Ring-Shaped Lug Electrical Connector with Spring Bias
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Solution Overview
Problem
Traditional electrical connection methods for aircraft grounding, such as lug structures, are prone to corrosion, require tools for installation and modification, and have difficulty in maintaining secure connections under vibration and exposure to environmental factors.
Innovation Solution
An electrical connection system featuring ring-shaped lugs with contact springs and a locking cap that provides a secure, tool-free, and corrosion-resistant connection to a conductive surface, utilizing a mounting stud with a spring bias for radial collapse and bayonet-style locking, along with integrated seals for environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional lugs with fasteners are used for electrical connections, then secure mounting to conductive surfaces is achieved, but tool installation and modification become necessary
Solution Approach 1:
The patent replaces the traditional mechanical fastener system (bolts, screws, wrenches) with a spring-loaded electrical contact mechanism. The spring applies continuous radial pressure to maintain reliable electrical connection without requiring mechanical fasteners, thereby eliminating the need for tools during installation and modification while maintaining connection security.
Solution Approach 2:
The spring-loaded contact mechanism automatically maintains pressure and connection security without requiring external fasteners or tools. The spring self-regulates the contact force between the electrical contact and the conductive surface, providing self-service functionality that eliminates manual intervention with tools.
2Reliability
If traditional lugs are used for electrical connections, then electrical connection is established, but corrosion resistance deteriorates due to moisture exposure
Solution Approach 1:
The patent employs a boot-like protective covering that flexibly encloses the electrical contact and mounting components. This flexible shell protects the internal components from moisture and corrosive environmental factors while allowing the spring mechanism to maintain its electrical connection function, thereby resolving the contradiction between maintaining electrical connection and resisting corrosion.
3Reliability
If traditional lugs with fasteners are used, then electrical connection is established, but modification and reconfiguration become difficult
Solution Approach 1:
The patent segments the electrical connection system into separable components: the boot-protected assembly can be independently removed and replaced without affecting the mounting stud or conductive surface. This segmentation allows for easy modification and reconfiguration while maintaining reliable electrical connection, as components can be individually accessed and replaced.
4Reliability
If traditional lugs are used for grounding connections, then ground reference is provided, but protection against environmental factors deteriorates
Solution Approach 1:
The boot-like flexible shell encapsulates the electrical contact and spring mechanism, providing protection against environmental factors such as moisture, corrosion, and contamination. This protective enclosure maintains the reliability of the grounding reference while shielding the internal components from harmful environmental effects.
Solution Approach 2:
By replacing traditional exposed mechanical fasteners with an enclosed spring mechanism within a protective boot, the system maintains reliable grounding reference while eliminating exposure to environmental factors that would otherwise degrade traditional lug structures.
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
The system offers a robust, secure, and easily installable electrical connection that withstands environmental stress and vibration, eliminating the need for tools and additional corrosion protection, while allowing for quick reconfiguration and maintenance.
Implementation Method 1
The contact spring is configured to at least partially collapse in the radial direction and to provide a spring bias against the mounting stud for providing an electrical connection
Implementation Method 2
Seals are positioned between the ring-shaped lugs, locking cap and the surface of the stud for sealing the system on the mounting stud
Data Source
AI summary
An electrical connection system includes a mounting stud having a base configured for mounting to a conductive surface. One or more one ring-shaped lugs, formed of an electrically conductive material, are configured for being positioned on the mounting stud for surrounding the mounting stud. The ring-shaped lug includes one or a plurality of interior channels extending around the inside diameter thereof. A contact spring is seated within a respective interior channel and is electrically conductive and dimensioned to extend radially inwardly from the channel and contact the mounting stud when the ring-shaped lug is positioned thereon. The contact spring is configured to at least partially collapse in the radial direction and to provide a spring bias against the mounting stud for providing an electrical connection between the ring-shaped lug and mounting stud. A locking cap is positioned on the mounting stud over the at least one ring-shaped lug for locking with the mounting stud and securing the ring-shaped lugs on the mounting stud for a secure electrical connection.