Description:FIELD OF THE INVENTION

The present invention relates to the field of electrical connectors, specifically designed for low voltage (LV) applications. It encompasses specially designed terminal connectors that utilize re-usable Allen screw mechanisms for improved connectivity and reliability in miniature circuit breaker (MCB) terminals and energy meter terminals. These connectors are engineered to address issues related to compatibility, corrosion, and thermal management in electrical installations, particularly where aluminum and copper conductors are used. The invention is applicable to industrial and utility applications, including electricity utilities, solar and wind installations, and various industrial settings such as process industries and data centers.

Application:

The invention is applicable in scenarios where reliable and efficient electrical connections are required, particularly in environments prone to thermal and corrosion challenges. The connectors are designed to be used in:

Utility Applications: Enhancing the reliability and efficiency of electrical networks by reducing technical losses and minimizing equipment failures and hot spot abnormalities. The connectors are suitable for use in electricity distribution systems, ensuring stable and secure connections in meter cabinets and circuit breaker panels.
Solar and Wind Installations: Providing robust and corrosion-resistant connections in renewable energy systems, where varying conductor materials and environmental conditions necessitate durable and adaptable connector solutions.
Industrial Installations: Facilitating efficient electrical connections in industrial settings, such as process industries and data centers, where high reliability and reduced maintenance requirements are critical. The connectors offer ease of installation and reusability, reducing downtime and operational costs.
Commercial Deployment: The connectors can be commercially deployed to utilities, industrial plants, and data centers, offering a cost-effective alternative to conventional tubular lugs. They can also be exported to other countries and integrated into joint collaboration and franchisee models for manufacturing, marketing, and sales.
Value Added Services (VAS): Offering installation services to customers as part of a value-added service package, enhancing customer satisfaction through improved reliability and reduced maintenance needs.

BACKGROUND OF THE INVENTION
In the realm of electrical engineering, connectors play a pivotal role in ensuring the safe and efficient transmission of electrical power across various systems. Low voltage (LV) applications, such as those involving miniature circuit breakers (MCBs) and energy meters, are particularly reliant on the integrity and performance of these connectors. The connectors must provide a secure and reliable interface between conductors, often made of different materials like copper and aluminum, to prevent issues such as thermal hotspots, corrosion, and equipment failures.

Electrical connectors are critical components in low voltage (LV) applications, facilitating the secure and efficient transmission of electrical power. In particular, connectors used in miniature circuit breakers (MCBs) and energy meters must ensure reliable connections to prevent issues such as thermal hotspots, corrosion, and equipment failures. Traditionally, connectors used in these applications have been made from copper due to its excellent electrical conductivity. However, the use of copper connectors presents several challenges, especially when interfacing with aluminum conductors. The joint of dissimilar metals can lead to increased contact resistance, resulting in thermal hotspots that can cause equipment failures and safety hazards. Additionally, copper connectors are susceptible to galvanic corrosion when in contact with aluminum, further degrading their performance over time.

The installation of traditional connectors often requires specific skills and tools, such as crimping machines, to ensure a secure connection. This process is not only time-consuming but also introduces the risk of workmanship errors, which can compromise the reliability of the connection. Moreover, crimping-type connectors are typically designed for single use, necessitating frequent replacements and contributing to higher procurement and disposal costs.

In many industrial and utility applications, the need for multiple types of connectors to accommodate different makes and models of MCBs and energy meters complicates inventory management and increases costs. This lack of standardization also poses challenges in terms of training and skill development for installation personnel, further increasing the potential for errors and inefficiencies.

The growing demand for reliable and efficient electrical connections in LV applications, particularly in environments where aluminum conductors are prevalent, underscores the need for innovative solutions that address the limitations of traditional connectors. The present invention seeks to fulfill this need by introducing a novel connector design that offers enhanced compatibility, corrosion resistance, and ease of installation, thereby improving the overall performance and reliability of electrical systems.

Prior Art Problems:
1. Compatibility Issues: Conventional connectors are often incompatible with aluminum conductors, leading to increased contact resistance and thermal hotspots due to the joint of dissimilar metals.
2. Corrosion and Oxidation: Copper connectors are prone to galvanic corrosion when used with aluminum conductors, resulting in degraded performance and increased maintenance requirements.
3. Single-Use Design: Traditional crimping-type connectors are designed for single use, necessitating frequent replacements and contributing to higher procurement and disposal costs.
4. Complex Installation Process: The use of crimping tools and specialized skills for installing traditional connectors increases installation time and costs, while also introducing the risk of workmanship errors.

