Abstract: Disclosed herein is an electrical connector set-screw. The electrical connector set-screw includes a body part and a head part. The body part includes a threaded section and a channel. The threaded section extends between a first end and an opposite second end of the body part. The channel extends through a portion of the body part. The channel is spaced from the first end and the second end of the body part The head part is connected to the body part. The head part includes a top section and an integral locking section. The top section is configured to be received by a tool. The integral locking section extends through the channel.

Abstract: The present invention relates to a new and improved connector bar and techniques for making the same. The connector bar includes a metal body having side-by-side conductor ports, transverse threaded pedestal mount apertures, and set screw openings. The transverse threaded pedestal mount apertures extend completely through the body of the connector bar and are adapted for attachment to a pedestal box. The set screw openings are adapted to each receive a set screw for securing a conductor in one of the conductor ports. Preferably, the transverse threaded pedestal mount apertures and set screw openings are formed from the same side of the connector bar.

Abstract: An electrical connector for clamping securely onto a threaded shaft includes a transformer bar, a connector body, a clamping component, and at least two columns for receiving streetlight taps. The transformer bar has a plurality of conductor bores, a distal end, and a bar top. The connector body is at the distal end and has first and second bosses at the bar top and first and second clamping sides. The clamping component is pivotally mounted by an attachment link to be selectively located adjacent one of the first and second clamping sides. Two columns are located adjacent the distal end of the transformer bar, protruding away from the transformer bar, one on each side, for supporting a streetlight tap and a redundant ground close to the connector body and a streetlight tap opposite the distal end.

Abstract: The present invention relates to a power supply terminal of connecting devices of electrical conduction that includes an insulating terminal block. An earth wire connecting block, zero wire connecting block and two live wire connecting blocks are juxtaposed in said terminal block. Said earth wire connecting block, zero wire connecting block and two live wire connecting blocks respectively have the corresponding wiring input terminal and wiring output terminal.

Abstract: A connector arrangement and techniques are provided for reducing eddy current losses and/or skin effects while enabling more readily serviceable series and phase connections between the coil ends 12 and 18 of a generator stator 10. This may be achieved by providing a connecting structure 24 that enables two parallel electrically conductive paths 26 and 28 that are electrically insulated from one another for passing a respective flow of electric current between the coil ends.

Abstract: An electrical connector for clamping securely onto a threaded shaft, comprising a transformer bar, a connector body, and a clamping component. The transformer bar includes a plurality of conductor bores therein, a distal end, an upper component having at least one setscrew extendable into one of the bores with wrenching on an exposed end thereof, and a lower component with a lower end surface remote from the exposed end of the setscrew. The transformer bar is substantially Z-shaped such that a bottom end of the upper component is adjacent a top end of the lower component. The connector body at the distal end includes at least one boss adjacent the lower surface of the lower component. The connector body also includes first and second connector sides. The clamping component is pivotally mounted by an attachment link to the boss to be selectively located adjacent each of the first and second connector sides.

Abstract: Busbar assemblies are disclosed. The busbar assemblies allow electric current to be distributed through electrically conductive cables that are held in contact with a substantially solid conductive bar by a cable retention system that does not require through-holes in the conductive bar and which decrease the bar's current carrying capacity. Further, the cable retention system retains the cables in consistent contact with the bar and resist loosening due to vibration and thermal cycling.

Abstract: The electrical connectors according to embodiments of the present invention include an elongated conductor body having an external contact surface, and a clamping device including a nut plate that spans the contact surface and carries a clamping screw for securing a threaded stud terminal to the contact surface. The nut plate and the conductor body are segments cut from stocks of metal extrusions. The body extrusion has one or more longitudinal ribs that are converted by coining into one or more rows of teeth that mesh with the stud terminal to block shift of the connector along the stud terminal.

Abstract: A connector adaptor (205) and method may include a terminal block (210) and a power conductor (215). The power conductor includes in-line, hyperboloid radial sockets (220) to be applied to pins 235 mounted in an array on a power distribution unit (106), and two-hole terminal connectors 225, where the two-hole terminal connectors are each coupled to a pair of threaded studs (230) extending from the terminal block, and where the connector adaptor is adapted to conduct power to an embedded computer chassis.

