WO2025224581A1

WO2025224581A1 - Connection system for delivering electric power

Info

Publication number: WO2025224581A1
Application number: PCT/IB2025/054080
Authority: WO
Inventors: Arthur James Jur; Douglas Taylor
Original assignee: Eaton Intelligent Power Ltd
Current assignee: Eaton Intelligent Power Ltd
Priority date: 2024-04-25
Filing date: 2025-04-17
Publication date: 2025-10-30
Anticipated expiration: 2026-10-25

Abstract

An apparatus includes: a rigid electrically conductive shell including an inner wall that defines an interior region; one or more rigid electrical conductors in the interior region; and a rigid electrically insulating support structure in the interior region. The rigid electrically insulating support structure holds each of the one or more rigid electrical conductors and electrically insulates each of the one or more rigid electrical conductors from the rigid electrically conductive shell.

Description

CONNECTION SYSTEM FOR DELIVERING ELECTRIC POWER

This application claims the benefit of U.S. Provisional Application No. 63/638,555, filed on April 25, 2024 and titled CONNECTION SYSTEM FOR DELIVERING ELECTRIC POWER, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

This disclosure relates to a connector system for delivering electric power.

BACKGROUND

Electrical power may be distributed throughout a building via cable and conduit. A busway system is an alternative to the traditional cable and conduit.

SUMMARY

In one aspect, an apparatus includes: a rigid electrically conductive shell including an inner wall that defines an interior region; one or more rigid electrical conductors in the interior region; and a rigid electrically insulating support structure in the interior region. The rigid electrically insulating support structure holds each of the one or more rigid electrical conductors and electrically insulates each of the one or more rigid electrical conductors from the rigid electrically conductive shell.

Implementations may include one or more of the following features.

The rigid electrically conductive shell may include a rigid tube having a circular crosssection. The rigid electrically insulating support structure may hold each of the one or more rigid electrical conductors at a fixed radial distance from the inner wall.

The rigid electrically insulating support structure may include an extruded non- conductive material.

Each of the one or more rigid electrical conductors may be a bar of an electrically conductive material.

The apparatus may include more than one rigid electrical conductor, and the rigid support electrically insulating structure may hold each rigid electrical conductor in a fixed spatial relationship relative to all of the other rigid electrical conductors and at a fixed radial distance from the inner wall.

At least a portion of the rigid electrically insulating support structure may be between each of the one or more rigid electrical conductors and the inner wall.

The rigid electrically conductive shell may extend from a first end to a second end, the rigid electrically insulating support structure may extend from the first end to the second end, and the one or more rigid electrical conductors may extend from the first end to the second end.

The rigid electrically conductive shell may be configured to attach to a separate connector portion that includes one or more electrically conductive receptacles, and attaching the rigid electrically conductive shell to the separate connector portion may electrically connects each of the one or more electrical conductors to one of the electrically conductive receptacles. The rigid electrically conductive shell may be configured for repeated attachment to and disconnection from the separate connector portion.

In another aspect, a system includes: a rigid assembly and a connector. The rigid assembly includes: an electrically conductive shell including an interior region; rigid electrical conductors in the interior region; and a rigid electrically insulating support structure in the interior that holds the rigid electrical conductors in a first fixed spatial arrangement, the rigid electrically insulating support structure surface features. The connector is configured to be electrically and mechanically attached to the rigid assembly, and the connector includes: a rigid electrically conductive connector housing configured to attach to the electrically conductive shell; electrically conductive receptacles in the connector housing; and a rigid electrically insulating connector support structure in the connector housing and including alignment features. The rigid electrically insulating connector support structure holds the electrically conductive receptacles in a second fixed spatial arrangement, and rotating the connector such that each of the alignment features is aligned with one of the surface features aligns the first fixed spatial arrangement with the second fixed spatial arrangement.

Implementations may include one or more of the following features.

The connector may be configured to be repeatedly electrically and mechanically attached to the rigid assembly.

The system also may include a second rigid assembly, and the connector may be configured to be electrically and mechanically attached to the second rigid assembly. The second rigid assembly may be configured to be electrically and mechanically attached to a second side of the connector, and the rigid assembly may be configured to be electrically and mechanically to a first side of the connector. The first side of the connector and the second side of the connector may be opposite sides of the connector.

