Mechanical Cable Connector Groove for Higher Pullout Resistance
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Solution Overview
Problem
Existing mechanical connectors for high-voltage electrical cables lack sufficient pullout performance, particularly for cables with conductor diameters between 1 and 80 millimeters, which can lead to unstable electrical connections and separation under tensile forces.
Innovation Solution
A mechanical connector with a conductive body featuring a longitudinal internal bore and a laterally-open groove with higher curvature than the bore, arranged opposite to a transverse threaded hole, enhances contact forces through a 'wedge-effect', improving the pullout resistance and stability of electrical cables by compressing the cable against the groove's edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional mechanical connector without a groove is used, then the structure is simpler, but the pullout performance and contact force are insufficient
Solution Approach 1:
The invention introduces a groove with specific curvature characteristics at a localized position on the internal wall of the connector body, opposite to the threaded hole. This local structural modification creates concentrated contact points that enhance pullout performance without requiring complete redesign of the entire connector structure.
Solution Approach 2:
The groove is designed with a curvature value higher than that of the longitudinal internal bore, creating a curved contact surface that concentrates mechanical stress and improves contact force between the cable and connector body, thereby enhancing pullout resistance.
2Reliability
If the connector body is designed without a groove, then manufacturing is easier, but electrical and mechanical performance are compromised
Solution Approach 1:
The groove is introduced as a localized feature on the internal wall, allowing the majority of the connector body to maintain its conventional simple cylindrical shape. This minimizes the impact on manufacturing processes while providing the necessary performance enhancement at the critical contact region.
3Force
If a groove with higher curvature is added to enhance contact force, then pullout resistance improves, but the device complexity increases
Solution Approach 1:
The groove is designed with a specific curvature profile that is higher than the longitudinal bore but maintains a regular geometric form. This curvature concentration creates effective contact points that generate sufficient contact force while the groove's systematic geometry allows for straightforward manufacturing through standard machining or molding processes.
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 enhanced contact forces and stability provided by the mechanical connector improve both mechanical and electrical stability, allowing for better resistance to pulling forces and maintaining secure connections during high-voltage applications.
Implementation Method 1
enhances contact forces through a 'wedge-effect', improving the pullout resistance and stability of electrical cables by compressing the cable against the groove's edges
Implementation Method 2
The groove has a higher curvature value than a curvature value of the longitudinal internal bore... improving the pullout resistance
Data Source
AI summary
The present invention relates to mechanical connector (10, 100) for connecting an electrical cable (1) comprising a longitudinal internal bore (14) configured for receiving the electrical cable (1) and a transverse threaded hole (22, 24, 26, 28, 102) extending into the longitudinal internal bore (14). The mechanical connector (10, 100) comprises a laterally-open groove (34) recessed in an internal wall (20) along a longitudinal direction (Y) of the longitudinal internal bore (14). The groove (34) has a higher curvature value (R2) than a curvature value (R1) of the longitudinal internal bore (34), and is substantially arranged opposite to the transverse threaded hole (22, 24, 26, 28, 102). The present invention further relates to methods for manufacturing such mechanical connector (10, 100) and a method for assembling the mechanical connector (10, 100) with an electrical cable (1).