Prior Art Disadvantages:
• Increased Technical Losses: Inefficient connections lead to higher technical losses, impacting the overall efficiency of electrical systems.
• Higher Maintenance Costs: Frequent replacements and corrosion-related issues increase maintenance costs and downtime.
• Limited Versatility: The need for multiple types of connectors for different makes and models of MCBs and energy meters complicates inventory management and increases costs.
Technical Solution of the Present Invention:
The present invention introduces specially designed terminal connectors utilizing re-usable Allen screw mechanisms, made from aluminum alloy 6082-T6, to address the aforementioned issues. These connectors feature:
• A universal design compatible with various makes and models of MCBs and energy meters.
• Copper and tin plating to prevent galvanic corrosion and ensure compatibility with both aluminum and copper conductors.
• A re-usable screw mechanism that eliminates the need for crimping tools and allows for multiple uses without damaging the threads.
• An increased cross-sectional area for improved heat dissipation and reduced thermal hotspots.

Technical Effect:
The invention significantly reduces contact resistance and thermal hotspots, enhancing the reliability and efficiency of electrical connections. It simplifies the installation process, reducing time and costs, while also minimizing the risk of workmanship errors. The re-usable design offers a cost-effective solution by eliminating the need for frequent replacements.
Technical Advancement:
The invention represents a technical advancement over prior art by providing a universal, re-usable connector solution that is compatible with both aluminum and copper conductors. It addresses the limitations of traditional connectors by offering improved corrosion resistance, enhanced heat dissipation, and simplified installation, thereby reducing technical losses and maintenance costs.
Need for the Present Invention:
The need for the present invention arises from the growing demand for reliable and efficient electrical connections in LV applications, particularly in environments where aluminum conductors are prevalent. The invention addresses the challenges associated with traditional connectors, offering a versatile and cost-effective solution that enhances the performance and reliability of electrical systems, while also reducing installation complexity and maintenance requirements.

OBJECT OF THE INVENTION

The primary object of the present invention is to provide an improved electrical connector for low voltage applications that overcomes the limitations of traditional connectors. Specifically, the invention aims to:

1. Enhance Compatibility: Develop a universal connector design that is compatible with various makes and models of miniature circuit breakers (MCBs) and energy meters, accommodating both aluminum and copper conductors without the need for multiple connector types.
2. Reduce Corrosion and Oxidation: Utilize materials and coatings, such as aluminum alloy 6082-T6 with copper and tin plating, to prevent galvanic corrosion and oxidation, thereby extending the lifespan and reliability of the connectors.
3. Improve Thermal Management: Increase the cross-sectional area of the connector to facilitate better heat dissipation, reducing thermal hotspots and enhancing the safety and efficiency of electrical connections.
4. Simplify Installation: Eliminate the need for specialized tools and skills, such as crimping machines, by incorporating a re-usable Allen screw mechanism that allows for easy and secure installation, reducing installation time and costs.
5. Provide Cost-Effective Solutions: Offer a re-usable connector design that minimizes the need for frequent replacements, thereby reducing procurement and disposal costs and providing a more economical solution compared to traditional single-use connectors.
6. Enhance Reliability and Performance: Reduce contact resistance and technical losses, thereby improving the overall reliability and performance of electrical systems in industrial, utility, and renewable energy applications.

By achieving these objectives, the invention seeks to address the growing demand for reliable, efficient, and cost-effective electrical connectors in low voltage applications, ultimately enhancing the safety and performance of electrical systems.

SUMMARY OF THE INVENTION

The following disclosure presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the present invention. It is not intended to identify the key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concept of the invention in a simplified form as a prelude to a more detailed description of the invention presented later.

The present invention provides an advanced electrical connector specifically designed for low voltage applications, addressing the limitations of traditional connectors used in miniature circuit breakers (MCBs) and energy meters. This connector employs a re-usable Allen screw mechanism and is constructed from aluminum alloy 6082-T6, offering significant improvements in compatibility, corrosion resistance, installation simplicity, thermal management, and cost-effectiveness. The invention enhances the reliability and performance of electrical systems across various industrial, utility, and renewable energy sectors.

Aspects of the Invention:

Aspect 1: Universal Compatibility
• The connector is designed with a special palm or pin that fits securely into the terminals of various makes and models of MCBs and energy meters. This universal design eliminates the need for multiple connector types, simplifying inventory management and reducing costs.
Aspect 2: Corrosion and Oxidation Resistance
• Constructed from aluminum alloy 6082-T6 and plated with copper and tin, the connector prevents galvanic corrosion and oxidation. This ensures long-term reliability and performance, particularly in environments where aluminum and copper conductors are used.
Aspect 3: Improved Thermal Management

• With an increased cross-sectional area compared to conventional lugs, the connector facilitates better heat dissipation and reduces thermal hotspots. This design enhances the safety and efficiency of electrical connections, especially in high-load applications.

