The terms “couple”, “coupled”, “couples”, “coupling”, “fixed”, “attached to”, “connect”, “connected”, and the like should be broadly understood to refer to connecting two or more elements or signals electrically and/or mechanically, either directly or indirectly through intervening circuitry and/or elements. Two or more electrical elements may be electrically coupled, either direct or indirectly, but not be mechanically coupled; two or more mechanical elements may be mechanically coupled, either direct or indirectly, but not be electrically coupled; two or more electrical elements may be mechanically coupled, directly or indirectly, but not be electrically coupled. Coupling (whether only mechanical, only electrical, or both) may be for any length of time, e.g., permanent or semi-permanent or only for an instant. “Communicatively coupled to” and “operatively coupled to” can refer to physically and/or electrically related components.

Where any conflict or ambiguity may exist between a document incorporated by reference and this detailed description, the present detailed description controls. Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context.

FIGS. 1-10 depict various views of a cutting and compression jaw apparatus 100. The cutting and compression jaw apparatus may be sized and shaped or otherwise configured to be coupled to a body assembly. The body assembly may be a manual or mechanical assembly or may be an electric or hydraulic assembly. Once the cutting and compression jaw apparatus 100 is coupled to the body assembly, the cutting and compression jaw apparatus 100 may be used to both cut and crimp a cable without having to remove the cutting and compression jaw apparatus from the body assembly. In particular, the cutting a compression jaw apparatus 100 is configured such that a user may insert a cable, such as a four-aught (4/0 or 0000) aluminum conductor steel reinforced (ASCR) cable, between a pair of jaws 102A, 102B. Example four-aught ASCR cables may be utilized in long, extra high voltage transmission lines or sub-service spans on a private premises and may include a central steel core surrounded by one or more layers of concentric stranded aluminum alloy and coated with zinc to protect from corrosion. In one specific example, the four-aught ASCR cable may include six strands of aluminum alloy concentrically arranged around a single steel core and includes a diameter of about 0.3-0.7 inches, a weight of about 0.1-0.5 pounds per linear foot, and a rated strength of about 8000-8500 lb./ft.

Each respective jaw of the pair of jaws 102A, 102B includes both a blade 104A, 104B and a compression pocket 106A, 106B that are positioned along the length of the respective jaw 102A, 102B, where the respective blades 104A, 104B and respective compression pockets 106A, 106B are sized and shaped or otherwise positioned, according to a non-limiting example, to be used for a four-aught ASCR cable. In one embodiment, the compression pockets 106A, 106B may be sized and shaped to (when used in combination with a crimping die set 130A, 130B) swage (using a fitting/sleeve) or crimp an end of the cable. The compression pocket 106A, 106B may be sized and shaped or otherwise configured to align with various sized crimping die sizes of a crimping die set 130A, 130B, and in a particular example the crimp pockets 106A, 106B may be sized and shaped to fit a crimping die set 130A, 130B having a BG-sized crimping terminal. According to various embodiments, an upper compression pocket 106A may be coupled to an upper crimping die 130A and the lower compression pocket 106B may be coupled to a lower crimping die 130B. The crimping die set 130A, 130B may be configured to perform a double-crimp of the same wire/cable during a single crimping operation. In particular, the crimping dies of the crimping die set 130A, 130B may be concave in shape and be forked or otherwise have a void 142 (see FIG. 10) extending along the length of the crimping die set 130A, 130B such that a wire/cable positioned across the width of the compression portion of the cutting and compression jaw apparatus 100 will have two compression or crimping points during a compression of the wire/cable (i.e., a double crimp) with a space between each crimp where the void 142 was positioned.

