Electrical Conduction Member With Projecting Leg And Sleeve
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Solution Overview
Problem
Electrical conduction members with stranded conductor cores face mechanical strength issues due to insufficient strength at the bare end of the wire, particularly when subjected to repeated bending during installation and maintenance, leading to potential rupture.
Innovation Solution
An electrical conduction member design featuring a projecting leg on the conductive bar with a sleeve encasing the unstripped wire portion, providing enhanced mechanical protection and resistance to bending stresses, utilizing a heat-shrinkable sleeve for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bare end of the wire is flattened during welding, then the wire can be connected to the bar, but the mechanical strength of the stripped end becomes insufficient and it may rupture under repeated bending
Solution Approach 1:
The wire is divided into two distinct portions: a stripped end for welding to the bar and an unstripped portion protected by the sheath. This segmentation allows the welded portion to provide electrical connection while the protected portion maintains mechanical strength and resists bending stresses.
Solution Approach 2:
The electrically insulating sheath acts as an intermediary protective layer around the unstripped portion of the wire. This sheath prevents direct exposure of the conductors to bending stresses and mechanical damage, while still allowing the stripped end to be welded to the bar.
2Ease of operation
If the wire is subjected to repeated bending during installation and maintenance, then the wire can be handled and installed, but the stripped end may rupture due to insufficient mechanical strength
Solution Approach 1:
Different portions of the wire have different properties: the stripped end is prepared for welding with exposed conductors, while the unstripped portion maintains its original structure with sheath protection. This local differentiation ensures that bending operations affect only the protected unstripped portion, preserving the integrity of the welded connection.
3Strength
If a sleeve is used to enclose the unstripped portion of the wire, then mechanical protection is enhanced, but the device complexity increases
Solution Approach 1:
The sleeve is discarded after serving its protective function during installation. It is placed over the unstripped portion to provide mechanical protection, then removed after the welding and installation process is complete, leaving a simple final structure without additional components.
Solution Approach 2:
The sleeve is a simple, inexpensive, disposable component used temporarily during the manufacturing and installation process. It provides essential mechanical protection during handling and welding, then is discarded, avoiding the need for permanent complex structural solutions.
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 significantly enhances the mechanical strength and resistance to bending stresses, ensuring the wire's unstripped portion can withstand handling and installation without rupture, while the stripped end remains protected from excessive forces.
Implementation Method 1
the sleeve is made of a heat-shrinkable material
Implementation Method 2
a bare end welded to the bar
Data Source
Figure 1~3
AI summary
The invention relates to an electrical conduction member comprising an electrically conductive bar (1) and an electrical wire (10) that is covered with an electrically insulating sheath (12) and has an exposed end (13) that is welded onto the bar. Said electrical conduction member is characterized in that a tab (14) that is uniform with the bar projects from one surface of said bar. Said electrical conduction member is characterized in that an unexposed portion of the wire is attached on the tab by means of a sleeve (20) enclosing the tab and said portion. The invention also relates to a method for manufacturing such an electrical conduction member.