In another aspect, a power distribution connection system includes: a first conductor portion including: a first rigid conduit, a first insulator in the first rigid conduit, and first electrical conductors in the first rigid conduit, the first insulator holding the first electrical conductors in a first fixed spatial relationship; a connector including a rigid shell, electrical connection portions in the rigid shell, and a connector insulator in the rigid shell, the connector insulator holding the electrical connection portions in a fixed spatial relationship; and a second conductor portion including: a second rigid conduit, a second insulator in the second conduit, and second electrical conductors in the second rigid conduit, the second insulator holding the second electrical conductors in a second fixed spatial relationship. The connector is configured to attach to the first and second conductor portions with the electrical connection portions in physical contact with the first electrical conductors and the second electrical conductors.

Implementations may include one or more of the following features.

The first conductor portion and the second conductor portions may be on opposite sides of the connector.

Each of the first conductor portion, the second conductor portion, and the connector may have mirror symmetry about a respective center line.

The rigid shell may be configured to attach to the first rigid conduit and the second rigid conduit. In use, the rigid shell, the first rigid conduit, and the second rigid conduit may provide a path to ground.

Implementations of any of the techniques described herein may include an apparatus, a device, a system, and/or a method. The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features will be apparent from the description and drawings, and from the claims.

DRAWING DESCRIPTION

FIG. 1A is a block diagram of a system.

FIGS. IB and 1C show a conductor portion. FIG. ID shows a connector portion.

FIG. IE is an exterior view of conductor portions and a connector portion in a disconnected state.

FIG. IF is an exterior view of the conductor portions and the connector portion of FIG. IE in a connected state.

FIGS. 2A and 2B show another example of a conductor portion.

FIG. 3 shows another example of a connector portion.

FIGS. 4A and 4B show an example of an assembly that includes the connector portion of FIG. 3 attached to the conductor portion of FIGS. 2A and 2B.

FIGS. 5 A and 5B show another example of a conductor portion.

DETAILED DESCRIPTION

FIG. 1A is a block diagram of a system 100 that includes a facility 110 that receives electrical power from and/or provides electrical power to a power grid 101. Within the facility 110, electrical power is distributed to one or more power consuming and/or power generating devices 190 by an electrical power connection system 130. For example, the connection system 130 may be configured to distribute electrical power having an RMS voltage of 600 volts (V) or less and currents of up to 600 amperes (A). The connection system 130 may be used at higher voltages and/or currents. Furthermore, the connection system 130 may be used as part of a direct current (DC) system or an alternating current (AC) system. For example, the connection system 130 may be used at voltages of 1000 VDC or greater. The connection system 130 also may be configured for use at higher or lower voltages and at various current levels.

In the example shown in FIG. 1A, the connection system 130 includes conductor portions 140a, 140b that are electrically and mechanically connected to each other by a connector portion 150. Other implementations are possible. For example, the facility 110 may include just one of the conductor portions 140a, 140b; more than two conductor portions 140a, 140b; and/or more than one connector portion 150.

As discussed below, the connection system 130 is a modular electrical power connection system that improves the delivery of electrical power throughout the facility 110 as compared to traditional wiring approaches. Traditional wiring approaches include (1) flexible wire(s) housed in a rigid conduit and (2) electrical cables that include flexible electrical conductor(s) encased in a flexible material. To install a system that is based on the first traditional approach, the rigid conduit is installed and then the flexible wire is pulled through the rigid conduit. Systems that are based on the first traditional approach may be time consuming and cumbersome to install. For example, the flexible wires are generally difficult to pull through the conduit, particularly when the conduit is long, bent, and/or in an inconvenient location. Furthermore, the rigid conduits are typically bent at wide angles to allow the flexible wires to be pulled through the rigid conduit, and this constrains the spatial arrangement of the system. To install a system that is based on the second traditional approach, the electrical cable is placed and mounted within the space to be powered. Systems that are based on the second traditional approach are limited on the number of applications allowed and typically require cable terminations that are time consuming to install and require specialized tools and expertise.

On the other hand, the connection system 130 includes the conductor portions 140a, 140b, both of which provide a respective rigid electrically conductive path 142a, 142b. Each conductive path 142a, 142b is pre-installed and spatially fixed within a respective rigid and electrically conductive conduit 144a, 144b. Thus, installation of the connection system 130 does not involve pulling flexible wires through a conduit or pulling and positioning flexible wires through the facility 110. Furthermore, the connection system 130 can be easily reconfigured to suit the constraints and features of the facility 110. For example, the conductor portions 140a and 140b may be cut-to-fit from a larger portion on-site or prior to delivery to the facility 110. Moreover, the conductor portions 140a, 140b can be cut-to-fit using ordinary tools that are typically available at the site and without specialized training. Additionally, the connector portion 150 allows the conductor portions 140a and 140b to be joined at an angle such that the connection system 130 can be easily configured relative to obstacles in the facility 110.

