Breakaway Pressure Pad Fastener for Conductor Protection
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Solution Overview
Problem
Existing electrical connectors face challenges in securely attaching and retaining conductors without damaging them, particularly when using fasteners that apply compression force, as they can lead to over-tightening and conductor damage due to friction and torque issues.
Innovation Solution
A fastener design incorporating a shearable section and a breakaway portion with torque limits, along with a pressure pad featuring surface features for conductor engagement, allows for secure attachment while preventing over-tightening and conductor damage by enabling the pressure pad to rotate independently of the shaft, thus reducing friction and torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fastener applies compression force to attach and retain a conductor, then the conductor is securely attached, but the conductor may be damaged due to over-tightening and friction
Solution Approach 1:
The fastener incorporates a breakaway portion with a predetermined torque limit that changes the mechanical parameter of torque transmission. When the torque exceeds the predetermined limit during installation, the breakaway portion fractures, preventing further torque transmission and protecting the conductor from damage while ensuring secure attachment up to the safe torque threshold
Solution Approach 2:
The fastener shaft is divided into distinct segments: an intact portion, a breakaway portion with predetermined torque limit, and a shearable section with higher torque limit. This segmentation allows the fastener to provide controlled torque transmission at different stages, ensuring secure conductor attachment while preventing over-tightening damage through the breakaway mechanism
2Reliability
If a fastener uses friction and torque to secure a conductor, then the conductor is retained, but special torque wrenches are required to prevent damage
Solution Approach 1:
The fastener incorporates a breakaway portion with a predetermined torque limit that automatically fractures when the torque exceeds this limit during installation. This self-limiting mechanism eliminates the need for special torque wrenches or complex control systems, as the fastener itself serves to prevent over-tightening and conductor damage
Solution Approach 2:
The breakaway portion is extracted as a separate, sacrificial element within the fastener structure. This portion is specifically designed to fail at a predetermined torque level, removing the need for external torque control devices and simplifying the installation process while ensuring conductor protection
3Power
If the pressure pad is fixed to the shaft, then torque is transmitted effectively, but friction causes over-tightening and conductor damage
Solution Approach 1:
The pressure pad is designed to rotate independently of the shaft during installation, changing from a static fixed connection to a dynamic rotating connection. This dynamic behavior reduces friction between the pressure pad and conductor, preventing over-tightening damage while allowing effective torque transmission through the shaft to secure the conductor
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 solution ensures a secure and efficient electrical connection by preventing conductor damage and eliminating the need for special torque wrenches, as the shearable and breakaway features allow for controlled torque application, ensuring proper attachment without over-tightening.
Implementation Method 1
The breakaway portion with a second torque limit less than the first torque limit rotatably fixing the pressure pad to the shaft. The fastener is rotated until the second torque limit is reached, fracturing the breakaway portion and allowing the pressure pad to rotate with respect to the shaft.
Implementation Method 2
A shearable section is positioned between the head and the shaft. The shearable section has a first torque limit. The fastener is further rotated until the first torque limit is reached, separating the head from the shaft.
Implementation Method 3
The pressure pad has a surface feature for contacting a conductor. The pressure pad featuring surface features for conductor engagement, allows for secure attachment while preventing over-tightening and conductor damage by enabling the pressure pad to rotate independently of the shaft, thus reducing friction and torque transmission.
Data Source
AI summary
A fastener used to secure an electrical conductor includes a head, a shaft, and a pressure pad. The head has an inner surface for receiving a drive tool. The shaft has an outer surface including a threaded portion. The pressure pad can include a surface feature. The pressure pad can also be releasably, rotationally-fixed to the shaft through a breakaway portion.