In order for an electric or hydraulic powered tool to have sufficient force to crimp cables such as the four-aught ASCR cable described above, at least four tons of force would be needed to crimp the cable. By positioning the compression pockets 106A, 106B more proximate the fulcrum point 140, which corresponds with the central apertures 108A, 108B (see FIG. 10) that traverses the width of both jaws 102A, 102B, the cutting and compression jaw apparatus 100 is able to generate sufficient force to crimp the cable. When the compression pockets 106A, 106B are positioned more distal to the fulcrum point 140, the compression portion may generate at least four tons of force, whereas when the compression pockets are positioned more proximate the fulcrum point 140, the compression portion may generate at least five-and-a-half tons or at least more than six tons of force. Similarly, the amount of force that may be provided by the cutting portion may be at least four tons of force when positioned more distal to the fulcrum point 140 and at least five-and-a-half tons or at least more than six tons of force if positioned more proximal to the fulcrum point 140. During assembly of the cutting and compression jaw apparatus 100, once the central apertures 108A of one jaw 102A are aligned with the central apertures 108B the other jaw 102B, a pivot pin channel 110 may be inserted through all respective central apertures 108A, 108B. One jaw 102A would have two central apertures 108A and the other jaw 102B would also have two central apertures 108B. According to one embodiment of jaw 102A, both of the central apertures 108A protrude through u-shaped or yoke shaped protrusions/ridges 132 positioned around the fulcrum point 140 that are separated by a groove 138A (see FIG. 10). Similarly, according to one embodiment of jaw 102B, the central apertures 108B protrude through u-shaped or yoke-shaped protrusions/ridges 134 positioned around the fulcrum point 140 that are separated by a groove 138B (see FIG. 10). In some embodiments, the protrusions/ridges 132 of jaw 102A and the protrusions/ridges 134 of jaw 102B are configured to hingedly interconnect such that each protrusion/ridge forms a knuckle of the hinged connection such that the pivot pin channel 110 may traverse a total of four knuckles. For example, depending upon orientation and which direction the pivot pin channel 110 is entering the central apertures 108A, 108B, the pivot pin channel 110 would traverse a first knuckle of a first jaw of the jaws 102A, 102B, a second knuckle of the opposite jaw 102A, 102B, a third knuckle of the first jaw of the jaws 102A, 102B, and a fourth knuckle of the opposite jaw 102A, 102B.

The pivot pin channel 110 may be cylindrically shaped and include respective ends 112, 114 (see FIG. 10) that are sized and shaped or otherwise configured to couple to a respective fastener 116. In one particular example, the respective ends 112, 114 of the pivot pin channel 110 are threaded and the fastener 116 secure to each end of the pivot pin channel 110 when the pivot pin channel 110 is coupled to the jaws 102A, 102B. According to one embodiment, a clevis 152 (see FIG. 11) may be connected to a housing 154 (see FIG. 11) of the body assembly 150 (see FIG. 11) and include bearing eyes 156 (see FIG. 11)) at the ends of the clevis prongs 158A, 158B (see FIG. 11) through which a pin 160 (see FIG. 11) is inserted in order to attach the cutting and compression jaw apparatus 100. For installation of the cutting and compression jaw apparatus 100, when the pivot pin channel 110 is aligned with the bearing eyes 156 of the clevis 152, a shaft of the pin 160 may be inserted through the first bearing eye 156 of the clevis 152, through the pivot pin channel 110, and through the second bearing eye 156 of the clevis 152 such that a pivot pin head of the pin 160, having a greater diameter than the shaft of the pivot pin 160, helps secure the shaft of the pivot pin 160 in place within the bearing eyes 156 of the clevis 152 and the pivot pin channel 110 so that one or more fasteners (not shown) may be connected to the end opposite (a threaded end) the pivot pin head and secure the cutting and compression jaw apparatus 100 to the body assembly 150 (see FIG. 11).

