Abstract: A slip-fit electrical connector compatible with different size threaded transformer studs includes a body having a plurality of transverse conductor receiving passageways, and intersecting conductor fastener receiving passageways. The body also has a multi-size transformer stud receiving passageway extending longitudinally inwardly from an end thereof, and at least one stud fastener receiving passageway intersecting the multi-size transformer stud receiving passageway. The multi-size transformer stud receiving passageway may be defined by an arcuate bottom, and a plurality of successively larger threaded stud landings with a lowermost threaded stud landing being bifurcated by the arcuate bottom. Each successive threaded stud landing may be bifurcated by a prior threaded stud landing. The threaded stud landings are for different size threaded transformer studs to conveniently and reliably fasten the transformer stud and connector together.

Abstract: A method includes providing a bus having first and second opposing surfaces; providing a plurality of posts, each having a lower open end; positioning each post to have the lower open end adjacent the first surface of the bus; and displacing material from the bus into the lower open end of each post to secure each post to the bus. The displacing may include impacting at least the second surface of the metal bus. Also, in some embodiments, each post may have a bore extending therethrough and the method may further include positioning a forming tool in the bore during the displacing or impacting. In some embodiments, the displacing leaves the first and second surfaces of the bus continuous, that is, a small stub of bus material is displaced from the bus into the lower open end of the post and without punching through the bus. A recess is left in the second side of the bus.

Abstract: A method for making an electrical connector of the bus and post type includes connecting the posts to the bus with respective locking pins so that the posts extend outwardly from the bus. Each locking pin engages a lower open end of a post and extends into and engages a respective opening in the bus. Each locking pin may be expanded radially outwardly to securely engage adjacent portions of the bus and post. Accordingly, strong mechanical and electrical connection is established between the bus and the posts. Expanding each locking pin outwardly may be achieved by impacting at least one end face of each locking pin. In some embodiments, each post further has an upper open end in communication with the open lower end to define a central bore.

Abstract: A method for making a connector includes selectively removing material from metal stock to form a monolithic body comprising a bus portion and a plurality of spaced apart stubs extending outwardly therefrom, and engaging a lower open end of each metal post and a respective stub of the monolithic body together. The starting stock need not be the full height of the posts and bus portion. Accordingly, the advantages of using extruded material versus cast material may be obtained without shortcomings in terms of excess material waste and associated expense. Each stub may be frustoconically-shaped with a desired taper angle. In one embodiment, each metal post may have a bore extending therethrough defining the lower open end and also defining an open upper end for receiving at least one electrical conductor. The metal post may also have at least one threaded passageway therein and extending transversely into the bore, such as to receive a fastener for securing the electrical conductor in the bore.

Abstract: A gel-filled casing for an electrical connection includes lower and upper housing portions, and a hinge connecting the lower and upper housing portions along respective edges thereof. First and second bodies of sealing gel are in respective interiors of the lower and upper housing portions. The gel-filled casing further includes at least one partial closure member for securing the lower and upper housing portions in a partially closed position with the first and second bodies of sealing gel being separated from one another. This allows the gel-filled casing to be shipped in the partially closed position. At least one full closure member is also included for securing the lower and upper housing portions in a fully closed position with the first and second bodies of sealing gel being brought together and surrounding the electrical connection for ensuring that the gel surrounds the exposed conductors for preventing contact with moisture.