Aspect 4: Simplified Installation
• The connector features a re-usable Allen screw mechanism, allowing for easy and secure installation without the need for specialized tools like crimping machines. This design reduces installation time and costs, while minimizing the risk of workmanship errors.
Aspect 5: Cost-Effective Solution
• The re-usable design of the connector minimizes the need for frequent replacements, reducing procurement and disposal costs. This cost-effective solution offers a more economical alternative to traditional single-use connectors, making it attractive for large-scale deployments.
Aspect 6: Enhanced Reliability and Performance
• By reducing contact resistance and technical losses, the connector improves the overall reliability and performance of electrical systems. This aspect is particularly beneficial in industrial, utility, and renewable energy applications, where consistent and efficient power delivery is critical.
Implementations of the Aspects:

Implementation of Aspect 1: Universal Compatibility
• The connector's design is rigorously tested across a wide range of MCB and energy meter models to ensure a secure fit and reliable performance, regardless of the manufacturer or model. This involves creating a standardized pin or palm design that can accommodate various terminal configurations, thereby streamlining inventory management and reducing the need for multiple connector types.
Implementation of Aspect 2: Corrosion and Oxidation Resistance
• The materials and coatings used in the connector are selected based on extensive environmental testing to withstand harsh conditions. The aluminum alloy 6082-T6 is chosen for its strength and conductivity, while the copper and tin plating is applied to prevent galvanic corrosion. This combination ensures the connector's durability and longevity, even in environments where aluminum and copper conductors are used together.
Implementation of Aspect 3: Improved Thermal Management

• The connector's increased cross-sectional area is optimized through thermal simulations and testing to ensure effective heat dissipation under various load conditions. This design reduces thermal hotspots and enhances the safety and efficiency of electrical connections, particularly in high-load applications. The connector's thermal performance is validated through rigorous testing to confirm its ability to maintain safe operating temperatures.

Implementation of Aspect 4: Simplified Installation
• The Allen screw mechanism is engineered for ease of use, allowing installers to quickly and securely connect conductors without the need for additional training or specialized tools. This design reduces installation time and costs, while also minimizing the risk of workmanship errors. The re-usable nature of the screw mechanism further enhances the connector's practicality and efficiency.

Implementation of Aspect 5: Cost-Effective Solution
• The re-usable design of the connector is validated through lifecycle testing to demonstrate its economic benefits over traditional connectors. By minimizing the need for frequent replacements, the connector reduces procurement and disposal costs, providing a compelling value proposition for customers. This cost-effectiveness makes the connector an attractive option for large-scale deployments in various applications.
Implementation of Aspect 6: Enhanced Reliability and Performance
• The connector's performance is evaluated through electrical testing to confirm its ability to reduce contact resistance and technical losses. This ensures reliable power delivery in diverse applications, enhancing the overall reliability and performance of electrical systems. The connector's design and materials are optimized to provide consistent and efficient power delivery, making it suitable for industrial, utility, and renewable energy applications.
Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The accompanying figures illustrate various components of the wearable ultrasound hardware system design. These figures are provided to enhance the understanding of the invention and are not intended to limit its scope.
FIG. 1
This figure illustrates the overall design of the electrical connector for use in MCB, highlighting its compact and robust structure. The connector features a re-usable Allen screw mechanism integrated into the connector body, designed for secure and reliable electrical connections.
FIG. 2
This figure provides a side view of the connector for use in MCB, detailing the dimensions of the connector body.
FIG. 3
This figure presents a side view of the connector for use in MCB, focusing on the length of the connector body, which measures 38 mm. This view highlights the threaded section designed to accommodate the Allen screw mechanism.
FIG. 4
This figure shows a top view of the connector for use in MCB, indicating the diameter of the connector's opening. The outer diameter is 18 mm, and the inner diameter is 10.50 mm, illustrating the connector's compatibility with different conductor sizes.
FIG. 5
This figure depicts the connector with labeled components for use in Energy meters, including the Allen screw mechanism (45) and the connector body (25). The dimensions are provided, with the total length being 45 mm and the length of the connector body being 25 mm.
FIG. 6
This figure provides a front view of the connector for use in Energy meters, showing the width of the connector body as 7.6 mm. This view emphasizes the slim profile of the connector, suitable for installations in confined spaces.
FIG. 7
This figure offers a cross-sectional view of the connector for use in Energy meters, highlighting the internal structure and the placement of the Allen screw mechanism. The view provides insight into the connector's design for efficient electrical conduction.
FIG. 8
This figure presents a detailed view of the connector's opening in Energy meters, with dimensions indicating the outer diameter of 12.5 mm and the inner diameter of 6 mm. This view underscores the connector's adaptability to various conductor sizes.
Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may not have been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of various embodiments of the present disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding, but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the present disclosure. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.
All terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which various embodiments belong. Further, the meaning of terms or words used in the specification and the claims should not be limited to the literal or commonly employed sense but should be construed in accordance with the spirit of the disclosure to most properly describe the present disclosure.
The terminology used herein is for the purpose of describing particular various embodiments only and is not intended to be limiting of various embodiments. As used herein, the singular forms "a," "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising" used herein specify the presence of stated features, integers, steps, operations, members, components, and/or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, members, components, and/or groups thereof.
The present disclosure will now be described more fully with reference to the accompanying drawings, in which various embodiments of the present disclosure are shown.