FIGS. IB and 1C show additional details of the conductor portion 140a. FIG. ID shows additional details of the connector portion 150. FIGS. 2A, 2B, 5 A, and 5B show other examples of a conductor portion. FIG. 3 shows an example of a connector portion, and FIGS. 4A and 4B show an example of an assembly formed by joining a connector portion and a conductor portion. An overview of the system 100 is provided prior to discussing these examples.

The facility 110 is any structure or area in which the connection system 130 is installed to provide electrical power to one or more of the devices 190. For example, the facility 110 may be a hospital, an office or apartment building, a retail establishment, a high rise, a factory, or a data center. The facility 110 may be a region or area that is not necessarily enclosed in a building or an area that is partially exposed. For example, the facility 110 may be a construction site or a temporary structure. The device 190 may be any device or system that consumes and/or generates electrical power. Specific examples of the device 190 include, without limitation, computing equipment, industrial machinery and equipment, generators, power converters, medical equipment, solar energy components, batteries, and lighting systems.

The power grid 101 distributes electrical power to commercial, residential, industrial, and/or municipal facilities. The power grid 101 is an alternating current (AC) power grid with a fundamental frequency of, for example, 50 or 60 Hertz (Hz). The power grid 101 may be a multi-phase (for example, three-phase) power grid. The power grid 101 may be low- voltage (for example, up to 1 kilovolt (kV)), medium-voltage or distribution voltage (for example, between 1 kilovolts (kV) and 35 kV), or high-voltage (for example, 35 kV and greater). The power grid 101 may include more than one sub-grid or portion. For example, the power grid 101 may include AC micro-grids, AC area networks, or AC spot networks that serve particular customers. These sub-grids may be connected to each other via switches and/or other devices to form the power grid 101. Moreover, sub-grids within the grid 101 may have different nominal voltages. For example, the power grid 101 may include a medium-voltage portion connected to a low- voltage portion through a distribution transformer.

The power grid 101 includes devices that generate, consume, transfer, distribute, and/or absorb electrical energy. The power grid 101 may include sources of electrical energy such as, for example, power plants, power generators, renewable energy sources, power stations, and/or one or more distributed energy resources (DER). A DER is an electricity-producing resource and/or a controllable load. Examples of DER include solar-based energy sources such as, for example, solar panels and solar arrays; wind-based energy sources, such as, for example, wind turbines and windmills; combined heat and power plants; rechargeable sources (such as batteries); natural gas-fueled generators; electric vehicles; and controllable loads, such as, for example, some heating, ventilation, air conditioning (HVAC) systems and electric water heaters.

The power grid 101 also may include one or more reclosers or switchgears, sectionalizers, transformers, and a point of common coupling (PCC) that provides an AC bus for more than one discrete load. The power grid 101 also includes transport media, such as, for example, transmission lines and electrical cables. All or part of the power grid 101 may be underground.

Moreover, although the power grid 101 is discussed as generally an AC power grid, some portions of the power grid 101 may utilize DC power. Furthermore, the connection system 130 may be configured for us in a DC system or application. For example, the connection system 130 may be used to distribute DC power in a battery installation or a solar installation. Additionally, although the connection system 130 is shown with the power grid 101, the connection system 130 may be used as part of a power distribution system that is not connected to the power grid 101 or a system that is intermittently connected to the power grid 101.

FIG. IB is a cross-sectional view of the conductor portion 140a in the X-Y plane. The conductor portion 140a includes conductors 142a and 142b that are in an interior 143 of the conduit 144a. The conductors 142a, 142b are identical to each other. The conductors 142a, 142b are rigid electrically conductive elements that extend along the Z axis (into and out of the page in FIG. IB). For example, each conductor 142a, 142b may be a rod of copper, aluminum, or another metal. Each conductor 142a, 142b may carry up to, for example, 200 Amperes (A) of electrical current.

The conduit 144a is a rigid electrically conductive hollow body with an exterior 147 and an interior wall 146. For example, the conduit 144a may be a metal tube, pipe, or shell. The conduit 144a may be, for example, steel. The conduit 144a acts as the electrical path to ground for the conductor portion 140a. The conduit 144a is shown as having a rectangular cross-section in the X-Y plane, but other shapes are possible. For example, the conduit 144a may have a circular cross-section.

