Electrical Contact Element with Segmented Splice for Aluminum Stranded Conductors
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Solution Overview
Problem
Existing electrical contact solutions, such as crimp connections, are not suitable for aluminum conductors due to the formation of an oxide layer that inhibits conductivity, especially when dealing with conductors made of multiple fine strands.
Innovation Solution
An electrical contact element with a connecting sleeve containing radially inwardly tapered splice segments, which break open and remove the oxide layer on individual strands of aluminum conductors during the crimping process, ensuring good electrical contact. The splice segments can be either part of the connecting sleeve or a separate component, and the surface is designed to be rough for effective oxide layer disruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple crimp connection is used for aluminum conductors, then the connection is easy to produce and flexible for assembly, but the oxide layer on the conductor strands prevents good electrical contact
Solution Approach 1:
The connecting sleeve is segmented into multiple radially inwardly tapered splice segments distributed around its circumference. These segments act as individual cutting edges that collectively process multiple conductor strands, enabling reliable contact with multi-strand aluminum conductors while maintaining an easy crimping operation.
Solution Approach 2:
The splice segments create localized sharp edges at specific positions around the connecting sleeve circumference. These localized sharp edges concentrate the mechanical action on the oxide layer at specific points, effectively breaking through the oxide barrier without requiring the entire connection surface to be complex or difficult to manufacture.
2Productivity
If a crimp connection squeezes aluminum conductor strands, then the connection is simple and quick to make, but the oxide layer is pressed between the conductor and connection side preventing good contact
Solution Approach 1:
The radially inwardly tapered splice segments perform a preliminary cutting action on the oxide layer before the final crimping compression is applied. This preliminary action removes the oxide barrier in advance, so that subsequent crimping can establish immediate electrical contact without pressing oxide layers into the connection interface.
Solution Approach 2:
Instead of trying to compress the oxide layer away during crimping, the invention inverts the approach by using the crimping force to drive sharp-edged splice segments that actively cut and remove the oxide layer. The mechanical action is reversed from compression-only to cutting-then-compression, achieving both speed and reliability.
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 design ensures reliable and efficient electrical contacting of aluminum conductors by breaking the oxide layer, allowing for effective conductivity across multiple strands, even in complex conductor configurations.
Implementation Method 1
the splice segments are radially inwardly tapered elements which serve to penetrate between the individual strands of an inserted electrical conductor during the squeezing process
Data Source
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AI summary
The invention relates to an electrical contact element (1) for contacting an electrical stranded conductor (20), wherein the electrical contact element has a connection side (3) and a plug side (2). For better electrical contacting of an electrical stranded conductor (20), there is a splicing element (10) in a connection sleeve (4) forming the connection side (3). The splicing element (10) is intended to fan out the individual strands of the conductor (20), to contact as large a surface of the individual strands as possible and to break the surface of the strands during a crushing or crimping process. The invention provides for a secure, electrical contacting of stranded conductors (20) wherein a surface of the individual strands, which is poorly conductive and unsuitable for contacting, is penetrated.