Threaded Electrical Connector with Axis-Aligned Contact Separation
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Solution Overview
Problem
Industrial electrical connectors face challenges in ensuring safe connect/disconnect operations in hazardous environments, as existing designs may still lead to arcing and explosions due to energized connectors, despite compliance with safety standards.
Innovation Solution
The electrical connector system mechanically isolates contacts from the environment by severing power upon disconnection, using a threaded coupling mechanism that aligns axes for contact or separation of contact surfaces, preventing sparks and arcing during energized operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are designed to meet safety standards with conventional designs, then compliance with safety standards is achieved, but arcing and explosions can still occur during energized connect/disconnect operations
Solution Approach 1:
The patent applies preliminary action by designing the connector to automatically sever electrical power to the contacts before they separate during disconnect operations. The threaded coupling mechanism ensures that power is mechanically severed in advance of contact separation, preventing arcing and sparks during the disconnect process while maintaining safety compliance
Solution Approach 2:
The patent uses a threaded coupling mechanism as an intermediary between the connector bodies that controls the sequence of operations. This intermediary mechanism ensures proper alignment and timing of contact engagement and disengagement, facilitating safe connect/disconnect operations while preventing harmful arcing
2Object-affected harmful factors
If connectors require de-energizing lines before connect/disconnect operations, then safety is improved, but operational efficiency and productivity decrease
Solution Approach 1:
The connector design performs the safety function of severing power preliminarily through its threaded coupling mechanism, eliminating the need for manual de-energizing procedures. This allows operators to perform connect/disconnect operations without interrupting the overall system power, thereby maintaining productivity while preventing sparks and arcing
Solution Approach 2:
The connector performs its own safety function automatically through the threaded coupling mechanism that mechanically severs power during disconnect. This self-service capability eliminates the need for external de-energizing procedures, allowing continuous operation and maintaining productivity while ensuring safety
3Ease of operation
If connector contacts are exposed to the surrounding environment, then ease of connection is improved, but risk of arcing and explosion increases in hazardous environments
Solution Approach 1:
The threaded coupling mechanism serves as an intermediary that controls the engagement and disengagement process. It ensures that contacts are properly aligned and engaged through the threading action, maintaining ease of operation while preventing exposed contacts from creating arcing hazards in the surrounding environment
Data Source
AI summary
An electrical connector system can comprise a first connector and a second connector. The first connector can include a first threaded coupling feature defining a first axis. The first connector can also include a first electrical contact with a first contact surface having an annular configuration centered on the first axis by a radius. The second connector can include a second threaded coupling feature defining a second axis. The second connector can also include a second electrical contact with a second contact surface offset from the second axis by the radius. The first and second threaded coupling features can be operable to engage one another to couple the first and second connectors to one another such that the first and second axes are aligned, thereby facilitating contact or separation of the first and second contact surfaces upon relative rotation of the first and second connectors.