Tapered Electrical Connector With Deformable Insert for Torque Resistance
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Solution Overview
Problem
Existing electrical connectors face challenges in providing a secure and reliable mechanical and electrical connection for electrical conductors, particularly in power distribution systems, where deformation and torque resistance are critical for maintaining connections under varying conditions.
Innovation Solution
The design incorporates a connector body with a conductor engagement section and a stud mounting section featuring a tapered bore and insert, allowing for deformation and secure threading, along with shear bolts for clamping, to ensure a robust connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional crimped connector body is used to secure the conductor, then the manufacturing process is simple, but the mechanical strength and reliability of the connection are insufficient under varying torque conditions
Solution Approach 1:
The connector body is divided into distinct functional sections: a conductor engagement section with a conductor bore for securing the conductor, and a stud mounting section with a socket bore for receiving the stud member. This segmentation allows each section to be optimized independently for its specific function, improving overall connection reliability while maintaining manufacturing feasibility.
Solution Approach 2:
The socket bore includes a tapered bore section that allows for deformation of the stud member during assembly. This dynamic design enables the connector to accommodate variations in assembly torque and maintain reliable electrical connection under varying operational conditions, rather than requiring a perfectly rigid fixed geometry.
2Reliability
If the stud member is rigidly fixed in the connector body, then the assembly process is straightforward, but the connection cannot accommodate torque variations and environmental factors
Solution Approach 1:
The socket bore is designed with a tapered section that permits controlled deformation of the stud member's insert section during assembly. This dynamic feature allows the connection to self-adjust under torque loads and environmental stress, improving torque resistance without requiring complex pre-adjustment mechanisms or specialized assembly tools.
Solution Approach 2:
The tapered bore section changes the geometric parameters of the stud member during assembly, allowing the insert section to deform and conform to the socket bore. This parameter change enables the connection to accommodate torque variations and maintain electrical contact reliability without adding complex adjustment mechanisms.
3Reliability
If the conductor is loosely secured in the connector body, then the assembly process is simple and quick, but the electrical and mechanical connection stability is insufficient
Solution Approach 1:
The conductor engagement section is pre-configured with a conductor bore that receives and secures the terminal end of the conductor before final assembly. This preliminary positioning ensures proper alignment and stable electrical contact are achieved automatically during the assembly process, eliminating the need for separate adjustment steps and reducing assembly time while maintaining connection stability.
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
This configuration provides a durable, mechanically and electrically secure connection that withstands torque and environmental factors, ensuring reliable operation in power distribution systems.
Implementation Method 1
The tapered insert section includes an internal cavity defined therein to permit deformation of the tapered insert section as the tapered insert section is forced into the tapered bore section
Implementation Method 2
at least one shear bolt mounted in the connector body and configured to clamp the conductor in the conductor bore to mechanically and electrically connect the conductor to the connector
Implementation Method 3
The stud member further includes a second threaded section threadedly engaging the first threaded section to secure the stud member to the connector body
Data Source
AI summary
According to embodiments of the invention, an electrical connector for use with an electrical conductor having a terminal end includes a connector body and a stud member. The connector body includes a conductor engagement section and a stud mounting section. The conductor engagement section is configured to receive the terminal end of the conductor to mechanically and electrically connect the conductor to the connector. The stud mounting section includes a socket bore including a tapered bore section. The stud member includes an elongate stud section extending to a free end, and a tapered insertion section. The tapered insert section is received in the tapered bore section. The tapered insert section includes an internal cavity defined therein to permit deformation of the tapered insert section as the tapered insert section is forced into the tapered bore section.