Due to the positioning of the compression pockets 106A, 106B being closer to the fulcrum point 140 and, thus, being able to provide force during operation than more distal portions of the jaws 102A, 102B, more rigid material is needed for the blades 104A, 104B, which are positioned more distal along the length of the jaws 102A, 102B in order to compensate for having less force available. In some embodiments utilizing an electric or hydraulic powered tool, the blades 104A, 104B may be able to generate at least 4-5 tons of force. For example, the amount of force generated by the electric or hydraulic power tool may be approximately 4 tons of force, and then the mechanical advantage provided during compression of the blades 104A, 104B about the fulcrum point 140 may provide an additional 1-2 tons of force at the distal portions of the jaws 102A, 102B that incorporate the blades 104A, 104B. In order to compensate for the difference in force available at the distal portions of the jaws 102A, 102B, the blades 104A, 104B incorporate a rigid material to provide a stronger blade surface. Example rigid materials can include a tungsten carbide material or diamond plated material that form the blade surface to compensate for the positioning of the blades 104A, 104B distally along the length of the jaws 102A, 102B. In some embodiments, the blades 104A, 104B may incorporate diamond particles ingrained within the blade material. If the material of the blades 104A, 104B is not sufficiently rigid, the blades 104A, 104B may buckle due to the rigidity of the cable, which may cause the blades 104A, 104B to flare outward or separate rather than slice through the diameter of the cable.

The blades 104A, 104B may incorporate a blade edge 120A, 120B that is shaped as a chisel or single bevel edge (as depicted), a V-shaped edge, a compound bevel edge, a convex edge, a hollow edge, a sabre edge, a double hollow edge, a double-double bevel edge, or any other edge shape capable of cutting a cable. According to one embodiment, the blades 104A, 104B may be removable or replaceable and incorporate a connection aperture 122A, 122B that align with corresponding connection apertures of the jaws 102A, 102B through which a connection pin (not shown) may be inserted to lock the respective blades 104A, 104B into position and couple the blades 104A, 104B to the jaws 102A, 102B. In particular, the jaws 102A, 102B may each form a blade mount 124A, 124B for housing a coupling portion 126A, 126B (see FIG. 10) of the blades 104A, 104B, the coupling portion 126A, 126B being approximately one-third of the height of the blades 104A, 104B opposite the blade edges 120A, 120B that includes the connection apertures 122A, 122B.

According to one embodiment the cutting and compression jaw apparatus 100 may be biased open using a spring 118 positioned opposite the fulcrum point 140 from the compression pockets 106A, 106B and the blades 104A, 104B. The force applied to the jaws 102A, 102B would overpower the spring force applied by the spring 118 that biases the cutting and compression jaw apparatus 100 to an open position. In some embodiments, the cutting and compression jaw apparatus 100 may include locking pins for use during storage that lock the cutting and compression jaw apparatus 100 at a closed position as a safety feature. The cutting and compression jaw apparatus 100 may includes at least two channels 128A, 128B, with a first channel 128A positioned on a first jaw 102A and a channel 128B positioned on a second jaw 102B. In some embodiments, each jaw 102A, 102B may include additional channels 128C, 128D in addition to the first and second channels 128A, 128B. In some embodiments, the additional channels 128C, 128D may be sized and shaped or otherwise configured to receive a pin 136. According to one embodiment, each of the connection points 128A, 128B may include apertures through which a pin or a fastener may be inserted to attach the cutting and compression jaw apparatus 100 to a body assembly 150 (see FIG. 11) of a motorized tool.

FIG. 11 is a perspective view of an example kit that includes the example cutting and compression jaw apparatus 100 and a body assembly 150. During operation in embodiments that incorporate a hydraulic functionality, the body assembly 150 may include an electric motor, a pump driven by the motor, an extensible piston disposed within a piston cylinder (i.e., a drive), and a housing. The pump may provide pressurized hydraulic fluid to the piston cylinder causing the piston to extend outward from the housing and actuate the jaws 102A, 102B, which pivot about the fulcrum point 140 and apply pressure to a cable positioned between either the blades 104A, 104B or the compression pockets 106A, 106B. When the pressure is released, the piston retracts thereby opening the cutting and compression jaw apparatus 100. In embodiments that incorporate an electromechanical functionality, electrical energy provided by a motor is converted to mechanical energy that actuates a mechanical driver (i.e., a drive), which causes the mechanical driver to extend outward from the housing and actuate the jaws 102A, 102B. During operation, the jaws 102A, 102B pivot about the fulcrum point 140 and apply pressure to a cable positioned between either the blades 104A, 104B or the compression pockets 106A, 106B.