Abstract: The present invention comprises a U-bolt connector for connecting pairs of stator coil headers 2 with ball headers 6 comprising, a U-bolt 16, top capping pieces 18,20, bottom capping pieces 20, 21, a variable piece 24, and a tightening mechanism 26. The top capping pieces 18,20 secure one ball connector in the pair of stator coil headers and the bottom capping pieces 20, 21 secure another ball connector in the pair of stator coil headers, while the variable piece 24 is disposed between the top capping pieces and the bottom capping pieces. The U-bolt 16 embraces the top capping pieces 18,20, the bottom capping pieces 20, 21 and the variable piece 24, where the tightening mechanism 26 holds the U-bolt tightly to the top capping pieces, the bottom capping pieces and the variable piece and is located at the end of the U-bolt.

Abstract: A connector for attachment to an extending transformer stud. The connector includes an elongate central body having a central aperture and an opening at one end for insertable accommodation of the transformer stud. The central aperture accepts a single or more than one size stud without increasing the size and cost needed for two separate mounting holes. The connector according to the present invention accepts the pitch of at least two different size threads and with the typical setscrew locking arrangement, maintains thread engagement on one side of the stud, thus securing the stud. The connector according to the present invention further provides a connector threadform having a reduced threadform angle than the stud threadform to provide greater conductivity and reduced electrical resistance between the stud and connector at lower set screw torque settings.

Abstract: An electrical connector for connecting a plurality of electrical conductors to a transformer stud. The electrical connector may include an electrically conductive body having a first and second generally rectangular portions connected in an offset arrangement. The first generally rectangular portion may have a transformer stud receiving passageway for receiving a transformer stud. The first and second generally rectangular portions may have respective first and second openings to define first and second keeper holders. Keepers are removably received in the keeper holders to secure electrical conductors therein.

Abstract: An electrical connector for a plurality of electrical cables may include an electrically conductive body having a plurality of spaced apart cable-receiving passageways for receiving electrical cable ends therein. The electrically conductive body may also have at least one respective fastener-receiving passageway intersecting each cable-receiving passageway, an insulating cover on the electrically conductive body, and respective cable and fastener inlets aligned with each cable-receiving and fastener-receiving passageway. A plurality of plug tether assemblies may each include a base engaged with an upper end portion of a respective cable inlet, and may have a first and second tether extending outwardly from the base. A cable inlet plug may be coupled to the first tether and be removably positioned in a respective cable inlet. A fastener inlet plug may be coupled to the second tether and removably positioned in a respective fastener inlet.

Abstract: An electrical connector for clamping securely onto a threaded shaft includes a transformer bar, a connector body, a clamping component, and at least two columns for receiving streetlight taps. The transformer bar has a plurality of conductor bores, a distal end, and a bar top. The connector body is at the distal end and has first and second bosses at the bar top and first and second clamping sides. The clamping component is pivotally mounted by an attachment link to be selectively located adjacent one of the first and second clamping sides. Two columns are located adjacent the distal end of the transformer bar, protruding away from the transformer bar, one on each side, for supporting a streetlight tap and a redundant ground close to the connector body and a streetlight tap opposite the distal end.

Abstract: A submersible electrical connector intended for use in a power distribution network permits a metal to stripped metal conductor connection to be visually inspected and verified by the installer while eliminating many opportunities for human error present with existing connectors. The connector in one embodiment includes a generally cup or dome-shaped enclosure which is preferably transparent. An open end of the enclosure mates with a seal body and a connector plate has a number of apertures adapted to receive the bare metal ends of conductors or wires inserted through the seal body. Each aperture in the connector has an associated set screw for securing the conductor thereto. A molded seal member is adapted to mate with the seal body and to provide a water-tight connection when mated with the enclosure. The seal member has a number of seal ducts each aligned with one of the apertures in the connector.

Abstract: An electrical connector system for use with a conductor includes an electrical connector and a plug assembly. The electrical connector includes a housing defining a conductor passage adapted to receive the conductor therethrough. The plug assembly includes a plug member and a plug sealant mounted on the plug member. The plug assembly is adapted to be inserted into the conductor passage to plug the conductor passage.

