Splice Electrical Connector for ACCC Cable Tensile Attachment
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Solution Overview
Problem
Conventional electrical connectors are not suitable for Aluminum Conductor Composite Core (ACCC) cables as they can crush or damage the composite core due to its low compression strength, preventing a secure mechanical attachment and tensile connection necessary for suspension from transmission towers.
Innovation Solution
A splice electrical connector design featuring two end members with a splice coupler and fastener, utilizing ductile conforming wedges that distribute the clamp loading along the composite core's length to prevent damage, ensuring a secure tensile connection without crushing the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional compression electrical connector is used to connect to an ACCC cable, then a mechanical attachment can be made, but the composite core will be crushed or damaged due to its low compression strength
Solution Approach 1:
Instead of using compression to create the mechanical attachment, the invention uses tension. The connector applies tensile forces through the aluminum conductor wires and end members, inverting the traditional compression-based attachment method to one that leverages the composite core's high tensile strength while avoiding its compression weakness
Solution Approach 2:
The invention replaces the traditional compression-based mechanical attachment system with a tension-based system. Rather than crushing the core to create attachment, the connector uses tensile loading through the conductor wires and end members to create a secure mechanical bond that exploits the composite core's superior tensile properties
2Reliability
If conventional connectors are used on ACCC cables, then connection can be made, but the composite core cannot withstand the compression force and the connection fails
Solution Approach 1:
The invention inverts the force application method by using tension instead of compression. The connector design applies tensile forces through the aluminum conductor wires and end members, converting a compression-based connection system into a tension-based system that the composite core can reliably withstand
Solution Approach 2:
The invention changes the mechanical parameter from compression force to tensile force. By modifying the force application mode from compressive to tensile, the connector achieves reliable attachment that matches the composite core's mechanical properties, specifically its high tensile strength and low compression resistance
3Strength
If a connector applies clamp loading to secure the cable, then a secure attachment is achieved, but the composite core is damaged due to concentrated compression
Solution Approach 1:
The invention inverts the stress application method by replacing compressive clamp loading with tensile forces. Instead of concentrating compressive stress on the composite core through traditional clamping, the connector distributes tensile forces through the aluminum conductor wires and end members, achieving secure attachment without damaging the core
Data Source
AI summary
A splice electrical connector for connecting core members of two cable conductors to each other is provided. The connector include two end members. Each end member comprises a first coupler end and a second wedge contact end. A splice coupler connects the first coupler ends of the two end members to each other. A fastener is connected to the splice coupler, wherein the fastener combines with the splice coupler to interlock the first coupler ends in mating portions of the splice coupler.