The conductors 142a and 142b are held in place in the interior 143 by an insulation assembly 170. FIG. 1C is a perspective exterior view of the insulation assembly 170, with hidden features depicted by dashed lines. The insulation assembly 170 is a rigid body 172 of electrically insulating material. The insulation assembly 170 may be made of any rigid material that does not conduct electricity. For example, the insulation assembly 170 may be a plastic, a polymer, a hardened rigid insulating foam, or a ceramic. The insulation assembly 170 may be a single piece or may include more than one piece. The insulation assembly 170 may be an extruded plastic material. In the example shown in FIG. 1C, the insulation assembly 170 includes open regions 171a, 171b that pass through the rigid body 172 along the Z axis. The conductor 142a is held in the open region 171a and the conductor 142b is held in the open region 171b. As shown in FIG. IB, the rigid body 172 is in the interior 143. The insulation assembly 170 electrically insulates the conductors 142a, 142b from each other and from the conduit 144a. Furthermore, portions of the insulation block are wedged between the interior wall 146 and the conductors 142a, 142b such that the insulation assembly 170 holds the conductors 142a, 142b in place in the interior 143. When held in the insulating assembly 170, the centers of the conductors 142a, 142b fall on a straight line 192. When the conductor portion 140a is positioned as shown in FIG. IB, the insulation assembly 170 holds the conductor 142a directly above the conductor 142b, where above is displacement in the Y direction.

The insulation assembly 170 does not move relative to the conductors 142a, 142b; and the insulation assembly 170 and the conductors 142a, 142b do not move relative to the conduit 144a. In other words, although the conductor portion 140a is made up of several components and may be cut-to-size, the conductor portion 140a is a single, rigid, integrated assembly.

The rigid body 172 includes sufficient insulating material to insulate the conductors 142a, 142b from the conduit 144a and to hold the conductors 142a, 142b in place in the interior 143. However, the rigid body 172 does not fill the entire interior 143 and there are regions 148 of free space in the interior 143. This configuration of the rigid body 172 reduces the amount of material and the weight of the conductor portion 140a as compared to a configuration in which the rigid body 172 and conductors 142a, 142b fill the interior 143. The conductor portion 140b includes the same features as the conductor portion 140a.

FIG. ID is a cross-sectional view of the connector portion 150. The connector portion 150 includes an electrically conductive shell 154 that encloses a rigid connector insulator 180 and electrically conductive connector regions 158a, 158b in a connector interior 153. The shell 158 is rigid, with an exterior 157 and an interior wall 156. The shell 154 is made of an electrically conductive material and may be the same material as the conduit 144a. For example, the shell 154 and the conduit 144a may be steel or another metal. The electrically conductive shell 154 is shaped and sized to mechanically connect to the conduits 144a and 144b. For example, the electrically conductive shell 154 includes a lip or flange 159 that extends in the Z direction. The lip 159 may engage a portion of an end of the conduit 144a with an interference fit to hold the connector portion 150 to the conductor portion 140a.

The electrically conductive connector regions 158a, 158b are electrically conductive receptacles or elements that are supported and held in the connector interior 153 by the connector insulator 180. The electrically conductive connector regions 158a, 158b are rigid and are made of the same material as the conductors 142a, 142b. For example, the regions 158a, 158b and the conductors 142a, 142b may be made of copper or aluminum. Each region 158a, 158b is, for example, a receptacle or conductive rod that contacts the respective conductor 142a, 142b when the conductor portion 140a is connected to the connector portion 150. The electrically conductive connector regions 158a, 158b are identical to each other.

The connector insulator 180 is a rigid electrically insulating body that holds the electrically conductive connector regions 158a, 158b in a fixed spatial arrangement in the connector interior 153. In the example shown in FIG. ID, the centers of the connector regions 158a, 158b fall on a straight line 191. When the connector portion 150 is positioned as shown in FIG. ID, the connector region 158a is directly above the connector region 158b.

FIG. IE is an exterior view of the conductor portions 140a, 140b and the connector portion 150 when disconnected from each other. FIG. IF is an exterior view of the conductor portions 140a, 140b and the connector portion 150 connected to each other as an assembled system 131. The dashed lines in FIGS. IE and IF indicate hidden features.

To connect the conductor portion 140a to the connector portion 150, the conductor portion 140a and/or the connector portion 150 are rotated and/or positioned such that the conductors 142a, 142b are aligned with the connector regions 158a, 158b. For example, the conductor portion 140a and the connector portion 150 are aligned when positioned as shown in FIGS. IB and ID. In another example, the conductor portion 140a and the connector portion 150 are aligned when the conductor portion 140a is rotated 180 degrees (°) in the X-Y plane relative to the position shown in FIGS. IB and the connector portion 150 may be positioned as shown in FIG. ID. To provide a counter-example, the conductor portion 140a and the connector portion 150 would not be aligned if the conductor portion 140a was rotated 90° in the X-Y plane relative to what is shown in FIG. IB and the connector portion 150 was positioned as shown in FIG. ID. After the conductor portion 140a is aligned with the connector portion 150, the lip 159 is connected the conduit 144a. For example, the lip 159 may have a slightly larger diameter than the conduit 144a such that the lip 159 slides over and engages with the exterior 147 to hold the connector portion 150 to the conductor portion 140a via an interference fit or frictional engagement between the lip and the exterior 147.