In addition, the spring force applied by the spring 118 causes the cutting and compression jaw apparatus 100 to bias open when not in use.

For embodiments in which the cutting and compression jaw apparatus 100 incorporates purely electric power rather than hydraulic, the body assembly 150 may incorporate an electric linear actuator that converts the rotary motion of the electric motor (i.e., a DC motor) to linear motion. In one embodiment, the linear actuator may be operated by a motor and include a piston rod bearing, a piston rod, a spindle, a barrel housing, a ball screw nut, a spindle bearing, and a drive shaft. The motor may create a rotary motion causing the spindle to rotate. The spindle may be coupled to a helical screw via a drive shaft, which in turn causes the ball screw nut to rotate. The ball screw nut is driven forward or backward during rotation along the helical screw. A hollow piston rod may be coupled to the ball screw nut, and the movement of the ball screw nut may cause the piston rod to move linearly outward, which causes the cutting and compression jaw apparatus 100 to close the jaws 102A, 102B, or to move linearly inward causing the jaws 102A, 102B to retract and open. According to one embodiment, a feedback mechanism provides positional information such that the linear actuator can be programmed to move to a certain position to cut the cable and then return to its rest position. In addition, the spring force applied by the spring 118 causes the cutting and compression jaw apparatus 100 to bias open when not in use.

During a first operation of the cutting and compression jaw apparatus 100, an operator may initially position a wire/cable between the blades 104A, 104B of a cutting portion of the jaws 102A, 102B and perform a cut of the wire/cable by engaging the blades 104A, 104B such that a height of a first blade edge 120A of the first blade 104A at least partially overlaps a height of the second blade edge 102B of the second blade 104B. According to one embodiment, the first operation of cutting the wire/cable provides at least four tons of force, and more particularly about four-and-a-half tons to six tons of force. Once the wire/cable is cut, thereby forming two ends, the blades 104A, 104B are disengaged. One of the ends of the cut wire/cable is then positioned between crimping die of the crimping die set 130A, 130B of a compression portion of the jaws 102A, 102B. During a second operation of the cutting and compression jaw apparatus 100, a compression of one of the ends of the cut wire/cable is performed by engaging the compression portion of the jaws 102A, 102B. According to one embodiment, the compression provided by the second operation provides at least four tons of force, and in a more particular embodiment at least five-and-a-half or six tons of force to compress the end of the cut wire/cable.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below, if any, are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of one or more embodiments has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments disclosed herein were chosen and described in order to best explain various aspects and the practical application, and to enable others of ordinary skill in the art to understand various embodiments with various modifications suited to the particular use contemplated.

In one embodiment “embodiment A”, a jaw apparatus includes a first jaw pivotably coupled to a second jaw at a fulcrum point, the first jaw having a first jaw length extending from a first jaw proximal end to a first jaw distal end and the second jaw having a second jaw length extending from a second jaw proximal end to a second jaw distal end, the fulcrum point being positioned more proximate both the first jaw proximal end and the second jaw proximal end than to the first jaw distal end and the second jaw distal end; a first cutting portion positioned along the first jaw length more proximate the first jaw distal end than to the fulcrum point; a second cutting portion positioned along the second jaw length more proximate the second jaw distal end than to the fulcrum point; a first compression portion positioned along the first jaw length in between the fulcrum point and the first cutting portion; and a second compression portion positioned along the second jaw length in between the fulcrum point and the second cutting portion.

