Composite Ferrule Threaded Joint for Insulated Extension Poles

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Solution Overview

Problem

Conventional metal ferrules used in extension poles are electrically conductive, leading to safety risks and reduced dielectric withstand, and they often have a loose connection due to sleeve interface clearances, causing deflection issues during use.

Innovation Solution

A non-conductive composite ferrule connection interface with a threaded design, featuring outwardly and inwardly threaded composite ferrules that form a tight, overlapping sleeve connection, eliminating metallic materials and enhancing insulating properties and rigidity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal ferrules are used for connection, then mechanical strength and ease of manufacture are improved, but electrical conductivity increases causing safety risks and reduced dielectric withstand

Engineering Contradiction:

Improvemechanical strengthVSAvoidelectrical conductivity

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces metal ferrules with composite ferrules made from non-conductive materials such as fiberglass-reinforced plastic or other dielectric composites. These composite materials provide the necessary mechanical strength for pole section connection while simultaneously eliminating the harmful electrical conductivity that posed safety risks near live lines. The composite ferrule thus resolves the contradiction by delivering both structural integrity and electrical insulation properties.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If metal ferrules with sleeve interface are used, then ease of manufacture is improved, but connection tightness deteriorates due to required clearances causing deflection

Engineering Contradiction:

Improveease of manufactureVSAvoidconnection tightness

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces the traditional metal-to-metal sleeve interface mechanism with a threaded connection system using composite ferrules. The threaded design allows for precise engagement and elimination of clearance-induced deflection, while the composite material properties enable tighter tolerances and more rigid connections. This substitution resolves the contradiction by achieving both manufacturing feasibility and superior connection tightness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If metal ferrules are used, then structural strength is improved, but dielectric withstand rating is reduced due to conductive path continuity

Engineering Contradiction:

Improvestructural strengthVSAvoiddielectric withstand rating

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs composite ferrule materials that inherently combine high mechanical strength with excellent dielectric properties. Materials such as fiberglass-reinforced polymers provide both the structural integrity needed for supporting pole loads and the electrical insulation required to maintain high dielectric withstand ratings. This composite material approach simultaneously satisfies both requirements without the trade-off inherent in metal ferrules.

Inventive Principle:

Principle #40Composite materials

4Ease of operation

If conventional metal ferrules are used, then ease of operation is compromised due to deflection, but threaded composite ferrules improve rigidity and control

Engineering Contradiction:

Improvepole controlVSAvoidconnection deflection

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent replaces the sleeve-based mechanical connection system with a threaded composite ferrule system that provides superior rigidity and minimal deflection. The threaded engagement mechanism, combined with the high stiffness of composite materials, creates a more stable and controllable connection that improves pole section rigidity while maintaining ease of assembly and operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11788566B2Composite ferrules for extension poles

Publication Date: 2023.10.17 MACLEAN JAMESON LLC

AI summary

A ferrule connection interface may have a first composite ferrule having an outwardly threaded portion opposite a pole receiving portion. The interface may have a first pole bonded via an engineered adhesive to the first composite ferrule at the pole receiving portion of the first composite ferrule. The interface may also have a second composite ferrule having an inwardly threaded portion opposite a pole receiving portion, the inwardly threaded portion tightly meshing with the outwardly threaded portion of the first composite ferrule to form a tight connection. The interface may also have a second pole bonded via the engineered adhesive to the second composite ferrule at the pole receiving portion of the second composite ferrule. Both first and second composite ferrules are characterized by a lack of any metallic and/or electrically conductive materials.