The present invention relates to an advanced electrical connector designed for low voltage applications, specifically targeting the challenges associated with traditional connectors used in miniature circuit breakers (MCBs) and energy meters. This connector employs a re-usable Allen screw mechanism and is constructed from aluminum alloy 6082-T6, offering significant improvements in compatibility, corrosion resistance, installation simplicity, thermal management, and cost-effectiveness. The invention enhances the reliability and performance of electrical systems across various industrial, utility, and renewable energy sectors.

Embodiments of the Invention:

Embodiment 1: Universal Compatibility

In the present embodiment the present invention addresses the need for a versatile electrical connector that can be seamlessly integrated into a wide range of miniature circuit breakers (MCBs) and energy meters, regardless of their make or model. This aspect of the invention is crucial for simplifying inventory management and reducing the complexity associated with maintaining multiple types of connectors for different systems.

Design Features:

1. Standardized Palm or Pin:
o The connector is equipped with a specially designed palm or pin that is engineered to fit securely into the terminals of various MCBs and energy meters. This standardized design is the result of extensive research and development, ensuring that the connector can accommodate different terminal configurations without compromising performance.
2. Precision Engineering:
o The universal compatibility is achieved through precise engineering, which involves detailed analysis of the terminal designs of different MCBs and energy meters. The connector's palm or pin is crafted to match the dimensions and shapes of these terminals, providing a snug fit that ensures reliable electrical contact.
3. Testing and Validation:
o To ensure universal compatibility, the connector undergoes rigorous testing across a wide range of MCB and energy meter models. This testing includes mechanical fit assessments, electrical performance evaluations, and stress tests to confirm that the connector can maintain its integrity and functionality under various conditions.
Benefits:
1. Simplified Inventory Management:
o By offering a universal connector design, the invention reduces the need for users to stock multiple types of connectors for different systems. This simplification of inventory management leads to cost savings and operational efficiency, as users can rely on a single connector type for various applications.
2. Ease of Deployment:
o The universal compatibility of the connector makes it easier for users to deploy the connector across different systems without the need for additional modifications or adjustments. This ease of deployment is particularly beneficial in large-scale installations where consistency and reliability are paramount.
3. Reduced Complexity:
o The standardized design of the connector reduces the complexity associated with installation and maintenance, as users do not need to navigate the intricacies of different connector types. This reduction in complexity translates to faster installation times and lower maintenance costs.
Implementation:
The implementation of universal compatibility involves a comprehensive approach to design and testing. The connector's palm or pin is crafted using advanced manufacturing techniques to ensure precision and consistency. Detailed measurements and analyses of various terminal designs are conducted to inform the connector's design, ensuring that it can accommodate a wide range of configurations.
During testing, the connector is subjected to various scenarios to validate its performance across different MCB and energy meter models. This includes testing for mechanical fit, electrical conductivity, and durability under stress. The results of these tests confirm the connector's ability to provide reliable and consistent performance, regardless of the system in which it is used.
Overall, the embodiment of universal compatibility in the present invention represents a significant advancement in electrical connector design, offering users a versatile and reliable solution that simplifies inventory management and reduces operational complexity.

Embodiment 2: Corrosion and Oxidation Resistance

The embodiment of corrosion and oxidation resistance in the present invention addresses the critical need for durable and reliable electrical connectors that can withstand the challenges posed by harsh environmental conditions and the use of dissimilar metals. This aspect of the invention is essential for ensuring the long-term performance and reliability of electrical systems, particularly in applications where aluminum and copper conductors are used together.

Design Features:

1. Material Selection:
o The connector body is constructed from aluminum alloy 6082-T6, a material chosen for its excellent balance of strength, conductivity, and resistance to environmental degradation. This alloy is known for its mechanical properties, making it suitable for applications that require both durability and electrical efficiency.
2. Copper and Tin Plating:
o To further enhance the connector's resistance to corrosion and oxidation, the aluminum alloy body is plated with layers of copper and tin. Copper plating provides a conductive surface that minimizes electrical resistance, while tin plating offers an additional layer of protection against oxidation and corrosion. This dual-layer plating is crucial for preventing galvanic corrosion, which can occur when aluminum and copper conductors are used together.
3. Environmental Testing:
o The materials and coatings used in the connector are selected based on extensive environmental testing. These tests simulate harsh conditions, such as exposure to moisture, temperature fluctuations, and corrosive substances, to ensure that the connector can maintain its integrity and performance over time.
Benefits:

1. Long-Term Reliability:
o By using materials and coatings that resist corrosion and oxidation, the connector ensures long-term reliability and performance. This is particularly important in environments where connectors are exposed to moisture, chemicals, or other corrosive elements that can degrade traditional materials.
2. Mitigation of Corrosion-Related Failures:
o The combination of aluminum alloy and copper-tin plating effectively mitigates the risk of corrosion-related failures, which are common when dissimilar metals are used together. This reduces maintenance requirements and extends the lifespan of the connector, providing a more dependable solution for electrical systems.
3. Enhanced Performance in Harsh Environments:
o The connector's resistance to environmental degradation makes it suitable for use in a wide range of applications, including industrial, utility, and renewable energy sectors. Its ability to withstand harsh conditions ensures consistent performance, even in challenging environments.
Implementation:

The implementation of corrosion and oxidation resistance involves a meticulous process of material selection, plating application, and testing. The aluminum alloy 6082-T6 is chosen for its mechanical and electrical properties, providing a robust foundation for the connector. The copper and tin plating is applied using advanced electroplating techniques, ensuring uniform coverage and adhesion to the aluminum substrate.