Other implementations are possible. For example, in some implementations, the diameter of the lip 159 on the connector portion 150 is slightly smaller than the diameter of each conductor portion 140a, 140b. In these implementations, the lip 159 may be tabs that fit into the open regions 148 of each conductor portion 140a, 140b and engage with the interior wall 146 to hold the conductor portions 140a, 140b to the connector portion 150.

When the conductor portion 140a is joined with the connector portion 150, the conductor 142a is placed in contact with the electrically conductive connector region 158a and the conductor 142b is placed in contact with the electrically conductive connector region 159b. The conductor portion 140b is connected to the opposite end of the connector portion 150 in the same manner.

When the conductor portions 140a, 140b are connected to the connector portion 150 (as shown in FIG. IE), the exterior of the conduits 144a and 144b and the shell 154 provide an electrically conductive path to ground for the assembled system 131. Additionally, the shell 154 provides structural strength to the assembled system 131. The conductors 142a, 142b of the conductor portions 140a, 140b and the electrically conductive connector regions 158a, 158b form a conductive path through the assembled system 131. The connector portion 150 may be removed from the conductor portions 140a, 140b without damaging the connector portion 150 or the conductor portions 140a, 140b. The connector portion 150 and the conductor portions 140a, 140b may be disassembled and reused to form other assemblies.

FIG. 2A is a perspective exterior view of part of another conductor portion 240. FIG. 2B is a cross-sectional view of the conductor portion 240. The conductor portion 240 is a three- phase conductor portion configured to carry up to, for example, 600A of electrical current (200A per phase). The conductor portion 240 may be used to carry AC or DC power. For example, the conductor portion 240 may be configured for operation at voltages of 1000 VDC or greater or for voltages below 1000 VDC. In another example, the conductor portion 240 may be configured for use at 600 VAC. These voltage and current values are provided as examples, and the conductor portion 240 may be configured for use at other voltage and current values.

The conductor portion 240 is tubular and has a circular cross-section in the X-Y plane. The conductor portion 240 includes a conduit 244 that has an exterior surface 247 and an interior wall 246 that defines an interior 243. The conduit 244 is rigid, hollow, and electrically conductive body that extends along the Z axis. For example, the conduit 244 may be a metal pipe or tube. The conduit 244 may be made of any rigid electrically conductive material. Examples of materials that may be used for the conduit 244 include, without limitation, steel, brass, graphite, and aluminum.

The conductor portion 240 includes insulating blocks 270a and 270b, each of which is made of a rigid material that does not conduct electricity. For example, the insulating blocks 270a and 270b may be made of a rigid plastic or a rigid, solidified foam. The insulating blocks 270a and 270b may be extruded plastic. The insulating blocks 270a and 270b are identical to each other and are joined at an interface 274. When positioned in the interior 243 and joined at the interface 274, the insulating blocks 270a and 270b have mirror symmetry about the X axis, are co-extensive with the conduit 244 along the Z axis, and define an open center region 248. Although portions of the insulating blocks 270a and 270b are in contact with the interior wall 246, each insulating block 270a, 270b includes a flat area that is not in contact with the interior wall 246. These flat areas define top and bottom open regions 249a and 249b. The insulating blocks 270a and 270b may be held to the interior wall 246 by an interference fit or an adhesive.

The insulating block 270a includes holding features 278a and 278b, which are recesses in the insulating block 270a that face the open center region 248. The holding feature 278a holds an electrical conductor 242a, and the holding feature 278b holds the electrical conductor 242b. Each holding feature 278a, 278b partially surrounds the respective electrical conductor 242a, 242b. The electrical conductors 242a, 242b may be further secured in the respective holding feature 278a, 278b by an interference fit. Similarly, the insulating block 270b includes holding features 278c and 278d, each of which holds a respective conductor 242a and 242d. The conductors 242a, 242b, 242c, 242d extend along the Z axis and are co-extensive with the conduit 244 and the insulating blocks 270a, 270b.

Each holding feature 278a, 278b, 278c, 278d holds the respective conductor 242a, 242b, 242c, 242d in a fixed position separated from the other conductors and insulated from the interior wall 246 of the conduit 244. The insulating blocks 270a, 270b are configured such that the conductors 242a, 242b, 242c, 242d are separated from each other by a clearance distance sufficient to ensure that there will not be arcing between the conductors 242a, 242b, 242c, 242d during use. In this way, the insulating blocks 270a and 270b hold the conductors 242a, 242b, 242c, 242d and also ensure that the conductors 242a, 242b, 242c, 242d are insulated from each other and the interior wall 246.

