Deflectable Electrical Connector for Thermal Cycling Stability
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Solution Overview
Problem
Splices and junctions in electrical power distribution systems experience loose connections due to cyclic heating and cooling of conductors and connectors, leading to reduced electrical performance.
Innovation Solution
An electrical connector design featuring multiple sections with deflectable top portions and base portions, incorporating channels and bore holes for fasteners, which store elastic potential energy to maintain a secure connection during thermal expansion and contraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rigid connector designs are used, then manufacturing simplicity is maintained, but connection stability deteriorates during thermal cycling
Solution Approach 1:
The connector transitions from a rigid static structure to a dynamic structure with movable top portions that can deflect independently. This allows the connector to adapt to thermal expansion and contraction of conductors, maintaining stable electrical connection during thermal cycling while managing the increased structural complexity through controlled mobility.
Solution Approach 2:
The connector is divided into multiple sections with separate top portions that can deflect independently from each other and from the base portion. This segmentation allows each section to respond individually to thermal changes in different conductors, improving overall connection stability while distributing the mechanical complexity across modular units.
2Adaptability or versatility
If fixed rigid connections are used, then structural simplicity is maintained, but adaptability to thermal changes deteriorates
Solution Approach 1:
The connector design changes the mechanical parameters of the top portions, allowing them to deflect and change position in response to thermal expansion and contraction. This parameter change enables the connector to accommodate thermal variations in conductors, providing adaptability while managing design complexity through controlled flexibility rather than rigid fixed connections.
3Reliability
If elastic potential energy storage is implemented, then connection force consistency is improved, but manufacturing complexity increases
Solution Approach 1:
The implementation of elastic potential energy storage requires the top portions to be designed with specific flexibility characteristics, transforming the connector from a static to a dynamic system. This improves force consistency by allowing the elastic elements to maintain constant pressure on conductors during thermal cycling, while the manufacturing complexity is managed through standardized flexible component design rather than complex assembly procedures.
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 connector effectively maintains a stable electrical connection by providing a compressive spring force that accommodates the expansion and contraction of conductors and connectors, ensuring consistent performance across heating and cooling cycles.
Implementation Method 1
the top portions of the electrical connector are able to deflect away from their respective base portions independently of each other
Implementation Method 2
store elastic potential energy to maintain a secure connection during thermal expansion and contraction
Implementation Method 3
During periods of high power demand, current flowing through the feeder and service lines will heat the conductors and the connectors. During periods of low power demand, current flowing through the feeder and service lines ceases or abates, and the conductors and connectors cool. Such cyclic heating and cooling can expand and contract the conducting components
Implementation Method 4
Such cyclic heating and cooling can expand and contract the conducting components, potentially undesirably loosening the electrical connection between the connector and the feeder or service lines
Data Source
AI summary
An electrical connector configured to maintain an electrical connection with a conductor during heating and cooling cycles is provided. The electrical connector includes connector sections, each comprising a base portion and top portion extending from the base portion. Each connector section defines a portion of a channel configured to receive one or more conductors and includes a bore in its base or top portion that communicates with the channel. A fastener inserted into the bore is configured to retain the conductor inserted into the channel, and the top portions are configured to deflect substantially independently of each other to provide a spring force that secures the fastener against the conductor.