Abstract: An electrical connector for clamping securely onto a threaded shaft, comprising a transformer bar, a connector body and a clamping component. The transformer bar has a plurality of conductor bores therein, a distal end, a bar top. The connector body is at the distal end and has a boss at the bar top and first and second clamping sides. The clamping component is pivotally mounted by an attachment link to be selectively located adjacent one of the first and second clamping sides.

Abstract: The terminal block assembly of this invention provides a finger safe method of distributing power while at the same time enabling the installer to make uniform and correct connections to a multiplicity of taps or ports. Each connection includes an abutment or seat physically to engage the end of the conductor and in addition the construction of the block and its insulating case provides the installer with visual access to the tip of the conductor in its proper seated position before the conductor is secured to the block with clamp screws. In order to provide such visual access the walls partially blocking the seating end of each conductor socket are scalloped or provided with an inverted conical section which enables the tip of each conductor to be seen from the top of the block. To facilitate this visual access the entire top of the insulating case is made from a transparent material.

Abstract: An electrical connector includes a respective removable fastener inlet closure cap for each tubular fastener inlet, and a respective flexible tether having a proximal end removably connected adjacent a corresponding tubular fastener inlet and a distal end integrally molded with a corresponding removable fastener inlet closure cap. The connector may include an electrically conductive body having spaced apart cable-receiving passageways for receiving respective electrical cable ends therein, with each cable-receiving passageway having a cable inlet opening. The electrically conductive body may also have at least one respective fastener-receiving passageway intersecting each of the cable-receiving passageways. The connector may also include an insulating cover on the electrically conductive body and including a respective integrally molded tubular fastener inlet aligned with each of the fastener-receiving openings.

Abstract: An electrical connector includes an electrically conductive body having spaced apart cable-receiving passageways for receiving respective electrical cable ends. The electrically conductive body may also have at least one respective fastener-receiving passageway intersecting each of the cable-receiving passageways. An insulating cover may be on the electrically conductive body and include an integrally molded respective tubular cable inlet aligned with each cable inlet opening. A respective insulating boot may be received in each of the tubular cable inlets. Each insulating boot may include a tubular sidewall having a progressively increasing diameter to an open outer end thereof, a removable boot closure cap for removable positioning in the open outer end of the tubular sidewall, and an integrally molded tether connecting the removable boot closure cap to the tubular sidewall.

Abstract: The terminal block assembly of this invention provides a finger safe method of distributing power while at the same time enabling the installer to make uniform and correct connections to a multiplicity of taps or ports. Each connection includes an abutment or seat physically to engage the end of the conductor and in addition the construction of the block and its insulating case provides the installer with visual access to the tip of the conductor in its proper seated position before the conductor is secured to the block. In order to provide such visual access the walls partially blocking the seating end of each conductor socket are scalloped or provided with an inverted conical section which enables the tip of each conductor to be seen from the top of the block. To facilitate this visual access the entire top of the insulating case is made from a transparent material.

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: An electrical connector for electrical cables includes an electrically conductive body, an insulating cover, and moveable cable seating indicators aligned with seating indicator openings in the conductive body. The electrically conductive body may have spaced apart cable-receiving passageways for receiving respective electrical cable ends therein, and with each cable-receiving passageway may have a cable inlet opening and a cable end viewing opening opposite the cable inlet opening. The electrically conductive body may also have at least one respective fastener-receiving passageway intersecting each of the cable-receiving passageways. A respective fastener may be provided in each of the fastener-receiving passageways. The moveable cable seating indicators provide a cover and permit visual confirmation of proper placement of the electrical cable end within a corresponding one of the cable-receiving passageways.

Abstract: A fast change electric transformer connector is disclosed, which includes a cable connector having a cable attachment section, a connector extension connected to the cable attachment section, and a stud slide adaptor connected to a side of the connector extension for slidably attaching the cable connector to a transformer stud; and a stud screw adaptor complimentary to a transformer stud. The cable attachment section includes a cable receiving body having multiple receiving slots for receiving cables; and multiple removable sliding cable fastening blocks disposed within the receiving slots for fastening the cables. Each sliding cable fastening block can be slid in or out from the receiving slot for conveniently installing a large cable. Also disclosed are a transformer connector and a transformer adaptor, which have an adaptor extension for connecting between the transformer stud and the cable connection portion of the connector/adaptor, for use when shorted cables are cut.

