Mechanical Lug Dovetail Interlock for Secure Conductor Connection
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Solution Overview
Problem
Prior mechanical lug connectors separate when tightening a screw to secure an electrical conductor due to the lack of interlocking features, compromising the integrity and strength of the connection.
Innovation Solution
A mechanical lug with a main body featuring an inner flange having a horizontal member and interlocking member with angled pockets, and an outer flange with hooks having tapered faces that interlock within the pockets, forming a strong dovetailed connection to prevent separation during tightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art mechanical lug connectors are used without interlocking features, then the structure is simple and easy to manufacture, but the flanges separate from each other when tightening the screw to secure the electrical conductor
Solution Approach 1:
The lug body is segmented into distinct functional components: an inner flange with angled pockets and an outer flange with hooks. This segmentation allows each component to perform its specific function while maintaining overall structural integrity, resolving the contradiction between connection reliability and structural simplicity.
Solution Approach 2:
The outer flange with hooks is nested within the inner flange structure, with the hooks positioned in the angled pockets. This nested configuration creates the interlocking mechanism that prevents flange separation during screw tightening, achieving reliable connection without excessive structural complexity.
2Reliability
If interlocking features are added to prevent flange separation, then the connection integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
Interlocking features are added only at critical locations where flange separation occurs, rather than throughout the entire lug structure. The angled pockets and hooks are strategically positioned to provide maximum stabilization with minimal additional manufacturing complexity.
Solution Approach 2:
The interlocking mechanism uses asymmetric geometry with angled pockets on the inner flange and corresponding hooks on the outer flange. This asymmetric design creates effective mechanical interlock while being straightforward to manufacture using standard forming processes.
Data Source
Figure 1~2
Figure 3A~3C
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AI summary
The present invention is directed to a mechanical lug with interlocking features that secures an electrical conductor. The mechanical lug has a main body and a mounting tongue extending from the main body. The main body includes an inner flange and an outer flange. The inner flange has a horizontal member and an interlocking member with angled pockets. The outer flange has hooks with a tapered face positioned in the angled pockets of the interlocking member of the inner flange thereby forming a dovetail interlock.