Environmental testing plays a crucial role in validating the connector's resistance to corrosion and oxidation. The connector is subjected to accelerated aging tests, which simulate long-term exposure to corrosive environments. These tests assess the connector's ability to maintain its structural integrity and electrical performance under conditions that mimic real-world applications.

Overall, the embodiment of corrosion and oxidation resistance in the present invention represents a significant advancement in connector technology, offering a durable and reliable solution that meets the demands of modern electrical systems. By addressing the challenges associated with dissimilar metal use and harsh environmental conditions, this embodiment ensures that the connector can deliver consistent performance and reliability over its operational lifespan.

Embodiment 3: Simplified Installation

In this particular embodiment the present invention focuses on enhancing the ease and efficiency of installing electrical connectors, addressing common challenges associated with traditional installation methods. This aspect of the invention is crucial for reducing installation time, costs, and the potential for errors, thereby improving the overall efficiency and reliability of electrical systems.

Design Features:

1. Re-usable Allen Screw Mechanism:
o The connector is equipped with a re-usable Allen screw mechanism, which serves as the primary means of securing conductors. This mechanism is designed to provide a strong and reliable connection without the need for specialized tools such as crimping machines. The Allen screw is engineered to be easily tightened and loosened using a standard Allen wrench, making the installation process straightforward and accessible.
2. Ease of Use:
o The Allen screw mechanism is specifically designed for ease of use, allowing installers to quickly and securely connect conductors without requiring additional training or expertise. The design ensures that the screw can be easily accessed and operated, even in confined spaces, facilitating a smooth installation process.
3. Re-usability:
o Unlike traditional crimping-type connectors, which are often single-use, the Allen screw mechanism is re-usable. This feature allows the connector to be used multiple times without compromising the integrity of the connection, providing a practical and cost-effective solution for various applications.
Benefits:

1. Reduced Installation Time and Costs:
o By eliminating the need for specialized tools and simplifying the installation process, the connector significantly reduces installation time and associated labor costs. This efficiency is particularly beneficial in large-scale projects where time and resources are critical factors.
2. Minimized Risk of Workmanship Errors:
o The straightforward design of the Allen screw mechanism minimizes the risk of workmanship errors, which can occur with more complex installation methods. This reduction in errors enhances the reliability and safety of the electrical connections, contributing to the overall performance of the system.

3. Increased Practicality and Efficiency:
o The re-usable nature of the Allen screw mechanism enhances the connector's practicality and efficiency, allowing it to be easily adjusted or re-installed as needed. This flexibility is advantageous in dynamic environments where system configurations may change over time.
Implementation:

The implementation of simplified installation involves the careful design and engineering of the Allen screw mechanism to ensure it meets the requirements of ease of use, reliability, and re-usability. The screw is crafted from durable materials to withstand repeated use and maintain a secure connection over time. The design process includes ergonomic considerations to ensure that the screw can be easily operated with a standard Allen wrench, even in challenging installation environments.

Testing and validation are critical components of the implementation process. The connector is subjected to various installation scenarios to assess the ease and speed of installation, as well as the reliability of the connection. These tests confirm that the Allen screw mechanism can consistently provide a secure and stable connection without the need for specialized tools or training.

Overall, the embodiment of simplified installation in the present invention represents a significant advancement in connector technology, offering a user-friendly and efficient solution that meets the demands of modern electrical systems. By addressing the challenges associated with traditional installation methods, this embodiment ensures that the connector can be easily and reliably installed, contributing to the overall success of electrical projects.

Embodiment 4: Improved Thermal Management

This embodiment of improved thermal management in the present invention addresses the critical need for effective heat dissipation in electrical connectors, particularly in high-load applications. This aspect of the invention is essential for enhancing the safety and efficiency of electrical connections, reducing the risk of thermal hotspots that can lead to equipment failures and safety hazards.

Design Features:

1. Increased Cross-Sectional Area:
o The connector is designed with an increased cross-sectional area compared to conventional lugs. This larger surface area facilitates better heat dissipation, allowing the connector to effectively manage the thermal energy generated during electrical conduction. The design ensures that heat is distributed more evenly across the connector, minimizing the formation of thermal hotspots.
2. Material Selection:
o The connector is constructed from aluminum alloy 6082-T6, which is known for its excellent thermal conductivity. This material choice enhances the connector's ability to transfer heat away from critical areas, further contributing to its thermal management capabilities.
3. Optimized Design:
o The connector's design is optimized through thermal simulations and testing to ensure effective heat dissipation under various load conditions. These simulations help identify the most efficient geometries and configurations for managing thermal energy, resulting in a connector that can maintain safe operating temperatures even in demanding applications.