Abstract: A connector is attachable to an extending transformer stud. The connector includes an elongate central body having a longitudinal bore opening at one end for insertable accommodation of the transformer stud. The longitudinal bore accepts more than one size stud without increasing the size and cost needed for two separate mounting holes. The connector according to the present invention accepts the pitch of at least two different size threads and with the typical setscrew locking arrangement, maintains thread engagement on one side of the stud, securing the stud and maintaining an electrical contact area between the stud and the connector.

Abstract: A fast change electric transformer connector is disclosed, which includes a cable connector having a cable attachment body with a plurality of cable attachment ports, a connector extension connected to the cable attachment body, and a stud slide adaptor connected to a side of the connector extension; and a stud screw adaptor complimentary to a transformer stud, for connecting the transformer stud and the stud slide adaptor of the cable connector. Further disclosed is a transformer adaptor, which includes an inter-connector having a screw threaded end for connecting to a cable connector, and a stud slide adaptor for adapting to a transformer stud; and a stud screw adaptor for connecting the transformer stud and the stud slide adaptor of the inter-connector. Using the transformer connector or adaptor of the present invention, a transformer can be replaced rapidly without disconnecting cables.

Abstract: A set screw connector includes an elongate generally rectangular conductive bus bar. The bus bar includes a first face having a plurality of spaced cable receiving apertures and a second face which is generally orthogonal to the first face having a plurality of spaced set screw apertures. The cable receiving apertures and the set screw apertures are in communication with one another. A cover formed of a thermoplastic elastomer (TPE) is molded over the bus bar. The molded cover further includes integrally formed auxiliary components insertable into at least one of the cable receiving apertures and the set screw receiving apertures.

Abstract: The disclosed electrical connector, which connects a terminal stud to multiple branch-circuit wires, comprises two primary components of extruded metal: (A) a conductor having a first portion providing branch-circuit securing devices, and a second portion providing one or more stud-contacting areas; and (B) a clamp for securing a stud against a contact area; the clamp and said second portion provide a slip-fit stud-receiving passage.

Abstract: An electrical connector having a parallelepiped-shaped block made of electrically conductive material. The block has conductor channels extending into the body from a first surface and set-screw channels extending into the block from a second surface, there being at least one set-screw channel associated with each conductor channel. Each set-screw channel intersects its associated conductor channel. Each conductor channel has a conductor receiving section and an adapter receiving section, the adapter receiving section located between the conductor receiving section and the associated set-screw channel. The connector has an elongated adapter for each conductor channel, the adapter generally sized and shaped to fit in the adapter receiving section in the conductor channel.

Abstract: A cable connector riser is provided configured to be positioned between a circuit board side of a receiving connector and a circuit board. The cable connector riser has a base portion having a thickness sufficient to provide clearance for a housing of a mating connector on a cable, the housing including a portion projecting downward towards the circuit board from a bottom surface of the mating connector.

Abstract: An electrical connector may be utilized to connect bus bars having a wide variety of configurations to a wide variety of electrical equipment, without modification to the bus bars, electrical equipment, or connector, with the exception of cutting the electrical connector to a desired length.

Abstract: The disclosed electrical connector, which connects a terminal stud to multiple branch-circuit wires, comprises two primary components of extruded metal: (A) a conductor having a first portion providing branch-circuit securing devices, and a second portion providing one or more stud-contacting areas; and (B) a clamp for securing a stud against a contact area; the clamp and said second portion provide a slip-fit stud-receiving passage.

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 set screw connector includes an elongate generally rectangular conductive bus bar. The bus bar includes a first face having a plurality of spaced cable receiving apertures and a second face which is generally orthogonal to the first face having a plurality of spaced set screw apertures. The cable receiving apertures and the set screw apertures are in communication with one another. A cover formed of a thermoplastic elastomer (TPE) is molded over the bus bar. The molded cover further includes integrally formed auxiliary components insertable into at least one of the cable receiving apertures and the set screw receiving apertures.

