherein said third material has a lower electrical resistence than said first material.

10. The electrical connector of claim 9, wherein the electrical resistence of said first material is less than that of a high-strength material selected from the group consisting of steel, iron, ceramic materials, and polymeric materials.

11. The electrical connector of claim 9, wherein the electrical resistence of said first material is less than about 10 microhm-cm.

12. The electrical connector of claim 11, wherein the electrical resistence of said first material is less than about 5 microhm-cm.

13. The electrical connector according to claim 1, wherein said first and second wires are insulated having an insulative covering and wherein said outer member and said electrically conductive member each has at least one piercing serration each of which is arranged to come into contact and pierce said insulative covering.

14. The electrical connector according to claim 13, wherein said piercing senations of said electrically conductive member and said outer member are ananged in near alignment with each other.

15. The electrical connector according to claim 1, wherein said first and second wires are respectively insulated having an insulative covering and uninsulated, and wherein said electrically conductive member has first and second sides and has at least one piercing senation on opposite faces of one of said sides with each piercing senation arranged to come into contact and pierce said insulative

16. A method of electrically connecting a tap wire to a source wire, said method comprising the steps of: positioning the tap wire and the source wire within opposing recesses of an outer member formed of a non-electrically conductive material; inserting an electrically conductive member between the tap wire and the source wire whereby the conductive member provides an electrical connection between the source wire and the tap wire; and inserting an inner member formed of a non-electrically conductive material within the outer member whereby a first portion of the electrically conductive member is positioned between the inner member and the tap wire and a second portion of the electrically conductive member is positioned between the inner member and the source wire.

17. The method of electrically connecting a tap wire to a source wire according to claim 16, wherein the step of inserting an electrically conductive member includes compressing a portion of the electrically conductive member located between the first portion and the second portion thereof, whereby the first portion and the second portion are moved toward each other thereby facilitating the insertion of the electrically conductive member between the source wire and the tap wire.

18. The method of electrically connecting a tap wire to a source wire according to claim 17, wherein the portion of the conductive member located between the first portion and the second portion protrudes beyond the outer member.

19. A method of electrically connecting a tap wire to a source wire, said method comprising the steps of: positioning an electrically conductive member on a non-electrically conductive inner member to form an assemblage; positioning the tap wire and the source wire within opposing recesses of a non-electrically conductive outer member; inserting the assemblage between the tap wire and the source wire such that a first portion of the electrically conductive member is positioned between the inner member and the tap wire and a second portion of the electrically conductive member is positioned between the non-electrically conductive inner member and the source wire whereby the electrically conductive member provides an electrical connection between the source wire and the tap wire.

20. A method of electrically connecting a tap wire to a source wire, wherein one of said tap and source wire has an insulative covering thereon, said method comprising the steps of: positioning the tap wire and the source wire within opposing recesses of an outer member formed of a non-electrically conductive material; inserting an electrically conductive member between the tap wire and the source wire, said electrically conductive member having at least one piercing serration with the piercing senation piercing the insulative covering whereby the conductive member provides an electrical connection between the source wire and the tap wire; and inserting an inner member formed of a non-electrically conductive material within the outer member whereby a first portion of the electrically conductive member is positioned between the inner member and the tap wire and a second portion of the electrically conductive member is positioned between the inner member and the source wire.

21. A method of electrically connecting a tap wire to a source wire each having an insulative covering thereon, said method comprising the steps of: positioning the tap wire and the source wire within opposing recesses of an outer member formed of a non-electrically conductive material having a piercing senation which is positioned to come into contact with and pierce said insulative covering; inserting an electrically conductive member between the tap wire and the source wire, said electrically conductive member has at least one piercing senation with the piercing serration piercing the insulative covering whereby the conductive member provides an electrical connection between the source wire and the tap wire; and inserting an inner member formed of a non-electrically conductive material within the outer member whereby a first portion of the electrically conductive member is positioned between the inner member and the tap wire and a second portion of the electrically conductive member is positioned between the inner member and the source wire.

