Break-Neck Screw Insert for Consistent Torque Control
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Solution Overview
Problem
Current set screw connections in electrical connectors rely on subjective torque application, leading to inconsistent force on wires, which can result in damage or loose connections, and existing solutions require additional or specialized tools to achieve standardized torque.
Innovation Solution
A screw insert with a body, first head, and second head connected by a neck that breaks when a predetermined torque is exceeded, limiting the torque applied to the set screw and ensuring consistent force, and a tool designed to work with this insert to manage torque effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If torque application is controlled by hand using conventional set screws, then ease of operation is improved, but manufacturing precision of torque application deteriorates
Solution Approach 1:
The patent changes the physical state of the neck from intact to broken, using this parameter change to indicate that predetermined torque has been reached. The neck is designed with specific geometric parameters (reduced cross-section, notches) that cause it to fail at a predetermined torque level, thereby controlling torque application precision without requiring specialized tools.
2Manufacturing precision
If torque gauges or specialized torque wrenches are used, then torque application precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the torque control function from complex external devices (torque gauges, specialized wrenches) and integrates it into the simple break-neck insert itself. The insert body with its weakened neck section serves as both the torque transmission element and the torque limit indicator, eliminating the need for additional complexity.
Solution Approach 2:
The break-neck insert is designed as a disposable component where the neck is intentionally made weak and sacrificial. Once the neck breaks at the predetermined torque, the insert has fulfilled its purpose and can be discarded, avoiding the need for expensive, reusable torque control devices.
3Reliability
If consistent torque is applied to set screws, then reliability of wire connection is improved, but ease of operation deteriorates
Solution Approach 1:
The insert performs self-service torque control through its own structural design. The weakened neck section automatically fails at the predetermined torque level, providing self-regulating torque control without requiring external monitoring or adjustment by the operator. This maintains ease of operation while ensuring reliable torque application.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The screw insert ensures that set screws are installed with a consistent torque, preventing wire damage and ensuring secure connections without the need for additional tools, thereby simplifying the installation process and adhering to standardized torque requirements.
Implementation Method 1
The neck is configured to break causing the second head to separate from the first head in response to a torque applied to the second head exceeding a predetermined value
Data Source
AI summary
A screw insert has a body configured to engage a threaded fastener and transmit a torque to the threaded fastener, a separable head connected to the body and a neck extending between body and the separable head. The neck is configured to break causing the separable head to separate from the body in response to a torque applied to the separable head exceeding a predetermined value.