Tap Clamp With Low-Resistivity Insert for Reduced Heat
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Solution Overview
Problem
Conductor tap clamps used for electrical communication generate excessive heat due to high resistivity materials, which can be mitigated by using different materials in the connector to adjust electrical properties.
Innovation Solution
A clamp design featuring a main housing portion with a body and an insert, where the insert has a lower resistivity than the body, allowing for efficient electrical communication and reduced heat generation by concentrating electrical potential, thereby enabling higher load handling without increasing mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high resistivity materials are used in the connector to maintain strength, then mechanical strength is improved, but heat generation increases due to excessive heat from high resistivity
Solution Approach 1:
The patent applies local quality by using different materials with different resistivities in different parts of the connector. The body is made from a first material (e.g., aluminum alloy) while the insert is made from a second material (e.g., copper alloy) with lower resistivity. This allows the insert to conduct electricity more efficiently and reduce heat generation at the critical electrical contact points, while the body maintains its mechanical strength and structural integrity.
Solution Approach 2:
The patent employs composite materials by combining two different materials in a single connector structure. The body and insert are made from different materials with complementary properties - the body material provides mechanical strength and the insert material provides low electrical resistivity. This composite approach allows the connector to simultaneously achieve both strength and low heat generation.
2Object-generated harmful factors
If more mass is used in manufacturing the connector to decrease heat generation, then heat generation is reduced, but the connector weight increases
Solution Approach 1:
Instead of increasing the overall mass of the connector, the patent applies local quality by placing a low-resistivity insert only in the specific area where electrical conduction occurs. This targeted approach reduces heat generation at the electrical contact points without adding unnecessary mass to the entire connector structure.
Solution Approach 2:
The patent changes the electrical resistivity parameter locally by introducing an insert material with lower resistivity than the body material. This parameter change allows the connector to handle higher electrical loads with reduced heat generation without requiring an increase in overall mass.
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 clamp effectively reduces heat generation and increases long-term stability by utilizing materials with different resistivities, allowing for efficient electrical communication and handling higher electrical loads.
Implementation Method 1
the insert providing electrical communication between the first surface and the second surface
Implementation Method 2
the insert having a lower resistivity relative to the body... reduced heat generation
Data Source
AI summary
Clamps and methods disclosed herein can help to provide efficient electrical communication between a first conductor and a second conductor. An example clamp includes a main housing portion that includes a first surface, a second surface, a body, and an insert, the insert providing electrical communication between the first surface and the second surface; a clamp member; and a fastener.