Insulated Cable-to-Pipe Connector for Current Transfer Isolation
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Solution Overview
Problem
Existing cable-to-pipe connectors fail to provide continuous current transfer from a cable to a utility pipe while electrically isolating the cable and pipe from a metal housing, leading to potential faults, shorts, and sparking hazards in gaseous environments due to the use of metal plugs that act as electrical conductors.
Innovation Solution
A cable-to-pipe connector comprising a conductive lug partially encased by an insulating shell, with a noncircular neck and body design, and a threaded member that secures the lug to prevent rotation, allowing only intended amperage to travel through the bonding cable within the metal housing, using a non-conductive insulating shell to prevent electrical bridging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal plug is used to connect the cable to the pipe, then electrical connection is established, but electrical isolation from the metal housing cannot be achieved
Solution Approach 1:
The connector is divided into separate functional segments: a metal conductive body for electrical connection, and a non-conductive insulating housing for isolation. This segmentation allows each component to perform its specific function without interfering with the other, resolving the contradiction between establishing electrical connection and preventing electrical bridging.
Solution Approach 2:
The non-conductive insulating housing acts as an intermediary between the metal conductive body and the external metal housing. This intermediary material blocks electrical current flow to the metal housing while allowing the conductive body to maintain its electrical connection function, thus preventing harmful electrical bridging.
2Productivity
If a metal plug is used for connection, then current transfer is enabled, but sparking hazards occur in gaseous environments
Solution Approach 1:
The connector separates the current transfer function (handled by the metal conductive body) from the housing structure (handled by the non-conductive insulating housing). This segmentation ensures that current flows only through the intended bonding cable and not through the metal housing, eliminating sparking hazards in gaseous environments while maintaining current transfer efficiency.
Solution Approach 2:
The design converts the potential harm of electrical bridging through metal housing into a benefit by using the non-conductive insulating housing to deliberately block current flow. This intentional isolation prevents current from taking unintended paths through the metal housing, transforming a potential safety hazard into a safety feature.
3Strength
If a metal plug is used, then structural strength is provided, but electrical faults and shorts occur
Solution Approach 1:
The connector is segmented into a metal conductive body that provides structural strength and mechanical connection, and a non-conductive insulating housing that provides electrical isolation. This segmentation allows the metal components to provide the necessary structural strength while the insulating housing prevents electrical faults and shorts, thereby improving overall electrical system reliability.
Solution Approach 2:
The connector employs composite construction combining metal materials for strength and conductivity where needed, and non-conductive insulating materials for electrical isolation. This composite approach allows the connector to simultaneously achieve structural strength, electrical conductivity for current transfer, and electrical insulation for fault prevention.
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
Ensures continuous and accurate current transfer without electrical faults or shorts, reducing the risk of sparking hazards by isolating the cable and pipe from the metal housing, facilitating fast and secure installation, and constraining amperage within the intended bonding cable.
Implementation Method 1
an insulating shell partially encasing by the conductive lug... electrically isolating the cable and pipe from the metal housing
Data Source
AI summary
A cable-to-pipe connector is provided. A cable-to-pipe connector for providing continuous transfer of current from a cable to a utility pipe in above grade and below grade systems, comprising a conductive lug comprising a head at a top end of the conductive lug affixed to a noncircular neck that is further affixed to a body in a linear formation, the head, the neck, and the body having decreasing diameters respectively. An insulating shell partially encasing by the conductive lug. A horizontal aperture at a midway point of the head. A first fastener extending from above a top of the head through the horizontal aperture. A threaded member at a base end of the conductive lug and a bottom end of the insulation shell.