Benefits:

1. Enhanced Safety:
o By reducing thermal hotspots, the connector enhances the safety of electrical connections. This reduction in localized heating minimizes the risk of overheating, which can lead to equipment damage, fires, or other safety hazards. The improved thermal management ensures that the connector can operate safely even under high-load conditions.
2. Increased Efficiency:
o Effective heat dissipation contributes to the overall efficiency of the electrical system. By maintaining lower operating temperatures, the connector reduces energy losses associated with heat generation, improving the system's performance and reliability.
3. Extended Lifespan:
o The ability to manage thermal energy effectively extends the lifespan of the connector and the connected equipment. By preventing excessive heat buildup, the connector reduces the wear and tear on components, leading to longer service life and reduced maintenance requirements.
Implementation:

The implementation of improved thermal management involves a comprehensive approach to design, material selection, and testing. The increased cross-sectional area is achieved through careful engineering, ensuring that the connector can accommodate the necessary conductor sizes while maximizing surface area for heat dissipation. The use of aluminum alloy 6082-T6 is integral to the connector's thermal performance, providing the necessary conductivity to transfer heat efficiently.
Thermal simulations play a crucial role in optimizing the connector's design. These simulations model the heat flow within the connector under various load conditions, allowing engineers to identify potential hotspots and adjust the design accordingly. The simulations are complemented by rigorous testing, where the connector is subjected to real-world load scenarios to validate its thermal performance. These tests confirm the connector's ability to maintain safe operating temperatures and effectively dissipate heat.

Overall, the embodiment of improved thermal management in the present invention represents a significant advancement in connector technology, offering a solution that enhances the safety, efficiency, and longevity of electrical systems. By addressing the challenges associated with heat dissipation, this embodiment ensures that the connector can deliver reliable performance in high-load applications, contributing to the overall success of electrical projects.

Embodiment 5: Cost-Effective Solution

The embodiment of a cost-effective solution in the present invention focuses on providing an economical alternative to traditional single-use electrical connectors. This aspect of the invention is crucial for reducing overall costs associated with procurement, installation, and maintenance, making it particularly attractive for large-scale deployments in various industrial, utility, and renewable energy applications.

Design Features:

1. Re-usable Design:
o The connector is engineered with a re-usable Allen screw mechanism, allowing it to be used multiple times without compromising the integrity of the connection. This design eliminates the need for frequent replacements, which are common with traditional crimping-type connectors that are typically single-use.
2. Durable Materials:
o Constructed from aluminum alloy 6082-T6, the connector is designed to withstand repeated use and environmental stresses. The choice of durable materials ensures that the connector maintains its performance and reliability over an extended period, further contributing to its cost-effectiveness.
3. Economic Manufacturing:
o The connector's design and manufacturing processes are optimized to reduce production costs while maintaining high quality. This economic approach to manufacturing ensures that the connector can be produced at a competitive price point, making it accessible for large-scale deployments.
Benefits:

1. Reduced Procurement Costs:
o The re-usable nature of the connector significantly reduces procurement costs, as fewer units are needed over the lifespan of a project. This reduction in initial investment is particularly beneficial for large-scale installations where cost savings can be substantial.
2. Lower Disposal Costs:
o By minimizing the need for frequent replacements, the connector reduces disposal costs associated with single-use connectors. This reduction in waste not only lowers costs but also contributes to environmental sustainability by decreasing the amount of discarded materials.
3. Economic Value Proposition:
o The connector's cost-effective design provides a compelling value proposition for customers, offering a reliable and durable solution at a competitive price. This economic advantage makes the connector an attractive option for projects with budget constraints or those seeking to maximize return on investment.
Implementation:

The implementation of a cost-effective solution involves a strategic approach to design, materials, and manufacturing processes. The re-usable Allen screw mechanism is engineered to ensure durability and ease of use, allowing the connector to be repeatedly installed and adjusted without degradation. The choice of aluminum alloy 6082-T6 provides the necessary strength and resilience to support the connector's re-usability.

Lifecycle testing is a critical component of the implementation process, validating the connector's economic benefits over traditional single-use connectors. These tests simulate long-term use and environmental exposure, assessing the connector's ability to maintain performance and reliability over time. The results of these tests confirm the connector's durability and cost-effectiveness, providing evidence of its value proposition for customers.

Manufacturing processes are optimized to balance cost and quality, ensuring that the connector can be produced economically without sacrificing performance. This optimization includes efficient material usage, streamlined production techniques, and quality control measures to maintain consistency and reliability.

