Rotating Contact Plate Screw Assembly for Electrical Connectors
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Solution Overview
Problem
Conventional electrical connectors and screws often damage conductors due to material differences and varying expansion rates, leading to loose connections, especially in environments with vibration, resulting in inadequate electrical contact and potential failure.
Innovation Solution
A screw assembly with a threaded body and a rotatable, flat contact plate coupled to a cup spring washer, which secures the conductor by allowing rotational movement and deflection to maintain contact, minimizing material damage and accommodating thermal expansion while resisting vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional pointed or tapered screw is used to secure the conductor, then the screw can be easily tightened, but it dents or damages the soft conductor strands
Solution Approach 1:
A flat contact plate is introduced as an intermediary element between the screw and the conductor. The plate has a flat contacting surface that distributes the clamping force evenly across the conductor strands, preventing dents and damage while still allowing the screw to effectively secure the conductor to the connector
2Adaptability or versatility
If different materials with different expansion rates are used for the screw and conductor, then material compatibility is achieved, but thermal expansion and contraction cause relative movement leading to loose connections
Solution Approach 1:
The contact plate is designed with rotational freedom relative to the threaded body, allowing it to dynamically adjust its orientation in response to thermal expansion and contraction of the conductor. This dynamic adjustment capability maintains consistent contact pressure and prevents loosening despite differential thermal movement between dissimilar materials
3Adaptability or versatility
If the connector is used in high vibration environments, then the connector can operate in demanding conditions, but vibration causes relative movement between screw and connector leading to loose connections
Solution Approach 1:
The rotatable contact plate design allows the connection assembly to dynamically respond to vibrational forces by permitting controlled relative rotation between the plate and threaded body. This dynamic capability prevents stress buildup and maintains secure contact despite vibration-induced movements, eliminating the need for periodic retorque maintenance
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 solution provides a secure, vibration-resistant electrical connection that maintains contact integrity across varying temperatures and material expansions, reducing the need for frequent maintenance and preventing connection failure.
Implementation Method 1
The spacer may alternatively or additionally be configured to deflect toward the threaded body when the plate contacts the conductor
Implementation Method 2
The plate is coupled to the threaded body to enable rotation of the plate relative to the threaded body
Data Source
AI summary
A screw assembly for use with an electrical connector securing a conductor includes a threaded body configured to be releasably coupled to a coupling portion of the connector. A contacting structure includes a plate spaced from the threaded body and has a flat contacting surface configured for contacting the conductor. The plate is coupled to the threaded body. The plate is rotatable relative to the threaded body when the threaded body is coupled to the coupling portion of the connector. The plate is restricted from movement away from said threaded body when the threaded body is not coupled to the coupling portion of the connector. A spacer may be positioned between the plate and the threaded body and is configured to urge the plate away from the threaded body.