Multi-Layer Grounding Connector for Lightning Protection
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Solution Overview
Problem
Conventional grounding kits and connecting elements with crimp joints are complex to manufacture and do not provide a reliable mechanical and electrical connection under operational conditions, especially in outdoor applications like cellular base stations and broadcast systems.
Innovation Solution
A connecting element with a stacked configuration of multiple layers, where at least one layer is made of sheet metal, offering high tensile strength and electrical conductivity, and comprising materials like copper, aluminum, or stainless steel, ensuring flexibility and robustness, with a jacket for protection and screw connections for easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimp joints are used to connect electrical conductors, then electrical connection is established, but manufacturing complexity increases and reliability decreases
Solution Approach 1:
The connecting element is divided into multiple separate layers (first layer, second layer, third layer) that are stacked together. Each layer can be manufactured independently using simple processes, avoiding complex crimp joint operations. The layers are then assembled through straightforward stacking and joining operations.
Solution Approach 2:
The invention uses a composite structure with at least three layers made of different materials optimized for specific functions: one layer for electrical conductivity (e.g., copper), one for mechanical strength (e.g., stainless steel), and one for flexibility (e.g., aluminum). This composite approach replaces complex crimp joints with a simpler stacked assembly that achieves both electrical and mechanical connection reliability.
2Strength
If single-material connecting elements are used, then manufacturing is simple, but mechanical strength and electrical conductivity cannot be optimized simultaneously
Solution Approach 1:
Different layers of the connecting element are made from different materials optimized for specific local requirements: the first layer uses material optimized for electrical conductivity, the second layer uses material optimized for mechanical strength, and the third layer uses material optimized for flexibility. This local optimization allows each layer to perform its specific function at the highest level while the overall assembly achieves comprehensive performance.
Solution Approach 2:
The connecting element employs a composite structure with at least three layers made of different materials. This composite approach enables simultaneous optimization of electrical conductivity, mechanical strength, and flexibility by selecting appropriate materials for each layer, thereby achieving high tensile strength without compromising electrical performance or manufacturability.
3Adaptability or versatility
If rigid monolithic connecting elements are used, then structural stability is high, but mechanical flexibility and adaptability decrease
Solution Approach 1:
The connecting element is segmented into multiple thin layers stacked together. This segmentation allows the assembly to be mechanically flexible and adaptable to different installation scenarios while maintaining structural stability through the collective strength of all layers. The stacked configuration enables bending and conforming to different geometries without compromising the integrity of individual layers.
Solution Approach 2:
The connecting element transitions from a rigid monolithic structure to a dynamic stacked configuration where multiple layers can move relative to each other. This dynamic structure provides mechanical flexibility for easy installation and adaptation to different target systems, while the friction and bonding between layers maintain sufficient structural stability during operation.
4Reliability
If dissimilar materials are combined in layers, then electrical conductivity and mechanical strength are optimized, but contact corrosion risk increases
Solution Approach 1:
The connecting element uses a three-layer structure where the middle layer acts as an intermediary between the first and third layers made of dissimilar materials. This intermediate layer prevents direct contact between incompatible materials, thereby eliminating galvanic corrosion while maintaining optimized electrical conductivity and mechanical strength through the composite structure.
Data Source
Figure 1a~2b
Figure 2c~3b
Figure 4
AI summary
The invention relates to a connecting element (100) for establishing an electrically conductive connection between two further elements (200, 300), particularly for connecting a body unit (200) of a grounding kit (1000) with a grounding element (300), wherein said connecting element (100) comprises at least two layers (102a, 102b) of electrically conductive material, wherein at least two layers (102a, 102b) comprise different material.