Wedge Connector Assemblies for High-Strength Tension Splices

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Solution Overview

Problem

Automatic connectors used in power distribution networks face issues with preparation, reliability, and performance when forming tension splices between high-voltage electrical conductors, particularly in terms of maintaining strong and durable connections.

Innovation Solution

A wedge connector assembly comprising resilient spring sleeve portions and wedge members that capture conductors within tapered cavities, forming a mechanical tension splice connection with a pullout strength of at least 70% of the rated break strength of each conductor, utilizing a coupling portion and wedge members driven into tapered sleeve cavities to secure the conductors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automatic connectors are used to form tension splices between electrical conductors, then the connection process is automated and productivity is improved, but the reliability and performance of the connection deteriorate due to preparation and performance issues

Engineering Contradiction:

Improveconnection process automationVSAvoidconnection reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The connector assembly is designed to automatically secure conductors through its own structural features - the tapered cavity and wedge member work together to self-lock the conductor in place without requiring external automation equipment or complex preparation steps, thus maintaining reliability while enabling automated installation

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The connector is divided into distinct functional components: a coupling portion for joining conductors, tapered cavities for conductor insertion, and wedge members for securing. This segmentation allows each component to perform its specific function optimally, improving both reliability and ease of automated assembly

Inventive Principle:

Principle #1Segmentation

2Device complexity

If conventional connectors are used to form mechanical tension splices, then the device complexity is low, but the pullout strength and connection performance deteriorate

Engineering Contradiction:

Improveconnector structure simplicityVSAvoidpullout strength

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The connector incorporates tapered (curved) cavities instead of straight cylindrical holes. This curvature allows the wedge member to progressively compress the conductor against the cavity walls, creating a self-tightening effect that dramatically increases pullout strength without adding complex external mechanisms

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The connector assembly combines different materials with complementary properties: conductive materials for electrical connection, resilient materials for the spring component that provides maintaining force, and wedge materials optimized for mechanical interlocking. This composite approach achieves high strength while keeping each component relatively simple

Inventive Principle:

Principle #40Composite materials

3Strength

If connectors are designed for high pullout strength with complex mechanisms, then the connection strength is improved, but the ease of operation and installation deteriorates

Engineering Contradiction:

Improvepullout strengthVSAvoidinstallation ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Instead of using complex mechanisms to actively secure the conductor, the design inverts the approach: the tapered cavity and wedge member are configured so that the conductor's own insertion motion and the wedge's driving force automatically create the securing action. The simpler the insertion, the stronger the lock - this inversion resolves the contradiction between strength and ease of operation

Inventive Principle:

Principle #13The other way round (Inversion)

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 wedge connector assembly provides a reliable and high-strength mechanical tension splice connection capable of withstanding significant tension loads, ensuring secure electrical connections between conductors with enhanced pullout resistance.

Implementation Method 1

first and second resilient spring sleeve portions located on the coupling portion... The first spring sleeve portion defines a first sleeve cavity... The second spring sleeve portion defines a second sleeve cavity

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9059522B2Wedge connector assemblies and methods for connecting electrical conductors using same

Publication Date: 2015.06.16 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

A wedge connector assembly for forming an electrical connection with first and second electrical conductors includes a coupling portion, first and second resilient spring sleeve portions located on the coupling portion, a first wedge member and a second wedge member. The first spring sleeve portion defines a first sleeve cavity tapering in a first direction away from the second spring sleeve portion and the second spring sleeve portion defines the second sleeve cavity tapering in a second direction away from the first spring sleeve portion. The first wedge member is configured to be forcibly driven into the first sleeve cavity in the first direction to capture the first conductor and the second wedge member is configured to be forcibly driven into the second sleeve cavity in the second direction to thereby capture the second conductor.