Insulation Piercing Tap Connector for Aerial Power Lines
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Solution Overview
Problem
Conventional tap clamps for aerial electrical power conductors mechanically clamp but do not simultaneously provide an electrical connection between tap conductors and main span conductors, requiring separate electrical connections.
Innovation Solution
A tap connector design featuring a tap body, keeper, stem, and insulation piercing assembly that allows for both mechanical clamping and electrical connection by piercing through insulation to create a conductive path between tap and main conductors, utilizing a non-conductive body with conductive teeth and flexible caps for insulation penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional tap clamps are used to mechanically clamp tap conductors to main span conductors, then mechanical clamping is achieved, but electrical connections cannot be made simultaneously
Solution Approach 1:
The patent combines the mechanical clamping function and electrical connection function into a single integrated tap connector device. The connector includes both clamping elements (jaws, screws) and insulation piercing elements (teeth that pierce through insulation) within one unified structure, allowing both mechanical attachment and electrical connection to be achieved simultaneously in a single installation operation.
Solution Approach 2:
The tap connector is designed as a multi-functional device that performs multiple operations: mechanical clamping of the conductor, insulation piercing to expose conductive material, and electrical connection establishment. This universal device replaces the need for separate clamping devices and separate electrical connection devices, simplifying the overall system.
2Reliability
If separate electrical connections are made from tap clamps, then electrical connection is achieved, but installation time increases
Solution Approach 1:
The insulation piercing teeth are pre-positioned within the connector body in a retracted or protected state. During installation, as the connector is assembled and tightened around the conductor, the teeth automatically advance to pierce the insulation at the precise moment when mechanical clamping is established, ensuring both functions are achieved in the correct sequence without requiring separate operations.
Solution Approach 2:
The connector design allows the insulation piercing action to occur automatically as part of the assembly process. The mechanical tightening motion that secures the conductor also drives the insulation piercing teeth forward to penetrate the insulation and establish electrical contact, eliminating the need for separate manual piercing or connection steps.
3Device complexity
If insulation piercing assembly is integrated with tap body, then single component achieves both functions, but manufacturing complexity increases
Solution Approach 1:
The connector is designed as an assembly of discrete components including the tap body, insulation piercing assembly, keeper, and stem, which can be manufactured separately using standard processes and then assembled. This modular segmentation allows each component to be optimized for its specific manufacturing requirements while still achieving overall integration in the final assembled product.
Solution Approach 2:
The connector utilizes composite construction combining different materials with specific properties: conductive materials for electrical contact surfaces, insulating materials for the body and tooth coatings, and mechanical fastening elements. This composite approach allows each material to be selected and manufactured independently based on its optimal properties, then combined in the final assembly.
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
Enables a single component to both clamp and electrically connect tap conductors to main conductors, simplifying installation and ensuring reliable electrical contact while maintaining insulation integrity.
Implementation Method 1
The insulation piercing assembly is capable of piercing insulation surrounding the main conductor and the tap conductor to create an electrically conductive path between the main conductor and the tap conductor
Implementation Method 2
The stem includes a stem coupling member at one end of a threaded shaft... The threaded shaft is positioned within a threaded aperture in the base wall. The stem coupling member is coupled to the keeper coupling member such that rotational movement of the stem is translated to linear movement of the keeper
Data Source
AI summary
A tap connector that includes a tap body and an insulation piercing assembly or module is provided. The insulation piercing assembly is secured to the tap body and movable relative to the tap body. The insulation piercing assembly includes a conductive body, at least two sets of electrically conductive insulation piercing teeth secured to the conductive body and a non-conductive cap or coating covering the teeth. When the teeth pierce the non-conductive caps or coating exposing the teeth, the teeth can pierce insulation surrounding the main and tap conductors creating an electrically conductive path between the main conductor and the tap conductor.