Shearable Connector Fastener for Variable Conductor Clamping
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Solution Overview
Problem
Existing fasteners for connecting electrical conductors to connector blocks often face challenges in securely maintaining electrical contact and accommodating conductors of varying sizes, while also ensuring reliable torque application and easy removal without causing damage or leakage.
Innovation Solution
A fastener design featuring a shearable bolt with a telescopically coupled first and second portion, where the second portion can rotate relative to the first after a predetermined torque is applied, allowing for adjustable engagement with conductors of different sizes and providing a positive indication of correct installation through shearing, while preventing fluid leakage and facilitating easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional fastener is used to connect electrical conductors to connector blocks, then the connection can be maintained, but the fastener cannot securely maintain electrical contact with conductors of varying sizes and may cause damage or leakage
Solution Approach 1:
The fastener is divided into a first portion (screw body) and a second portion (insert) that can move relative to each other. The second portion telescopes within the first portion to accommodate conductors of different sizes, while maintaining secure electrical contact through the compression spring mechanism
Solution Approach 2:
The fastener incorporates a dynamic adjustment mechanism where the second portion can move axially within the first portion. A compression spring provides continuous pressure to maintain reliable electrical contact as the insert adjusts to different conductor diameters, transforming a static fastener into a dynamic, adaptive connection system
2Ease of operation
If a traditional fastener is used, then installation can be performed, but torque application is difficult to control and may cause over-tightening or damage
Solution Approach 1:
The second portion of the fastener is designed as a disposable component that is discarded after a single use. This allows the fastener to be optimized for ease of installation with a drive slot for tool engagement, while the controlled torque mechanism ensures proper connection without worrying about reusing the fastener
Solution Approach 2:
The fastener is pre-configured with a drive slot in the first portion that accepts a installation tool. This preliminary design feature enables controlled torque application during installation, ensuring the connection is made with the correct force before the fastener is discarded
3Ease of repair
If a traditional fastener is used, then connection can be made, but removal is difficult and may cause damage to the connector block
Solution Approach 1:
By dividing the fastener into two separable portions where the second portion is discarded after use, the design allows the first portion (screw body) to remain in the connector block without requiring removal. This eliminates the risk of damaging the connector block during removal while still providing secure connection during use
Solution Approach 2:
The second portion of the fastener is designed to be discarded after a single installation cycle, while the first portion (screw body) remains permanently installed in the connector block. This approach simplifies the removal process by eliminating the need to extract the fastener entirely, preventing damage to the connector block
Data Source
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Figure 3A
AI summary
A fastener for connecting an electrical conductor to a connector body includes a first portion adapted to engage an opening of the connector body and a second portion engaging the first portion. The second portion includes a head, a base coupled to the first portion and including an end adapted to engage the electrical conductor, and a shearable section positioned between the head and the base.