Overall, the embodiment of a cost-effective solution in the present invention represents a significant advancement in connector technology, offering a practical and economical alternative to traditional connectors. By addressing the challenges associated with procurement and disposal costs, this embodiment ensures that the connector can deliver reliable performance and value in large-scale deployments, contributing to the overall success of electrical projects.

Embodiment 6: Enhanced Reliability and Performance

The embodiment of enhanced reliability and performance in the present invention focuses on optimizing the electrical connector to deliver consistent and efficient power across various applications. This aspect is crucial for ensuring the stability and effectiveness of electrical systems, particularly in industrial, utility, and renewable energy sectors where reliable power delivery is paramount.

Design Features:

1. Reduced Contact Resistance:
o The connector is engineered to minimize contact resistance, which is a key factor in ensuring efficient electrical conduction. By optimizing the contact surfaces and using materials with high conductivity, the connector reduces the resistance encountered at the connection points, thereby enhancing the flow of electrical current.
2. Minimized Technical Losses:
o Technical losses, often caused by inefficient connections and heat generation, are significantly reduced through the connector's design. The increased cross-sectional area and high-conductivity materials work together to lower energy losses, ensuring that more power is delivered to the intended load.
3. Robust Construction:
o The connector is constructed from durable materials, such as aluminum alloy 6082-T6, which provide the necessary strength and resilience to withstand environmental stresses and mechanical wear. This robust construction ensures that the connector maintains its performance over time, even in demanding conditions.
Benefits:

1. Consistent Power Delivery:
o By reducing contact resistance and technical losses, the connector ensures consistent power delivery across electrical systems. This consistency is crucial for applications where stable and reliable power is necessary to maintain operations and prevent disruptions.
2. Improved System Efficiency:
o The reduction in energy losses contributes to the overall efficiency of the electrical system. By delivering more power to the load and minimizing waste, the connector enhances the system's performance, leading to cost savings and improved operational effectiveness.
3. Increased Reliability:
o The connector's ability to maintain low contact resistance and minimize technical losses enhances the reliability of the electrical system. This reliability is particularly important in critical applications, such as industrial processes and renewable energy installations, where power interruptions can have significant consequences.
Implementation:

The implementation of enhanced reliability and performance involves a comprehensive approach to design, materials, and testing. The connector's contact surfaces are optimized through precision engineering to ensure maximum conductivity and minimal resistance. This optimization includes selecting materials with high conductivity and designing contact geometries that facilitate efficient current flow.

Electrical testing plays a crucial role in validating the connector's performance. The connector is subjected to rigorous tests that simulate real-world operating conditions, assessing its ability to reduce contact resistance and technical losses. These tests include measuring the connector's electrical conductivity, evaluating its thermal performance, and analyzing its behavior under varying load conditions. The results of these tests confirm the connector's ability to deliver reliable and efficient power across diverse applications.

The robust construction of the connector is achieved through careful material selection and manufacturing processes. Aluminum alloy 6082-T6 is chosen for its strength and conductivity, providing a durable foundation for the connector. Manufacturing techniques are optimized to ensure consistency and quality, maintaining the connector's performance over its operational lifespan.

Overall, the embodiment of enhanced reliability and performance in the present invention represents a significant advancement in connector technology, offering a solution that meets the demands of modern electrical systems. By addressing the challenges associated with contact resistance and technical losses, this embodiment ensures that the connector can deliver reliable and efficient power in critical applications, contributing to the overall success of electrical projects.

Constructional and Functional Interrelations:

The construction of the connector involves a carefully engineered body made from aluminum alloy 6082-T6, which provides the necessary strength and conductivity. The copper and tin plating on the connector body serves to prevent galvanic corrosion and oxidation, ensuring long-term reliability. The Allen screw mechanism is integrated into the connector body, allowing for easy and secure installation without the need for specialized tools. The increased cross-sectional area of the connector facilitates improved thermal management, reducing thermal hotspots and enhancing safety.

Functionally, the connector is designed to provide a secure and reliable connection between conductors, reducing contact resistance and technical losses. The universal compatibility of the connector allows it to be used across various makes and models of MCBs and energy meters, simplifying inventory management and reducing costs. The re-usable design of the connector minimizes the need for frequent replacements, providing a cost-effective solution for large-scale deployments.

DETAILED DESCRIPTION OF FIGURES
FIG. 1
This figure illustrates the overall design of the electrical connector, showcasing its compact and robust structure. The connector is designed with a re-usable Allen screw mechanism integrated into the connector body, which is engineered to provide secure and reliable electrical connections. The figure highlights the connector's cylindrical shape, which facilitates easy insertion into terminals of various makes and models of miniature circuit breakers (MCBs) and energy meters. The design ensures a snug fit, minimizing contact resistance and enhancing electrical conductivity.
FIG. 2
This figure provides a detailed side view of the connector, focusing on the dimensions of the connector body. The length of the connector is shown as 20 mm, and the height is 9.5 mm, emphasizing its compact size, which is suitable for a wide range of applications. The figure also highlights the precision engineering of the connector, which ensures that it can accommodate different terminal configurations without compromising performance. The side view illustrates the alignment of the Allen screw mechanism, which is designed for ease of access and operation.