Abstract: An apparatus is disclosed for clamping cable. The apparatus is a barrier that clamps and/or adheres to the cable. The barrier has a base, and the base has a diameter greater than an aperture through which the cable passes. The base of the barrier hinders the cable from pulling through the aperture, yet the barrier allows the cable to push through the aperture.

Abstract: The present invention comprises, among other things, an electrical termination lug and a terminal strip. The electrical termination lug is made out of a conductive material having a plurality of non-threaded cavities in which to receive conductors, and a plurality of threaded cavities in which to receive set screws. The terminal strip is adapted to retain the lugs, and is made out of non-conductive material. In addition, the terminal strip comprises, among other things, a first wall, a second wall, isolation walls, and retaining members. Further, the terminal strip member defines a hole through the first wall of the terminal strip and a hole through the second wall of the terminal strip member, each adjacent to one of the threaded and non-threaded cavities in the termination lug.

Abstract: Abstract of the Disclosure An electrical connector for connecting a plurality of electrical conductors to a transformer conductor, such as in a confined space, includes a generally rectangular flat base with offset keeper holders extending from opposite sides of the base. The base has opposing first and second ends and a medial portion extending therebetween. The first end is to be connected to the transformer conductor, while electrical conductors are to be connected to the second end. The electrical connector includes at least one medial keeper holder extending outwardly from a first side of the medial portion of the base, and at least one medial keeper received in the at least one medial keeper holder to secure an electrical conductor therein. At least one end keeper holder extends outwardly from a second side of the second end of the base and is longitudinally offset and on an opposite side from the at least one medial keeper holder.

Abstract: An electrical connector having a parallelepiped-shaped block made of electrically conductive material. The block has conductor channels extending into the body from a first surface and set-screw channels extending into the block from a second surface, there being at least one set-screw channel associated with each conductor channel. Each set-screw channel intersects its associated conductor channel. Each conductor channel has a conductor receiving section and an adapter receiving section, the adapter receiving section located between the conductor receiving section and the associated set-screw channel. The connector has an elongated adapter for each conductor channel, the adapter generally sized and shaped to fit in the adapter receiving section in the conductor channel.

Abstract: An electrical connector for transformer studs accommodates two different size transformer studs in the same slip-fit blind hole. The hole is provided with circumferential arc recesses which are sized and threaded to match the threads on the two different size studs. One or more jam screws force the stud into the respective recesses, and the matching threads provide a substantial contact area and an effective and efficient long lasting and sturdy electrical transformer connection.

Abstract: An electrical component grounding device includes a ground bar, a fastener, and an elongate backing plate. The ground bar includes an elongate electrical contact bridge having at least one electrical contact, a retainer bracket angularly depending centrally of the bridge, and a fastener receiver. The fastener communicates with the ground bar via the fastener receiver. The elongate backing plate has a fastener receiver mating with the fastener and is operative to engage together the ground bar and the backing plate about a support structure. The backing plate and the fastener further cooperate to support the backing plate for rotatable positioning relative to the ground bar to facilitate assembly of the grounding device to the support structure.

Abstract: A connector is attachable to an extending transformer stud. The connector includes an elongate central body having a longitudinal bore opening at one end for insertable accommodation of the transformer stud. An elongate conductor accommodating body extends along the central body in side-by-side relationship thereto. The conductor accommodating body includes a plurality of spaced apart conductor insertion apertures. The apertures are spaced along the length of the conductor accommodating body so as to be longitudinally coextensive with the longitudinal bore of the central body.

Abstract: A clamp-on multiple lug buss bar assembly that is attached to the electrical terminal stud that extends upwardly from the top surface of an electrical power transmission transformer that is used in an underground transformer vault. After its installation, a mold is placed thereover with its bottom edge contacting the top surface of the transformer. The height of the mold is such that it covers the top edge of the conductor plates that form part of the buss bar assembly. Additionally the mold has risers extending up from its top surface that surround the bottom end of the spade connector fingers extending upwardly from the conductor plates. The cavity of the mold is filled with an epoxy resin and when it has set forms a water tight casing for the electrical conductor plates, the electrical terminal stud extending upwardly from the transformer and the top wall of the transformer.

