Submersible Set-Screw Connector with Metal-Plastic Segmentation
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Solution Overview
Problem
Conventional submersible electrical set-screw connectors face issues as they become compromised in severe and demanding operating environments, with existing solutions failing to maintain reliable electrical connections due to material limitations, particularly with plastic threads yielding at operating temperatures.
Innovation Solution
A submersible electrical set-screw connector design featuring a metal threaded body with an overmolded insulating plastic head, where the plastic material is only torqued at room temperature, ensuring the metal threads do not yield under temperature stress, thus maintaining a secure and insulated connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic threads are used in submersible electrical connectors, then ease of manufacture and insulation are improved, but reliability deteriorates due to material yielding at operating temperatures
Solution Approach 1:
The connector is divided into two distinct segments: a metal body portion containing the threaded section, and a plastic head portion providing insulation. This segmentation allows each material to perform its optimal function - metal provides mechanical strength and thread integrity at high temperatures, while plastic provides electrical insulation and ease of manufacturing.
Solution Approach 2:
The connector combines two different materials - metal (for the body and threads) and plastic (for the head and insulation). This composite structure leverages the superior temperature resistance and mechanical strength of metal while utilizing the electrical insulation properties and manufacturing ease of plastic, resolving the contradiction between ease of manufacture and reliability.
2Strength
If metal threaded bodies are used, then strength and temperature resistance are improved, but electrical insulation deteriorates
Solution Approach 1:
The connector is divided into two distinct segments: a metal body portion containing the threaded section, and a plastic head portion providing insulation. This segmentation allows each material to perform its optimal function - metal provides mechanical strength and thread integrity at high temperatures, while plastic provides electrical insulation and ease of manufacturing.
Solution Approach 2:
The connector combines two different materials - metal (for the body and threads) and plastic (for the head and insulation). This composite structure leverages the superior temperature resistance and mechanical strength of metal while utilizing the electrical insulation properties and manufacturing ease of plastic, resolving the contradiction between ease of manufacture and reliability.
3Adaptability or versatility
If conventional set-screw assemblies are used, then adaptability is improved, but reliability deteriorates in severe operating environments
Solution Approach 1:
The connector combines two different materials - metal (for the body and threads) and plastic (for the head and insulation). This composite structure leverages the superior temperature resistance and mechanical strength of metal while utilizing the electrical insulation properties and manufacturing ease of plastic, resolving the contradiction between ease of manufacture and reliability.
Solution Approach 2:
The invention changes the material parameter of the threaded section from plastic to metal, fundamentally altering the thermal and mechanical properties. This parameter change enables the connector to withstand severe operating environments including high temperatures and harsh chemicals while maintaining thread integrity and electrical insulation.
Data Source
AI summary
Disclosed herein is an electrical connector set-screw. The electrical connector set-screw includes a body part and a head part. The body part includes a threaded section and a channel. The threaded section extends between a first end and an opposite second end of the body part. The channel extends through a portion of the body part. The channel is spaced from the first end and the second end of the body part The head part is connected to the body part. The head part includes a top section and an integral locking section. The top section is configured to be received by a tool. The integral locking section extends through the channel.