The insulating blocks 270a, 270b are fixed within the interior 243 and do not rotate or translate relative to the conduit 244. Thus, although the conductor portion 240 includes the conductors 242a, 242b, 242c, 242d; the insulating blocks 270a, 270b; and the conduit 244, these components are integrated such that the conductor portion 240 is a rigid, integrated, tubular assembly that is easy to install.

In addition to the holding features, the insulating blocks 270a, 270b include respective surface features 275a, 275b (for example, ridges and recess) that increase the surface creepage distance along the insulator between any two adjacent conductors. The surface features 275a, 275b also provide alignment guides to ensure proper connection between the conductor portion 240 and a separate connector portion (such as shown in FIGS. 4A and 4B). For example, when joined at the interface 274, the insulating blocks 270a, 270b define alignment regions 277a, 277b, 277c, 277d that have flat surfaces that face the open center region 248. The alignment regions 277a, 277b, 277c, 277d are spaced 90° apart from each other along a circular path.

Each conductor 242a, 242b, 242c, 242d is a rigid electrically conductive body (such as a metal bar or rod) sized to carry currents of up to 100A or 200 A. Any electrically conductive material can be used for the conductors 242a, 242b, 242c, 242d. Examples of materials that can be used for the conductors 242a, 242b, 242c, and 242d include, without limitation, aluminum, copper, and silver. The conductor portion 240 may be used to distribute three-phase electrical power. In these implementations, the each of the conductors 242a, 242b, 242c may be one of the three-phases and the conductor 242d may be the neutral. The conduit 244 is electrically conductive and provides a conductive ground path.

As noted above, the conductor portion 240 may be configured to carry currents of 600A. Other implementations are possible. For example, the conductor portion 240 may be configured for use at voltages of 1000 VDC or greater, voltages of 600V AC or greater, and/or at currents greater than 600A. For implementations in which the conductor portion 240 is configured to carry larger currents and/or operate at higher voltages, the conductor portion 240 is larger than in implementations intended for lower currents and voltages. For example, the diameter of the conductors 242a, 242b, 242c, 242d is greater and the insulating blocks 270a, 270b are thicker for implementations in which the conductor portion 240 is intended for higher currents and/or voltages.

FIG. 3 is a perspective exterior view of a connector portion 350 that extends in the Z direction from a first end 384 to a second end 385. The connector portion 350 is configured to mechanically and electrically connect to the conductor portion 240.

The connector portion 350 includes an electrically conductive shell 354 that extends along the Z axis. The shell 354 is tubular and has a circular cross-section in the X-Y plane. The electrically conductive shell 354 includes an interior wall 356 that defines an interior region 353 and a lip 359 that extends in the Z direction to the second end 385. The opposite side of the connector portion 350 includes an identical lip 359a that extends in the -Z direction to the first end 384. The shell 354 may be made of any rigid, electrically conductive material. For example, the shell 354 may be steel. The shell 354 may be made of the same material as the conduit 244.

The connector portion 350 includes a rigid insulating block 380 and electrically conductive connector regions 358a, 358b, 358c, 358d that extend along the Z axis in the interior region 353. The insulating block 380 is held by a support wall 395 that extends in the X-Y plane. The insulating block 380 is concentric with the shell 354. In the example shown in FIG. 3, the insulating block 380 has a square cross-section in the X-Y plane with a diagonal flange feature 381a, 383b, 383 c, 383 d extending from each of the four corners of the square. Each connector region 358a, 358b, 358c, 358d is mounted on a different one of the four sides of the insulating block 380.

The insulating block 380 is made of any material that does not conduct electricity or is a very poor conductor of electricity. For example, the insulating block 380 may be a rigid plastic or a ceramic. The insulating block 380 may be extruded plastic. The connector regions 358a, 358b, 358c, 358d are made of any electrically conductive material and are the same material as the conductors 242a, 242b, 242c, 242d. The insulating block 380 and the electrically conductive connector regions 358a, 358b, 358c, 358d do not move independently of the shell 354. FIG. 4A is a partial perspective exterior view of an assembly 431 formed by joining the connector portion 350 and the conductor portion 240. In FIG. 4 A, the shell 354 of the connector portion 350 is shown as being transparent for illustration purposes. However, the shell 354 may be opaque.