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: The multi-tap pad connector includes an integral conductive body with a longitudinal axis. A threaded female blind aperture is formed about a portion of the longitudinal axis for receiving the output from a secondary side of a transformer or similar electrical source. The body further includes a plurality of secondary electrical connection channels which are oriented perpendicularly with respect to the longitudinal axis. Oblique flanges are formed over the secondary electrical connection channels and include threaded apertures therethrough. The threaded apertures are directed to the secondary electrical connection channels. Allen set screws pass through the threaded apertures and into the secondary electrical connections channels to secure the secondary connectors both electrically and mechanically to the multi-tap pad connector.

Abstract: An electrical bus assembly distributes high current electrical power to a plurality of different devices simultaneously. The electrical bus assembly has a busbar assembly having an electrical conductor and a plurality of studs. At least one multi-contact connector is mounted to the busbar assembly and has a plurality of individual pin contacts in electrical communication with one another, so as to facilitate the transfer of electrical power therethrough. An array of such bus assemblies, defining an electrical power distribution module is also disclosed.

Abstract: A reusable power cable connector system for medium voltage, underground electric power cables for connecting the power lines in one of a plurality of possible connection configurations, which includes a conductive body having a central portion and terminals, each terminal being arranged for receiving a power cable and projecting from the central portion and formed for receiving an end of a power cable, the terminals being formed as legs. The body is coated with an electrically insulating material. There are releasable fasteners cooperating with the terminals for releasably fastening the power cable to the terminal. End caps are releasably connected to the terminals for protecting the ends of the legs both when a cable is connected to such leg and when a cable is not connected to such leg and the end caps are releasably connected to the connector as well as insulation cooperating with the legs for sealing a power cable which is releasably attached to the connector.

Abstract: A connector has an attaching portion with a first axis extending in a first direction, a first free end adapted to receive a mating connection element, and a second end spaced from the first free end along the first axis. The connector further has first and second arm portions coupled to the second end of the attaching portion and extending outwardly therefrom. Each of the arm portions has a second longitudinal axis extending transverse to the first axis of the attaching portion. Each of the first and second arm portions further has a plurality of ports for receiving conducting devices or conductors, each of the ports being open towards a direction that is transverse to the second longitudinal axis. Preferably, the first and second arm portions and the attaching portion are integrally formed as a unitary, one-piece member.

Abstract: A low resistance electrical connector comprising a flat bar having multiple lateral fingers projecting from the bar to form flat compression pads for attachment of electrical connectors, and an insulating housing surrounding said bar and including relatively short cylindrical projections enclosing a short extent of each finger and presenting a circular shoulder at the proximal end of each finger or the inner end of each compression pad so that a rocket may telescope over the shoulder and seal the connection to each pad. The number of fingers projecting from each bar may vary and they may project from one or both lateral sides of the bar. The connector is made by laser or waterjet cutting a flat sheet or bar of conductive metal such as copper, aluminum or a laminate to form a blank. The sheet is cut to avoid excessive scrap so that the space between fingers becomes the fingers of another blank. The blank is deburred and placed in a mold to form the insulating housing and cylindrical projections.

Abstract: An electrical set screw connector has an insulating cover over a metal body which includes conductor receiving passages or ports and intersecting set screws adapted to clamp down on conductor ends in the conductor receiving passages or ports. The connector insulating cover includes a vestibule or tubular chamber for each set screw. The outer end of the vestibule is restricted to capture the screw and each vestibule is internally threaded. The outer end of each vestibule includes a drive hole for the set screw. The connector insulating cover is made by dipping using the backed out set screws as core pins for each set screw vestibule with removable shanks in the set screw recesses forming the drive holes.

Abstract: Connectors having multiple posts upstanding from a common cross-connection bus are produced by a method that includes the steps of making an extrusion that encompasses the end projection of the connector including the bus and the posts, and then using hollow end-milling cutters to form the posts.