Bush Deformation for Corrosion Protection in Electrical Terminals
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Solution Overview
Problem
Existing devices for fixing electrical connection terminals to substrates often require stripping of paint or coatings, leading to potential corrosion due to exposed substrate surfaces, especially around holes drilled for assembly, which can compromise the integrity of the electrical and mechanical connection.
Innovation Solution
A device featuring a bush with deformation regions that expand laterally and axially upon dowel insertion, forming crimps to conceal cracks in the substrate's paint or coating, ensuring effective electrical contact and protection against corrosion without requiring access to both substrate sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a screw and nut assembly is used to fix the terminal to the substrate, then the terminal can be held tightly to the substrate, but the surface of the substrate must be stripped of paint or coating which exposes the substrate to corrosion
Solution Approach 1:
The fixing device is divided into separate functional components: a ring that provides mechanical anchoring and electrical contact, a socket that secures the terminal, and a screw for assembly. This segmentation allows the ring to be inserted into a pre-drilled hole without requiring paint stripping, as the ring's internal expansion mechanism provides sufficient holding force while the paint remains intact to protect the substrate surface.
Solution Approach 2:
The ring acts as an intermediary component between the substrate and the terminal. It is inserted into a hole drilled through the substrate and expands internally to anchor securely, while its external surface provides a mounting platform for the terminal. This intermediary allows the substrate paint to remain intact on the outer surface, preventing corrosion exposure.
2Ease of operation
If the flange is not pressed fully against the substrate during assembly, then the tensile force can be applied to the dowel, but this creates a gap between the flange and substrate exposing cracked paint to the elements
Solution Approach 1:
The ring is pre-inserted into the hole in the substrate before applying the tensile force to the dowel. This preliminary positioning ensures that when the dowel is subsequently forced into the ring, the flange is already in place to bear against the substrate front face, concealing any cracked paint around the hole. The sequence of operations is designed to ensure proper alignment and contact.
Solution Approach 2:
The ring undergoes a parameter change in its internal dimensions when the tensile force is applied to the dowel. The dowel's expansion causes the ring to expand radially, creating a secure mechanical lock within the hole. This expansion occurs after the ring is already positioned with its flange bearing against the substrate, ensuring that the expansion force is transmitted through the flange-substrate contact rather than causing misalignment.
3Reliability
If the ring is expanded radially to lock in the hole, then the terminal can be fixed to the substrate, but the cracks on the rear face of the substrate remain exposed
Solution Approach 1:
The solution addresses the rear face corrosion problem by extending the protective function into a new dimension - the rear face of the substrate. The deformation zone is specifically positioned and configured to create a crimp that wraps around and covers the rear face area, thereby protecting cracked paint on the rear face without compromising the radial expansion mechanism that provides mechanical locking.
4Reliability
If paint stripping is required to ensure good electrical contact, then electrical contact quality is improved, but additional manufacturing steps and corrosion protection measures are required
Solution Approach 1:
The ring's internal surface serves a dual function: it provides both mechanical anchoring through radial expansion and electrical contact with the substrate. The material and surface properties of the ring are designed to ensure good electrical contact without requiring the substrate paint to be stripped. The ring effectively serves itself by providing both mechanical and electrical functions while maintaining the integrity of the substrate coating.
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 device provides reliable electrical contact and enhanced corrosion protection by forming crimps that cover cracks on both the front and rear faces of the substrate, maintaining the integrity of the connection and preventing exposure to elements.
Implementation Method 1
a bush for location within the opening of the support and provided with opposed front and rear ends between which extends a through-hole, the bush having a first deformation region configured for lateral expansion; a dowel configured for forced insertion into the through-hole so as to cause deformation of the bush
Implementation Method 2
the bush includes a second deformation region configured for axial contraction and lateral expansion upon forced insertion of the dowel in the bush
Data Source
AI summary
The invention relates to a device for fixing an electrical connection terminal to a support having an opening extending between opposed front and rear faces, the device comprising: a bush for location within the opening of the support and provided with opposed front and rear ends between which extends a through-hole, the bush having a first deformation region configured for lateral expansion; a dowel configured for forced insertion into the through-hole so as to cause deformation of the bush, the dowel being provided with connection means engageable with a connector to facilitate the forced insertion of the dowel into the bush and to facilitate fastening of a terminal to the support; characterised in that the bush includes a second deformation region configured for axial contraction and lateral expansion upon forced insertion of the dowel in the bush.