To join the connector portion 350 to the conductor portion 240, the connector portion 350 and the conductor portion 240 are first aligned with each other. The connector portion 350 is aligned with the conductor portion 240 when each diagonal flange feature 383a, 383b, 383c, 383 d is positioned to contact one of the alignment regions 277a, 277b, 277c, 277d.

After aligning the connector portion 350 and the conductor portion 240, the lip 359a is slid over the exterior surface 247 of the conductor portion 240 until the conductors 242a, 242b, 242c, 242d of the conductor portion 240 contact respective electrically conductive connector regions 358a, 358b, 358c, 358d of the connector portion 350. The lip 359a engages with the exterior surface 247 to mechanically hold the connector portion 350 to the conductor portion 240 and the electrically conductive connector regions 358a, 358b, 358c, 358d contact the respective conductors 242a, 242b, 242c, 242d. Thus, the connector portion 350 and the conductor portion 240 are mechanically and electrically connected. Although the connector portion 350 is shown as being connected to one conductor portion, a second conductor portion that is substantially identical to the connector portion 240 may be attached to the second end 385 of the connector portion 350.

FIG. 4B is a cross-sectional view of the assembly 431 in the X-Y plane taken at the location labeled 4B — 4B in FIG. 4A. As shown in FIG. 4B, the insulator block 380 is in the open center region 248 and is positioned in the open center region 248 with each of the diagonal flange features 381a, 381b, 381c, 381d in contact with one of the alignment regions 277a, 277b, 277c, 277d. Each conductor 242a, 242b, 242c, 242d is held in contact with one of the electrically conductive connector regions 358a, 358b, 358c, 358d. The lip 359a surrounds and contacts the exterior surface 247 of the conductor portion 240 to mechanically secure the conductor portion 240 to the connector portion 350. The interior of the assembly 431 is not completely filled and there are void spaces in the interior, such as the open center region 248, which is surrounded by the insulating block 380.

FIG. 5A is an exterior perspective view of another conductor portion 540. FIG. 5B is a cross-sectional view of the conductor portion 540 in the X-Y plane. The conductor portion 540 includes an electrically conductive conduit 544 that has an exterior surface 547 and an interior wall 546 that defines an interior 543. Insulation blocks 570a, 570b are in the interior 543. The insulation blocks 570a, 570b have mirror symmetry about the X axis and hold electrical conductors 542a, 542b, 542c, 542d in a fixed spatial relationship with each other and at a distance that is large enough to prevent arcing during use of the conductor portion 540. Specifically, the insulation block 570a includes holding features 578a and 578b that hold the conductors 542a and 542b, respectively. The insulation block 570b includes holding features 578c and 578d that hold the conductors 542c and 542d, respectively. The holding features 578a, 578b, 578c, 578d are recesses that receive and partially surround the respective conductors.

Portions of the insulation blocks 570a, 570b are in contact with the interior wall 546 and the insulation blocks 570a, 570b do not move relative to the conduit 544. For example, the insulation blocks 570a, 570b may be held to the interior wall 546 with an interference or frictional connection or with an adhesive. The insulation blocks 570a, 570b are solid, rigid bodies of non-electrically conductive material, such as extruded plastic or ceramic. Although portions of the insulation blocks 570a, 570b contact the interior wall 546, the insulation blocks 570a, 570b do not have a circularly shaped outer surface and do not completely conform to the interior wall 546. There are void regions 548 of open space in the interior 543 between the insulation blocks 570a and/or 570b and the interior wall 546 even when the insulation blocks 570a, 570b and the conductors 242a, 242b, 242c, 242d are in the interior 543. Each void region 548 is a pocket of open space that extends through the conductor portion 540 in the Z direction but is not necessarily fluidly connected to any other of the void regions 548.

The electrical conductors 542a, 542b, 542c, 542d are solid, rigid bodies of electrically conductive material. For example, each electrical conductor 542a, 542b, 542c, 542d may be a copper or aluminum bar or rod. Each electrical conductor 542a, 542b, 542c, 542d may be configured to carry for example, 100A of electrical current. The insulation blocks 570a, 570b and the conductors 542a, 542b, 542c, 542d extend along the Z axis and are co-extensive with the extent of the conduit 544 along the Z axis.

The insulation blocks 570a, 570b include respective surface features 575a, 575b that face the interior 543 and the center of the conduit 544. The surface features 575a, 575b increase the creepage distance between each adjacent conductor and also act as alignment features to ensure that a connector portion (not shown) is properly aligned with the conductor portion 540 prior to joining the connector portion to the conductor portion 540.

These and other implementations are within the scope of the claims.

