Electrical Connector Fastener with Conductive Shunt
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing threaded fasteners used in electrical connectors tend to loosen over time due to thermal cycling, causing issues with electrical conductivity and mechanical force, as biasing members with high electrical resistance interfere with current flow.
Innovation Solution
A fastener system comprising a threaded bolt, a keeper member, and a biasing member with a Belleville washer configuration that provides an electrical shunt and maintains mechanical force, using conductive materials like aluminum for the bolt and stainless steel or BeCu for washers to ensure reliable conductivity and torque retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a biasing member is used to maintain mechanical force in a setscrew connector, then the mechanical force is maintained, but the electrical resistance increases
Solution Approach 1:
The connector is divided into separate functional components: a setscrew for applying mechanical force, a biasing member for maintaining that force, and a conductor for providing the electrical shunt path. This segmentation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
A conductor is introduced as an intermediary element that provides a parallel electrical path around the high-resistance biasing member. This intermediary component carries the electrical current that would otherwise have to pass through the biasing member, thus maintaining electrical conductivity while allowing the biasing member to perform its mechanical function.
2Strength
If a threaded fastener is used to connect electrical couplings, then mechanical connection is achieved, but the fastener loosens over time due to thermal cycling
Solution Approach 1:
The biasing member is designed as a dynamic, resilient element that can continuously adjust its force output in response to thermal expansion and contraction. This dynamic response maintains constant mechanical connection strength despite temperature variations and cycling loads.
Solution Approach 2:
The biasing member's elastic properties are selected to provide optimal force maintenance across the expected temperature range. By carefully choosing the material and geometry parameters of the biasing member, the system compensates for thermal effects and maintains stable fastening.
3Device complexity
If only a portion of the outer strands contact the connector structure, then the connector design is simple, but the electrical conductivity is reduced
Solution Approach 1:
The connector design concentrates the electrical conduction function in a specific local region through the conductor element, while other regions maintain their structural or mechanical functions. This local specialization of quality allows simple overall design while achieving high electrical conductivity where needed.
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 effectively maintains electrical conductivity and mechanical clamping force, preventing fastener loosening by directing current through conductive paths and using harder materials to reduce thermal expansion effects, ensuring reliable electrical connections.
Implementation Method 1
The collapsible portion provides an electrical shunt around the biasing member
Implementation Method 2
the use of a biasing member, employed to maintain the mechanical force applied at the electrical interface between the conductor and the connector, will offset the action of the thermal expansion and contraction
Implementation Method 3
This is due to the thermal cycling nature of electrical loads, resulting in thermal expansion and contraction respectively
Implementation Method 4
The fastener includes a threaded bolt, a keeper member and a biasing member. The threaded bolt has a first end and a second end with a threadform extending thereabout
Data Source
AI summary
A fastener for a connector in an electrical coupling including a threaded bolt, a keeper member and a biasing member. The keeper member having a base and a distal member spaced apart from each other and a collapsible portion coupling the base and the distal member to each other in electrical communication. The second end of the threaded bolt extends to the base and is in electrical communication therewith. The distal member has a conductor contact surface. The biasing member includes an inner washer, an outer washer, and a Belleville washer positioned therebetween. The biasing member is insertable between the base and the distal member so that the inner washer is positioned between the base and the Belleville washer and the outer washer is positioned between the Belleville washer and the distal member. The collapsible portion provides an electrical shunt around the biasing member.