Captive Shear Bolt Assembly for Retaining Sheared Bolt Heads

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Solution Overview

Problem

Existing shear bolts used in tap connectors do not prevent the sheared section from falling, which can lead to safety issues and operational challenges.

Innovation Solution

A captive shear bolt assembly is designed with a bolt and a shear coupling, where the bolt includes a head, an extension, and a shank with a shear section that shears at a predetermined torque, ensuring the sheared portion remains secured to the bolt.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a typical shear bolt is used that shears under threshold torque, then the bolt can provide controlled torque limitation, but the sheared portion falls to the ground below causing safety issues and operational challenges

Engineering Contradiction:
Improvesafety and operational reliabilityVSAvoidsheared portion falling to ground
Core Design Contradiction:
ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies the nesting principle by placing the sheared portion of the bolt inside a retaining structure (such as a hollow bolt body or retaining cavity) that captures and holds the sheared segment. The bolt shaft is nested within a retaining structure that prevents the sheared portion from falling, while still allowing the bolt to function as intended. This resolves the contradiction by maintaining the torque limitation function while eliminating the safety hazard of falling debris.

Inventive Principle:
Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent introduces an intermediary component (retaining structure, hollow bolt body, or capture mechanism) that mediates between the shearing action and the potential harm. This intermediary structure captures the sheared portion and prevents it from falling to the ground, while allowing the bolt to perform its torque limitation function. The intermediary element resolves the contradiction by decoupling the shearing function from the harmful effect.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If the bolt structure is modified to retain the sheared portion, then safety and operational reliability are improved, but the device complexity increases

Engineering Contradiction:
Improvesafety and operational reliabilityVSAvoidbolt structure complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the retention function with the existing bolt structure by integrating the retaining structure as part of the bolt itself (such as a hollow bolt body that contains the sheared portion). This merging approach combines multiple functions (torque limitation and debris containment) into a single integrated component, reducing the need for separate retaining mechanisms and minimizing overall device complexity while improving safety.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent makes the bolt multi-functional by designing it to simultaneously perform torque limitation and retain the sheared portion. The hollow bolt body or integrated retaining structure serves dual purposes: it allows the bolt to shear at the designated point for torque control while also capturing and holding the sheared segment. This multi-functionality resolves the contradiction by adding safety functionality without requiring separate dedicated retaining components.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 captive shear bolt assembly effectively prevents the sheared section from falling, enhancing safety and operational reliability by ensuring the sheared portion remains securely attached to the bolt.

Implementation Method 1

The shear section may be located at a shoulder, a head, and/or the threads of the typical shear bolt. When a typical shear bolt shears, the sheared portion of the bolt is separated from the securing portion of the shear bolt.

Methodology Applied
Scientific EffectShear stress: Shear Stress

Data Source

PatentUS12286996B2Captive shear bolt
Publication Date: 2025.04.29 BURNDY LLC
  • US12286996B2 patent drawing
  • US12286996B2 patent drawing
  • US12286996B2 patent drawing

AI summary

A captive shear bolt assembly includes a bolt and a shear coupling. The bolt may have a head, an extension, and a shank. The shear coupling may be configured to be received by the extension. The shear coupling may be configured to receive the extension via an orifice in the shear coupling. The shear coupling may be configured to shear when an upper head of the shear coupling is driven at a threshold torque. When the shear coupling has sheared, the extension may be configured to captively secure the upper head to the bolt. The captive shear bolt assembly may be used in a tap connector for electrically connecting a main conductor to a tap conductor.