Angled Electrical Insulator with Integrated Vise Jaws
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Solution Overview
Problem
Conventional insulators and associated ties or clamps fail to provide reliable and economical mechanical and electrical support for a wide range of electrical conductor sizes, especially in angled configurations greater than 5°, leading to inadequate grip strength and increased risk of electrical resistance path reduction and dry-arc distance reduction.
Innovation Solution
An electrical insulator apparatus with a central axis, internal cavity, and spaced fins, featuring a jaw platform with a planar surface aligned to intersect the internal cavity, allowing for secure side-saddle mounting of conductors using a pin and fasteners, which distributes lateral forces effectively to the mounting pin, reducing cantilever moments and creep.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tie-wire is used to secure conductors, then cost is reduced, but conductor grip strength becomes insufficient and consistency varies
Solution Approach 1:
The insulator body incorporates an integrated vise-top mechanism with movable jaw pieces that automatically grip the conductor when the second jaw piece is moved toward the first jaw piece, eliminating the need for separate tie-wire materials and manual tying operations. The insulator performs both its insulating function and the conductor securing function through its own structural components.
2Reliability
If preformed tie-wire is used, then conductor grip strength and consistency improve, but cost increases and resistance path to ground is reduced
Solution Approach 1:
The insulator body incorporates an integrated vise-top mechanism with movable jaw pieces that automatically grip the conductor when the second jaw piece is moved toward the first jaw piece, eliminating the need for separate tie-wire materials and manual tying operations. The insulator performs both its insulating function and the conductor securing function through its own structural components.
3Reliability
If clamp-top fittings are used, then conductor grip strength improves, but cost increases and conductor position is raised above normal mounting position
Solution Approach 1:
The patent merges the insulator body with the conductor securing mechanism by integrating the vise-top jaw pieces directly into the insulator structure. The first jaw piece is positioned on the insulator body and the second jaw piece is connected to the first jaw piece, allowing the insulator to perform both electrical insulation and mechanical conductor retention functions through a unified structure.
4Adaptability or versatility
If vise-top insulators are used, then accommodation of wide range of conductor sizes is achieved, but conductor grip strength becomes less than preformed ties and clamp-top fittings
Solution Approach 1:
The patent employs movable jaw pieces where the second jaw piece can be moved relative to the first jaw piece along the insulator body. This dynamic mechanism allows the jaw pieces to clamp onto conductors of varying sizes with adjustable grip strength, combining the versatility of accommodating different conductor dimensions with the mechanical advantage of a clamping action that provides sufficient grip strength.
Data Source
AI summary
An electrical insulator apparatus and methods of using the same are provided. The apparatus includes an insulator body formed about a central axis, the insulator body having a plurality of spaced fins positioned along an exterior of the insulator body. A first jaw portion is positioned on an upper portion of the insulator body. A second jaw portion is positioned proximate to the first jaw portion and is movable with respect to the first jaw portion. At least one fastener is connected between the first and second jaw portions. A jaw platform is positioned at least partially between the first and second jaw portions, wherein the first and second jaw portions and the jaw platform form a notch sized to receive an electrical conductor, wherein the jaw platform substantially lies within a first plane angled substantially between 6° and 184° with respect to the central axis of the insulator body.