In one example of the jaw apparatus of embodiment A, the first cutting portion comprises a first blade mount configured to receive a first detachable blade and the second cutting portion comprises a second blade mount configured to receive a second detachable blade. Further, in some instances, the first blade mount and the second blade mount are aligned along the respective first jaw length and second jaw length when the first jaw and the second jaw are positioned in a closed position, the closed position engaging the first jaw and the second jaw such that the first jaw and the second jaw are adjoining. In addition, in some instances, when the first jaw and the second jaw are in the closed position and the first detachable blade is mounted to the first blade mount and the second detachable blade is mounted to the second blade mount, a first blade edge of the first detachable blade at least partially overlaps with a second blade edge of the second detachable blade. In some embodiments, at least one of the first blade edge and the second blade edge is concave.

In some instances, the first compression portion of embodiment A includes a first compression pocket configured to receive a first compression die of a compression die set and the second compression portion of embodiment A includes a second compression pocket configured to receive a second compression die of the compression die set, wherein the first compression pocket and the second compression pocket are each semi-circular in shape such that a circular aperture is formed when the first compression pocket and the second compression pocket are aligned and adjoining.

In some instances of embodiment A, the first jaw is pivotally coupled to the second jaw at the fulcrum point via a hinged connection between multiple knuckles, the multiple knuckles including a first knuckle of the first jaw, a second knuckle of the second jaw, a third knuckle of the first jaw, and a fourth knuckle of the second jaw, wherein a first receiving channel is positioned between the first knuckle and the third knuckle of the first jaw that is configured to receive one of the second knuckle and the fourth knuckle of the second jaw, and a second receiving channel is positioned between the second knuckle and the fourth knuckle of the second jaw that is configured to receive one of the first knuckle and the third knuckle of the first jaw. Further, in some instances, each of the first knuckle, the second knuckle, the third knuckle, and the fourth knuckle comprise respective central apertures passing therethrough at the fulcrum point, the respective central apertures being configured to receive a pivot pin channel. In some examples, the pivot pin channel comprises a cylinder having first end configured to receive a first fastener and having a second end opposite the first end configured to receive a second fastener.

In some instances of embodiment A, the jaw apparatus further includes a spring connecting the first jaw and the second jaw, the spring being positioned along the first jaw length relative the fulcrum point opposite from the first cutting portion and first compression portion of the first jaw and being positioned along the second jaw length relative the fulcrum point opposite from the second cutting portion and the second compression portion of the second jaw. In some instances, the spring is configured to bias open the first jaw and the second jaw when the jaw apparatus is not in operation. Further, in some instances, the first cutting portion and the second cutting portion are capable of providing at least four tons of force when engaged, and wherein the first compression portion and the second compression portion are capable of providing at least four tons of force when engaged.

In another embodiment, “embodiment B” a cutting a compression kit is disclosed that includes a cutting and compression jaw apparatus and a body assembly that includes a drive for operating the cutting and compression jaw apparatus. The cutting and compression jaw apparatus includes a first jaw pivotably coupled to a second jaw at a fulcrum point, the first jaw having a first jaw length extending from a first jaw proximal end to a first jaw distal end and the second jaw having a second jaw length extending from a second jaw proximal end to a second jaw distal end, the fulcrum point being positioned more proximate both the first jaw proximal end and the second jaw proximal end than to the first jaw distal end and the second jaw distal end. The cutting and compression jaw apparatus also includes a first cutting portion positioned along the first jaw length more proximate the first jaw distal end than to the fulcrum point. In addition, the cutting and compression jaw apparatus includes a second cutting portion positioned along the second jaw length more proximate the second jaw distal end than to the fulcrum point, and a first compression portion positioned along the first jaw length in between the fulcrum point and the first cutting portion. The cutting and compression jaw apparatus also includes a second compression portion positioned along the second jaw length in between the fulcrum point and the second cutting portion.