22. An electrical connector assembly for connecting electrical conductors with at least one conductor having an insulated covering and containing an electrically conductive core, said electrical connector comprising: a receptacle element which has two ears that define channels for partially enclosing respectively said electrical conductors; a tapered element provided with two ears that are dimensioned to be inserted between said first edges of said receptacle element; and an intermediate member dimensioned to be situated between said receptacle element and said tapered element and having oppositely disposed cable engaging sections with edges which are dimensioned so as to be complementary to and capable of accepting edges of said tapered element, said intermediate member being a one-piece member having integral movable sections disposed inwardly from said cable-engaging sections, at least one cable engaging section having at least one piercing member and at least one slot ananged in parallel with and in alignment with said at least one piercing member, said movable sections of said intermediate member being folded so that said at least one piercing member fits into said at least one slot, said piercing member being suitable for piercing said electrical insulating covering and making electrical contact with at least one of said electrically conductive cores.

23. The electrical connector of claim 22, further comprises at least one piercing member located along at least one of its cable-receiving channel thereof.

24. The electrical connector assembly according to claim 23, wherein said piercing members of said receptacle element and of said intermediate member are in near alignment with each other when said intermediate member is situated between said receptacle element and said tapered element.

25. The electrical connector assembly according to claim 23, wherein said receptacle element and said intermediate member each comprise an electrically conductive material.

26. The electrical connector assembly according to claim 23, wherein said receptacle element comprises an electrical conductive material and said intermediate member comprises an electrically insulative material.

27. The electrical connector assembly according to claim 23, wherein said receptacle element comprises an electrically insulative material and said intermediate member comprises an electrically conductive material.

28. The electrical connector assembly according to claim 27 wherein said tapered element comprises an electrically conductive material.

29. The electrical connector assembly according to claim 27 wherein said tapered element comprises an electrically insulative material.

30. The electrical connector assembly according to claim 23, wherein all of the electrical conductors have an insulated covering and wherein each of the cable- engaging sections has at least one piercing member and at least one slot ananged in parallel with and in alignment with at least one piercing member.

31. A method of forming an intermediate member for an electrical connector assembly comprising the steps of: a) providing a plate having:

(i) oppositely disposed top and bottom portions having unequal lengths;

(ii) oppositely disposed side portions with edge portions thereat and extending upward at an acute angle from said bottom portion;

(iii) at least one penetrating means formed into at least one edge portion of said side portions; and

(iv) at least one slot separated from said at least one penetrating means by a predetermined distance and parallel with and in alignment with said at least one penetrating means; b) bending said plate at two first predetermined locations each relative to respective edge portions so as to form first curved portion; c) bending said plate at two second predetermined locations each relative to respective edge portions as to form second curved portions that are disposed inwardly from plate portions between said first and second curved portions; d) bending said plate at two third predetermined locations each relative to respective edge portions so as to form third curved portions that are disposed inwardly from plate portions between said first and second curved portions; and e) gripping said at least one penetrating means so as to insert said at least one penetrating means into a respective slot thereof and so that the separation between said first and second curved portions form a concave surface therebetween.

32. A method of forming an intermediate member for an electrical connector assembly comprising the steps of: a) providing a plate having: i)oppositely disposed top and bottom portions having unequal lengths; ii) oppositely disposed side portions with edge portions thereat and extending upward at an acute angle form said bottom portion; iii) at least one penetrating means formed into one edge portion of said side portions; and iv) at least one slot separated from said at least one penetrating means by a predetermined distance and parallel with and in alignment with said at least one penetrating means; f) bending said plate at two first predetermined locations each relative to respective edge portions so as to form first curved portion; g) bending said plate at two second predetermined locations each relative to respective edge portions so as to form first curved portion; h) bending said plate at the edge of said plate having said penetrating means at two third predetermined locations each relative to respective edge portions so as to form third curved portions that are disposed inwardly from plate portions between said first and second curved portions; i) bending said plate at the edge of said plate not having said penetrating means so that the separation between its first and second curved portions form a concave surface therebetween; gripping said at least one penetrating means so as to insert said at least one penetrating means into a respective slot thereof and so that the separation between said first and second curved portions form a concave surface therebetween.