Spring-Loaded Contact Element for Insulated Down Conductor
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Solution Overview
Problem
Existing connection elements for insulated conductors in external lightning protection systems are complex, prone to mechanical damage, and lack reliability due to assembly tolerances and weather effects, making assembly and disassembly difficult and potentially damaging the semi-conductive layers, which can lead to disturbed discharges.
Innovation Solution
A one-piece conductive connection element with spring-loaded arms or fingers that securely contact the field control layer, allowing for compensation of mechanical movements and thermal expansion without damaging the insulated conductor, and a socket with recesses for spring-loaded contact pins to ensure reliable and long-term electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-part connection elements are used to connect the insulated down conductor to the equipotential bonding system, then the connection can be established, but the assembly complexity increases and assembly tolerances cannot be compensated, leading to questionable contact reliability
Solution Approach 1:
The patent combines multiple separate connection elements into a single integrated one-piece connection element that includes the connection body, contact element, and centering element as unified components. This merging eliminates assembly tolerances between multiple parts and ensures reliable electrical contact while reducing assembly complexity to a single insertion operation.
Solution Approach 2:
The one-piece connection element performs multiple functions simultaneously: it provides electrical contact through the conductive contact element, ensures proper positioning through the centering element, and enables easy installation through the integrated design. This multi-functionality resolves the contradiction by achieving reliable contact without requiring complex multi-step assembly procedures.
2Stability of the object's composition
If connection elements are firmly fixed in the support body, then connection stability is improved, but disassembly and reassembly become difficult or impossible
Solution Approach 1:
The connection element incorporates a spring element that provides dynamic characteristics to the otherwise static connection. The spring allows the connection element to be firmly held in the support body under normal conditions while enabling easy removal by applying sufficient force to compress the spring, thus resolving the contradiction between stability and ease of disassembly.
3Reliability
If existing connection elements are used, then connection can be established, but relative movement may mechanically damage the thin outer semiconductive layer, leading to disturbed discharges
Solution Approach 1:
The connection element features a centering element with a specific geometric design that locally provides guiding and centering functionality. This centering element ensures that the insulated down conductor is properly positioned during insertion and operation, preventing relative movements that could damage the thin semiconductive layer, thus protecting layer integrity while accommodating necessary movements.
4Productivity
If assembly process is made quick and intuitive, then productivity is improved, but assembly reliability may be compromised
Solution Approach 1:
The connection element is pre-configured with the contact element and centering element in fixed positions during manufacturing. This preliminary action ensures that when the connection element is inserted into the support body, the electrical contact and centering functions are automatically established without requiring precise manual alignment, thus achieving both quick assembly and high reliability.
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
Enables quick and intuitive assembly and disassembly with enhanced contact reliability, preventing damage to the insulated conductor and ensuring stable electrical connections under varying conditions.
Implementation Method 1
at least one conductive connection element (5), which is connected to the field control layer (8b) on the one hand and to a potential equalization (6) on the other hand, wherein the connection element (5) can be introduced into the space between the insulated down conductor (8) and the interior of the support body (1) or the support tube (7) or is arranged there
Implementation Method 2
allowing for compensation of mechanical movements and thermal expansion without damaging the insulated conductor
Data Source
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AI summary
The invention relates to a device for making contact with a field control layer of an insulated down conductor in external lightning protection, wherein the insulated down conductor is guided at least over a length section in the interior of a support body or a support pipe, spaced apart therefrom, furthermore with a conductive connecting element, which is connected at one end to the field control layer and at the other end to an equipotential bonding, and the connecting element is in the interspace between the insulated down conductor and the interior of the support body or the support pipe or can be brought into this interspace. In accordance with the invention, the connecting element is formed integrally and has a plurality of arms or fingers which are under mechanical prestress or spring force and which come to bear against the surface of the field control layer, without damaging same.