In some examples of embodiment B, the drive comprises at least one of an electromechanical drive and a hydraulic drive, wherein the drive is configured to pivot the first jaw relative the second jaw during operation.

The first cutting portion of embodiment B may also include a first blade mount configured to receive a first detachable blade and the second cutting portion comprises a second blade mount configured to receive a second detachable blade. Further, the first blade mount and the second blade mount may be aligned along the respective first jaw length and second jaw length when the first jaw and the second jaw are positioned in a closed position, the closed position engaging the first jaw and the second jaw such that the first jaw and the second jaw are adjoining

In some examples of embodiment B, the first compression portion comprises a first compression pocket configured to receive a first compression die of a compression die set and the second compression portion comprises a second compression pocket configured to receive a second compression die of the compression die set, wherein the first compression pocket and the second compression pocket are each semi-circular in shape such that a circular aperture is formed when the first compression pocket and the second compression pocket are aligned and adjoining.

Also disclosed herein is a method that includes positioning an object to be cut between a first cutting portion of a first jaw of a cutting and compression apparatus and a second cutting portion of a second jaw of the cutting and compression apparatus, the first jaw having a first jaw length extending from a first jaw proximal end to a first jaw distal end and the second jaw having a second jaw length extending from a second jaw proximal end to a second jaw distal end, the cutting and compression apparatus including a fulcrum point positioned more proximate both the first jaw proximal end and the second jaw proximal end than to the first jaw distal end and the second jaw distal end, wherein the first cutting portion is positioned along the first jaw length more proximate the first jaw distal end than to the fulcrum point, and the second cutting portion is positioned along the second jaw length more proximate the second jaw distal end than to the fulcrum point. The method also includes engaging at least one of the first jaw and the second jaw such that a first blade of the first cutting portion engages a second blade of the second cutting portion, thereby cutting the object into a first portion and a second portion. In addition, the method includes positioning one of the first portion and the second portion between a first compression portion of the first jaw and a second compression portion of the second jaw, the first compression portion being positioned along the first jaw length in between the fulcrum point and the first cutting portion, and the second compression portion being positioned along the second jaw length in between the fulcrum point and the second cutting portion. Further, the method includes re-engaging the at least one of the first jaw and the second jaw such that the first compression portion engages with the second compression portion thereby compressing the one of the first portion and the second portion positioned between the first compression portion and the second compression portion.

In some examples of the method, engaging the at least one of the first jaw and the second jaw includes activating an electromechanical drive operatively coupled to at least one of the first jaw and the second jaw, and the re-engaging the at least one of the first jaw and the second jaw comprises re-activating the electromechanical drive.

In some examples of the method, engaging the at least one of the first jaw and the second jaw applies at least four tons of force to the object, and wherein the re-engaging the at least one of the first jaw and the second jaw applies at least four tons of force.

In another embodiment, “embodiment C” a device includes a first cutting portion, a second cutting portion spatially positioned to engage the first cutting portion during a cutting operation, a first compression portion, a second compression portion spatially positioned to engage the first compression portion during a compression operation, and an engaging mechanism. The engaging mechanism is operatively coupled to the first cutting portion, the second cutting portion, the first compression portion, and the second compression portion. Further, the engaging mechanism is configured to perform the cutting operation by engaging the first cutting portion and the second cutting portion, and the compression operation by engaging the first compression portion and the second compression portion.

In one example of the device 200 of embodiment C, as depicted by FIGS. 12-21, the first cutting portion is a first blade mount configured to receive a first detachable blade and the second cutting portion is a second blade mount configured to receive a second detachable blade. In some instances, when the first detachable blade is mounted to the first blade mount and the second detachable blade is mounted to the second blade mount, a first blade edge of the first detachable blade at least partially overlaps with a second blade edge of the second detachable blade during the cutting operation.

In another example of the device of embodiment C, the first cutting portion includes a first blade integrally fixed to the first cutting portion and the second cutting portion includes a second blade integrally fixed to the second cutting portion