Slip-fit connector compatible with different size transformer studs and related methods

1. A slip-fit electrical connector compatible with different size threaded transformer studs and comprising:

a body having a plurality of transverse conductor receiving passageways therein, and a plurality of conductor fastener receiving passageways therein intersecting respective transverse conductor receiving passageways;

a plurality of conductor fasteners in respective conductor receiving passageways;

said body also having a multi-size transformer stud receiving passageway extending inwardly from an end thereof, and at least one stud fastener receiving passageway therein intersecting the multi-size transformer stud receiving passageway; and

at least one stud fastener in the at least one stud fastener receiving passageway;

the multi-size transformer stud receiving passageway being defined by a smooth arcuate bottom, and a plurality of successively larger threaded stud landings with a lowermost threaded stud landing being bifurcated by the smooth arcuate bottom, and each successive threaded stud landing being bifurcated by a prior threaded stud landing, the threaded stud landings being compatible with different size threaded transformer studs.

2. A slip-fit electrical connector according to claim 1 wherein each threaded stud landing has a respective different radius of curvature.

3. A slip-fit electrical connector according to claim 1 wherein each threaded stud landing has an oversized radius of curvature for each respective different size transformer stud.

4. A slip-fit electrical connector according to claim 1 wherein the multi-size transformer stud receiving passageway further comprises an arcuate top merged with an uppermost threaded stud landing and connected to the at least one stud fastener receiving passageway.

5. A slip-fit electrical connector according to claim 4 wherein the arcuate top has a smooth surface.

6. A slip-fit electrical connector according to claim 4 wherein the arcuate top has a first radius of curvature.

7. A slip-fit electrical connector according to claim 1 wherein the smooth arcuate bottom has a second radius of curvature.

8. A slip-fit electrical connector according to claim 1 wherein the plurality of threaded stud landings are two in number.

9. A slip-fit electrical connector according to claim 1 wherein said body has a generally rectangular shape.

10. A slip-fit electrical connector according to claim 1 wherein said body comprises first and second generally rectangular elongate portions connected in an offset arrangement.

11. A slip-fit electrical connector according to claim 1 wherein said body comprises aluminum.

12. A slip-fit electrical connector compatible with different size threaded transformer studs and comprising:

a body having a plurality of transverse conductor receiving passageways therein, and a plurality of conductor fastener receiving passageways therein intersecting respective transverse conductor receiving passageways;

a plurality of conductor fasteners in respective conductor receiving passageways;

said body also having a multi-size transformer stud receiving passageway extending inwardly from an end thereof, and at least one stud fastener receiving passageway therein intersecting the multi-size transformer stud receiving passageway; and

at least one stud fastener in the at least one stud fastener receiving passageway;

the multi-size transformer stud receiving passageway being defined by a smooth arcuate bottom, a plurality of successively larger threaded stud landings with a lowermost threaded stud landing being bifurcated by the arcuate bottom, and a smooth arcuate top merged with an uppermost threaded stud landing and connected to the at least one stud fastener receiving passageway, each successive threaded stud landing being bifurcated by a prior threaded stud landing, and the threaded stud landings each having a respective different radius of curvature.

13. A slip-fit electrical connector according to claim 12 wherein each threaded stud landing has an oversized radius of curvature for each respective different size transformer stud.

14. A slip-fit electrical connector according to claim 12 wherein the plurality of threaded stud landings are two in number.

15. A slip-fit electrical connector according to claim 12 wherein said body has a generally rectangular shape.

16. A slip-fit electrical connector according to claim 12 wherein said body comprises first and second generally rectangular elongate portions connected in an offset arrangement.

17. A slip-fit electrical connector compatible with different size threaded transformer studs and comprising:

a body having a plurality of transverse conductor receiving passageways therein, and a plurality of conductor fastener receiving passageways therein intersecting respective transverse conductor receiving passageways;

said body also having a multi-size transformer stud receiving passageway extending inwardly from an end thereof, and at least one stud fastener receiving passageway therein intersecting the multi-size transformer stud receiving passageway; and

the multi-size transformer stud receiving passageway being defined by an unthreaded arcuate bottom, and a plurality of successively larger threaded stud landings with a lowermost threaded stud landing being bifurcated by the unthreaded arcuate bottom, and each successive threaded stud landing being bifurcated by a prior threaded stud landing.