Claims

WHAT IS CLAIMED IS:

1. An apparatus comprising: a rigid electrically conductive shell comprising an inner wall that defines an interior region; one or more rigid electrical conductors in the interior region; and a rigid electrically insulating support structure in the interior region, wherein the rigid electrically insulating support structure holds each of the one or more rigid electrical conductors and electrically insulates each of the one or more rigid electrical conductors from the rigid electrically conductive shell.

2. The apparatus of claim 1 , wherein the rigid electrically conductive shell comprises a rigid tube having a circular cross-section.

3. The apparatus of claim 2, wherein the rigid electrically insulating support structure holds each of the one or more rigid electrical conductors at a fixed radial distance from the inner wall.

4. The apparatus of claim 1 , wherein the rigid electrically insulating support structure comprises an extruded non-conductive material.

5. The apparatus of claim 1, wherein each of the one or more rigid electrical conductors comprises a bar of an electrically conductive material.

6. The apparatus of claim 1 , wherein the apparatus comprises more than one rigid electrical conductor, and the rigid support electrically insulating structure holds each rigid electrical conductor in a fixed spatial relationship relative to all of the other rigid electrical conductors and at a fixed radial distance from the inner wall.

7. The apparatus of claim 1 , wherein at least a portion of the rigid electrically insulating support structure is between each of the one or more rigid electrical conductors and the inner wall.

8. The apparatus of claim 1, wherein the rigid electrically conductive shell extends from a first end to a second end, the rigid electrically insulating support structure extends from the first end to the second end, and the one or more rigid electrical conductors extend from the first end to the second end.

9. The apparatus of claim 1 , wherein the rigid electrically conductive shell is configured to attach to a separate connector portion that comprises one or more electrically conductive receptacles, and attaching the rigid electrically conductive shell to the separate connector portion electrically connects each of the one or more electrical conductors to one of the electrically conductive receptacles.

10. The apparatus of claim 9, wherein the rigid electrically conductive shell is configured for repeated attachment to and disconnection from the separate connector portion.

11. A system comprising: a rigid assembly comprising: an electrically conductive shell comprising an interior region; rigid electrical conductors in the interior region; and a rigid electrically insulating support structure in the interior that holds the rigid electrical conductors in a first fixed spatial arrangement, the rigid electrically insulating support structure comprising surface features; and a connector configured to be electrically and mechanically attached to the rigid assembly, the connector comprising: a rigid electrically conductive connector housing configured to attach to the electrically conductive shell; electrically conductive receptacles in the connector housing; and a rigid electrically insulating connector support structure in the connector housing and comprising alignment features, wherein the rigid electrically insulating connector support structure holds the electrically conductive receptacles in a second fixed spatial arrangement, and rotating the connector such that each of the alignment features is aligned with one of the surface features aligns the first fixed spatial arrangement with the second fixed spatial arrangement.

12. The system of claim 11, wherein the connector is configured to be repeatedly electrically and mechanically attached to the rigid assembly.

13. The system of claim 11, further comprising a second rigid assembly, and wherein the connector is configured to be electrically and mechanically attached to the second rigid assembly.

14. The system of claim 13, wherein the second rigid assembly is configured to be electrically and mechanically attached to a second side of the connector, and the rigid assembly is configured to be electrically and mechanically to a first side of the connector.

15. The system of claim 14, wherein the first side of the connector and the second side of the connector are opposite sides of the connector.

16. A power distribution connection system comprising: a first conductor portion comprising: a first rigid conduit, a first insulator in the first rigid conduit, and first electrical conductors in the first rigid conduit, wherein the first insulator holds the first electrical conductors in a first fixed spatial relationship; a connector comprising a rigid shell, electrical connection portions in the rigid shell, and a connector insulator in the rigid shell, wherein the connector insulator holds the electrical connection portions in a fixed spatial relationship; and a second conductor portion comprising: a second rigid conduit, a second insulator in the second conduit, and second electrical conductors in the second rigid conduit, wherein the second insulator holds the second electrical conductors in a second fixed spatial relationship; wherein the connector is configured to attach to the first and second conductor portions with the electrical connection portions in physical contact with the first electrical conductors and the second electrical conductors.

17. The power distribution connection system of claim 16, wherein the first conductor portion and the second conductor portions are on opposite sides of the connector.

18. The power distribution connection system of claim 16, wherein each of the first conductor portion, the second conductor portion, and the connector have mirror symmetry about a respective center line.

19. The power distribution connection system of claim 16, wherein the rigid shell is configured to attach to the first rigid conduit and the second rigid conduit.

20. The power distribution connection system of claim 19, wherein, in use, the rigid shell, the first rigid conduit, and the second rigid conduit provide a path to ground.