Connector Assembly with Conductive Fastener for Cable Joints
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Solution Overview
Problem
Conventional electrical connectors concentrate electrical current on outer conductor elements, leading to increased heat generation and cable failure, especially at cable terminating ends and joints, due to the insulating effects of water-blocking materials which increase electrical resistance.
Innovation Solution
The development of a connector assembly with a conductive fastener that penetrates into multiple conductor elements or strand layers, establishing a direct metal-to-metal contact to distribute current more evenly across the cable cross-section, thereby bypassing the insulating effects of water-blocking materials, and using a conductive shim to enhance electrical communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water-blocking materials are used to protect against moisture intrusion, then cable protection against environmental conditions is improved, but electrical resistance among conductor elements increases leading to increased heat generation
Solution Approach 1:
The connector establishes separate electrical contact paths with different conductor elements (inner and outer strands) through multiple contact points, segmenting the current flow to bypass water-blocking materials and reduce localized resistance and heat generation
Solution Approach 2:
The connector body acts as an intermediary conductive path that directly connects inner and outer conductor elements, bypassing the insulating water-blocking materials and providing a low-resistance current path
2Ease of operation
If conventional connectors are used at cable terminating ends, then cable connection is achieved, but electrical current is concentrated on outer conductor elements leading to increased heat generation and cable failure
Solution Approach 1:
The connector is designed with differentiated contact characteristics for inner and outer conductor elements, creating non-uniform current distribution that directs current through multiple paths including inner strands, thereby preventing current concentration on outer elements alone
Solution Approach 2:
The connector extends contact points in multiple spatial dimensions (radial and axial directions) to engage multiple conductor elements simultaneously, transforming the current path from a concentrated surface contact to a distributed three-dimensional contact network
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
This solution reduces heat generation and improves the reliability of electrical connections by evenly distributing current, reducing the risk of cable failure and maintaining stable resistance and temperature during repeated load cycles.
Implementation Method 1
The passage is sized to accommodate a conductive fastener... the first fastener end extends into the socket cavity and penetrates into the multiple conductor elements or strand layers
Data Source
AI summary
Assemblies and methods are provided for establishing an electrical connection and enhancing connectability that utilize an electrical connector having a housing and a socket for receiving an electrical conductor having multiple conductor elements or conductor layers. A conductive fastener extends through the housing into the socket. The fastener can penetrate multiple conductor elements to establish an electrical connection among conductor elements. One or more of the conductor elements can include a cutaway segment that receives a conductive fastener to establish an electrical connection among the connector, fastener, and multiple conductor elements. A conductive shim may be disposed about one or more of the conductor elements and received within the cutaway segment, and the conductive fastener can engage the conductive shim to establish electrical contact among multiple conductor elements through the shim.