18. A slip-fit electrical connector according to claim 17 wherein each threaded stud landing has a respective different radius of curvature.

19. A slip-fit electrical connector according to claim 17 wherein each threaded stud landing has an oversized radius of curvature for each respective different size transformer stud.

20. A slip-fit electrical connector according to claim 17 wherein the multi-size transformer stud receiving passageway further comprises an arcuate top merged with an uppermost threaded stud landing and connected to the at least one stud fastener receiving passageway.

21. A slip-fit electrical connector according to claim 17 wherein the arcuate top has a smooth surface and a first radius of curvature; and wherein the unthreaded arcuate bottom has a smooth surface and a second radius of curvature.

22. A slip-fit electrical connector according to claim 17 wherein the plurality of threaded stud landings are two in number.

23. A slip-fit electrical connector according to claim 17 wherein said body has a generally rectangular shape.

24. A slip-fit electrical connector according to claim 17 wherein said body comprises first and second generally rectangular elongate portions connected in an offset arrangement.

25. A method for making a slip-fit electrical connector compatible with different size threaded transformer studs and comprising:

forming, in a body, a plurality of transverse conductor receiving passageways, and a plurality of conductor fastener receiving passageways intersecting respective transverse conductor receiving passageways; and

forming, in the body, a multi-size transformer stud receiving passageway extending inwardly from an end thereof, and at least one stud fastener receiving passageway therein intersecting the multi-size transformer stud receiving passageway, the multi-size transformer stud receiving passageway being defined by an unthreaded arcuate bottom, and a plurality of successively larger threaded stud landings with a lowermost threaded stud landing being bifurcated by the unthreaded arcuate bottom, and each successive threaded stud landing being bifurcated by a prior threaded stud landing.

26. A method according to claim 25 wherein forming the multi-size transformer stud receiving passageway comprises:

drilling a plurality of successively larger bores vertically offset from one another; and

forming threaded surfaces for the threaded stud landings by helical interpolation.

27. A method according to claim 25 further comprising positioning conductor fasteners in the conductor receiving passageways, and at least one stud fastener in the at least one stud fastener receiving passageway.

28. A method according to claim 25 wherein each threaded stud landing has a respective different radius of curvature.

29. A method according to claim 25 wherein each threaded stud landing has an oversized radius of curvature for each respective different size transformer stud.

30. A method according to claim 25 wherein the transformer stud receiving passageway further comprises an arcuate top merged with an uppermost threaded stud landing and connected to the at least one stud fastener receiving passageway.

31. A method according to claim 25 wherein the arcuate top has a smooth surface and a first radius of curvature; and wherein the unthreaded arcuate bottom has a smooth surface and a second radius of curvature.

32. A method according to claim 25 wherein the plurality of threaded stud landings are two in number.

33. A method for making a slip-fit electrical connector for a threaded transformer stud comprising:

forming, in a body, a plurality of transverse conductor receiving passageways, and a plurality of conductor fastener receiving passageways intersecting respective transverse conductor receiving passageways;

forming, in the body, a transformer stud receiving passageway extending longitudinally inwardly from an end thereof at least one bore and forming at least one set of threads along surfaces of the at least one bore using helical interpolation; and

forming, in the body, at least one stud fastener receiving passageway intersecting the transformer stud receiving passageway.

34. A method according to claim 33 further comprising positioning conductor fasteners in the conductor receiving passageways, and at least one stud fastener in the at least one stud fastener receiving passageway.

35. A method according to claim 33 wherein the transformer stud receiving passageway is a multi-size transformer stud receiving passageway 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, and each successive threaded stud landing being bifurcated by a prior threaded stud landing.

36. A method according to claim 35 wherein each threaded stud landing has a respective different radius of curvature.