Conductive Insert for Electrical Connector Shear Bolt Retention
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Solution Overview
Problem
Shear bolt connectors in electrical transmission lines suffer from limited contact between conductors and bolts, leading to untimely interruptions and costly disconnections, especially when conductors have low deformability, which can result in severed strands and reduced tension retention.
Innovation Solution
An electrical connector assembly featuring a conductive housing with a deformable conductive insert and bolts that urge the insert against the conductor, providing enhanced retention and conductivity through engagement features and a bolt recess to distribute force evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolts directly deform the conductor to create contact, then electrical connection is established, but conductor strands can be severed and tension retention is reduced
Solution Approach 1:
The patent introduces a deformable insert as an intermediary component between the bolt and the conductor. The insert deforms under bolt pressure to create electrical contact, while the bolt itself does not directly contact or deform the conductor, thereby preventing strand severing. This mediator approach resolves the contradiction by decoupling the contact function from the fastening function.
Solution Approach 2:
The patent segments the connection system into distinct functional components: the bolt provides mechanical fastening, the deformable insert provides electrical contact through controlled deformation, and the conductor carries current. This segmentation allows each component to perform its specific function without compromising the others, particularly protecting the conductor from direct bolt-induced deformation.
2Reliability
If the threaded end of the bolt creates contact with the conductor, then electrical connection is achieved, but the contact amount is limited by the uneven interface
Solution Approach 1:
The patent changes the deformation parameter of the insert, allowing it to deform elastically under bolt pressure to conform to the conductor surface. This deformation capability enables the insert to create a uniform contact interface across its entire contact surface, rather than being limited to the threaded pattern of the bolt, thereby improving contact uniformity and electrical connection reliability.
3Strength
If conductors have low deformability, then conductor integrity is maintained, but the bolt cannot penetrate sufficiently to create adequate contact
Solution Approach 1:
The deformable insert serves as a mediator that bridges the compatibility gap between rigid conductors and bolt fastening. The insert absorbs the deformation requirement, deforming under bolt pressure to ensure adequate contact with low-deformability conductors, while the conductor itself maintains its structural integrity without being directly deformed by the bolt.
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 increases retention and conductivity, reduces strand severing, and maintains tension effectively, addressing the limitations of traditional shear bolt connectors by ensuring secure and consistent electrical connections.
Implementation Method 1
The conductive insert includes a curved geometry and engagement features capable of deformably engaging a conductor
Implementation Method 2
The bolt is positioned within the housing and positioned to urge the conductive insert against the conductor when the bolt is adjusted
Data Source
AI summary
An electrical connector, an insert for an electrical connector, and an electrical assembly are disclosed. The electrical connector includes a conductive housing and a conductive insert positioned within the conductive housing. The conductive housing includes a configuration for receiving a conductor and being in electrical communication with the conductor through the insert.