Convex Cover Element for Electrical Connector Borehole Sealing
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Solution Overview
Problem
Existing electrical connectors face challenges in simplifying the mounting process of cable connectors and ensuring improved electrical properties of the closed connection, particularly due to irregularities in the surface caused by screw heads and boreholes.
Innovation Solution
A cover element with a convexly arched cylindrical surface is used to seal the recesses in the boreholes, providing a smooth surface for sleeve mounting and ensuring electrical conductivity, optionally with an outer thread or press fit for fixation, and featuring an actuation aid for easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If screws with predetermined breaking points are used to eliminate protruding screw heads, then the surface smoothness is improved, but open recesses are created that interrupt the lubricating film
Solution Approach 1:
The invention extracts the problematic feature (protruding screw head) by using breakaway screws that shear off during assembly. The screw shaft remains embedded in the borehole providing mechanical fastening, while the head is removed to create a smooth outer surface that allows proper application of lubricating film for sleeve installation.
Solution Approach 2:
The invention introduces a cover element as an intermediary component that closes the borehole opening after the breakaway screw has been installed and sheared off. This cover element restores the continuity of the outer surface, preventing lubricant penetration into the borehole while maintaining the mechanical fastening function.
2Ease of operation
If a smooth outer surface is required for sleeve mounting, then the mounting process is simplified, but the structural integrity and fastening capability are compromised
Solution Approach 1:
The fastening system is segmented into two functional parts: the screw shaft embedded in the borehole that provides mechanical fastening strength, and the removable screw head that creates surface irregularity. By separating these functions and removing only the head portion, the invention maintains fastening capability while achieving surface smoothness for ease of sleeve mounting.
Solution Approach 2:
The cover element acts as an intermediary that restores the smooth surface after the breakaway screw has provided its fastening function. It closes the borehole opening without compromising the mechanical connection, thereby enabling proper sleeve installation while maintaining structural integrity.
3Shape
If breakaway screws are used to create a smooth surface, then the outer contour is improved, but recesses remain that allow lubricant penetration and disrupt the lubricating film
Solution Approach 1:
The invention removes the harmful feature (open borehole recess) by using breakaway screws that leave only a minimal opening, and further by introducing a cover element that completely closes this opening. This eliminates the pathway for lubricant penetration while maintaining the beneficial smooth outer contour.
Solution Approach 2:
The cover element serves as an intermediary barrier that prevents lubricant from penetrating into the borehole region. It maintains the smooth outer contour necessary for proper lubricating film formation while blocking the harmful effect of lubricant film disruption that would occur through open recesses.
Data Source
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AI summary
The present invention relates to a cover element for an electrical connector and to such an electrical connector. In particular, the present invention relates to electrical connectors which interconnect electrically conductive cables. According to the present invention, a cover element (110) for an electrical connector has a cylindrical base body with a barrel surface (116), a first cover surface (112) which, in the mounted state of the cover element, forms a part of an outer surface of the electrical connector (100), and a second cover surface (114) which in the mounted state faces an inner side of the electrical connector. According to the invention, the first cover surface (1 12) has a convex form. In particular, the first cover surface (112) is formed as a sector of a cylinder barrel or of a sphere surface.