Shearable Fastener with Blocking Insert for Electrical Connectors
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Solution Overview
Problem
Existing connection methods using fasteners face challenges in preventing over-torque, which can lead to insecure connections or component damage, and require expensive torque wrenches or multiple tools, which are not always available or easily usable.
Innovation Solution
A shearable fastener design featuring a head, base, shearable section, and removable blocking insert, where the shearable section has a predetermined torque limit and the blocking insert limits access to the base, allowing the fastener to shear and prevent over-torque, and can be used with a drive tool to secure electrical conductors to a connector block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a torque wrench is used to prevent over-torque, then connection security is improved, but device complexity and cost increase
Solution Approach 1:
The fastener itself performs the torque limiting function through its shearable section, eliminating the need for external torque-wrenching equipment. The fastener automatically shears when torque exceeds the predetermined limit, making the system self-regulating and removing the complexity of requiring specialized tools.
Solution Approach 2:
The torque limiting function is extracted from the tool (torque wrench) and integrated directly into the fastener design. The shearable section acts as an intrinsic torque-limiting mechanism, separating the fastening function from the torque control function and embedding the latter within the fastener itself.
2Reliability
If multiple torque wrenches are used for different torque limits, then reliability is improved, but ease of operation deteriorates
Solution Approach 1:
A single standard drive tool can be used with multiple shearable fasteners of different torque limits, as each fastener self-regulates its own torque requirement. This eliminates the need for multiple specialized torque wrenches while maintaining the ability to control different torque levels through the fastener design itself.
Solution Approach 2:
Different torque limits are achieved by varying the parameters of the shearable section (such as thickness, material properties, or geometry) rather than requiring different tools. This allows a single tool to work with fasteners designed for different torque requirements by simply changing the fastener parameters.
3Adaptability or versatility
If an adjustable torque wrench is used, then versatility is improved, but ease of operation worsens due to setup complexity
Solution Approach 1:
The torque limit is predetermined and built into the fastener design during manufacturing, eliminating the need for field adjustment or setup. The shearable section is pre-configured with specific dimensional or material properties that define its torque limit, so no adjustment is needed when the fastener is installed.
Solution Approach 2:
The shearable fastener is designed as a disposable component that is replaced rather than adjusted. Each fastener is manufactured with a specific torque limit and is discarded after use, eliminating the complexity of adjustable mechanisms while providing versatility through selection of different fastener types.
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 shearable fastener effectively prevents over-torque by shearing at a predetermined limit, ensuring secure connections without damaging components and allowing for easy installation without the need for multiple torque wrenches, while enabling secure electrical connections.
Implementation Method 1
The shearable section is positioned between the head and the base and has a predetermined torque limit
Data Source
AI summary
A fastener (20) includes a head (22), a base (26), a shearable section (24), and a removable blocking insert (50). The head (22) has an inner surface (30) that includes a first socket (36) for receiving a drive tool (T). The base (26) includes an outer surface (38) having a base thread (44). The shearable section (24) is positioned between the head (22) and the base (26) and has a predetermined torque limit. The removable blocking insert (50) is positioned to hinder access of a drive tool (T) to the base (26).