Insulated Conductor Joint with Segmented Fastener
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conductor connection assemblies for electrical switching apparatus, such as circuit breakers, face challenges in achieving sufficient electrical insulation while maintaining the ability to be easily unfastened and disassembled, as traditional encapsulation methods render joints impossible to separate once assembled.
Innovation Solution
A conductor connection assembly comprising a first and second electrical conductor with a fastening mechanism and an insulator, allowing for easy assembly and disassembly, where the joint is electrically insulated when fastened and unfastened, utilizing a fastener and insulator configuration that allows for electrical connection and insulation without requiring complete replacement of the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the joint is fully encapsulated in epoxy insulation, then electrical insulation is improved, but ease of disassembly deteriorates
Solution Approach 1:
The insulator is divided into two distinct portions: a first portion that overlays the fastening mechanism to provide electrical insulation, and a second portion that receives the fastening mechanism and allows for reversible attachment. This segmentation enables the insulator to be removed and reattached without damaging the joint components, resolving the contradiction between providing reliable electrical insulation and maintaining ease of disassembly.
Solution Approach 2:
The insulator acts as an intermediary component between the fastening mechanism and the external environment. It provides electrical insulation while being designed with a receiving portion that allows the fastening mechanism to be inserted and removed. This intermediary structure enables both electrical insulation and reversible assembly, resolving the contradiction between reliability and ease of repair.
2Volume of moving object
If the joint is made compact to reduce size, then volume is improved, but electrical insulation difficulty worsens
Solution Approach 1:
The insulator utilizes the dimensional space around the fastening mechanism by overlaying it and extending along the conductor. This three-dimensional configuration provides comprehensive electrical insulation coverage within the compact joint structure, resolving the contradiction between compact size and adequate insulation coverage.
Solution Approach 2:
The insulator is positioned specifically at critical locations where electrical insulation is most needed - overlaying the fastening mechanism and surrounding areas where conductive components are in close proximity. This localized insulation approach provides effective electrical isolation within the compact joint volume, resolving the contradiction between small size and insulation effectiveness.
Data Source
AI summary
An electrically insulated conductor connection assembly and a method for providing the same are provided. The electrically insulated conductor connection assembly includes first and second electrical conductors each comprising a body portion and an end portion. A fastening mechanism electrically and mechanically connects the end portions of the first electrical conductor to the end portion of the second electrical conductor, and an insulator overlays and electrically insulates the fastening mechanism. The end portions of the first and second electrical conductors and the fastening mechanism form a joint, which is structured to be fastenable and unfastenable. When the joint is fastened and the insulator is overlaying the fastening mechanism, the joint is electrically insulated.