FIG. 3
This figure presents another side view of the connector, with a focus on the length of the connector body, which measures 38 mm. This view highlights the threaded section designed to accommodate the Allen screw mechanism, ensuring a secure and stable connection. The figure emphasizes the robust construction of the connector, which is made from durable materials to withstand environmental stresses and mechanical wear. The design facilitates easy installation and removal, making the connector a versatile solution for various electrical systems.
FIG. 4
This figure shows a top view of the connector, indicating the diameter of the connector's opening. The outer diameter is 18 mm, and the inner diameter is 10.50 mm, illustrating the connector's compatibility with different conductor sizes. The top view provides a clear perspective of the connector's internal structure, highlighting the precision engineering that ensures a low-resistance electrical connection. The figure also emphasizes the connector's ability to accommodate both aluminum and copper conductors, reducing the risk of galvanic corrosion.
FIG. 5
This figure depicts the connector with labeled components, including the Allen screw mechanism (45) and the connector body (25). The dimensions are provided, with the total length being 45 mm and the length of the connector body being 25 mm. The figure highlights the integration of the Allen screw mechanism into the connector body, which allows for easy and secure installation without the need for specialized tools. The labeled components provide a clear understanding of the connector's design and functionality, emphasizing its re-usability and cost-effectiveness.
FIG. 6
This figure provides a front view of the connector, showing the width of the connector body as 7.6 mm. This view emphasizes the slim profile of the connector, which is suitable for installations in confined spaces. The front view highlights the alignment of the Allen screw mechanism, ensuring that it can be easily accessed and operated. The figure also illustrates the connector's robust construction, which is designed to maintain performance and reliability over time, even in demanding conditions.
FIG. 7
This figure offers a cross-sectional view of the connector, highlighting the internal structure and the placement of the Allen screw mechanism. The view provides insight into the connector's design for efficient electrical conduction, emphasizing the alignment of the contact surfaces to minimize resistance. The cross-sectional view illustrates the integration of the copper and tin plating, which enhances the connector's resistance to corrosion and oxidation. This figure underscores the connector's ability to deliver consistent and reliable performance across various applications.
FIG. 8
This figure presents a detailed view of the connector's opening, with dimensions indicating the outer diameter of 12.5 mm and the inner diameter of 6 mm. This view underscores the connector's adaptability to various conductor sizes, ensuring a secure and reliable connection. The figure highlights the precision engineering of the connector's internal structure, which facilitates efficient electrical conduction and minimizes contact resistance. The detailed view also emphasizes the connector's compatibility with both aluminum and copper conductors, providing a versatile solution for modern electrical systems.

Best Mode of Working the Invention:

The best mode of working the invention involves utilizing the connector in low voltage applications where reliable and efficient electrical connections are critical. The connector is particularly well-suited for use in industrial, utility, and renewable energy applications, where it can enhance the reliability and performance of electrical systems. The connector's universal compatibility, corrosion resistance, simplified installation, improved thermal management, and cost-effectiveness make it an ideal choice for users seeking to improve the efficiency and reliability of their electrical systems. By following the embodiments and implementations outlined above, users can achieve optimal performance and reliability from the connector in their specific applications.

Advantages of the Invention:

1. Universal Compatibility:
o The connector's standardized design allows it to fit securely into a wide range of miniature circuit breakers (MCBs) and energy meters, eliminating the need for multiple connector types. This universal compatibility simplifies inventory management and reduces costs associated with maintaining various connector models.

2. Corrosion and Oxidation Resistance:
o Constructed from aluminum alloy 6082-T6 and plated with copper and tin, the connector offers superior resistance to galvanic corrosion and oxidation. This ensures long-term reliability and performance, particularly in environments where aluminum and copper conductors are used together, reducing maintenance requirements and extending the lifespan of the connector.

3. Improved Thermal Management:

With an increased cross-sectional area, the connector facilitates better heat dissipation, reducing thermal hotspots and enhancing the safety and efficiency of electrical connections. This is particularly beneficial in high-load applications, where effective thermal management is critical to preventing equipment failures and safety hazards.

4. Simplified Installation:
o The re-usable Allen screw mechanism allows for easy and secure installation without the need for specialized tools like crimping machines. This design reduces installation time and costs, while minimizing the risk of workmanship errors, making the connector accessible to installers with varying levels of expertise.
5. Cost-Effective Solution:
o The re-usable design minimizes the need for frequent replacements, reducing procurement and disposal costs. This cost-effective solution offers a more economical alternative to traditional single-use connectors, making it attractive for large-scale deployments and projects with budget constraints.

6. Enhanced Reliability and Performance:
o By reducing contact resistance and technical losses, the connector improves the overall reliability and performance of electrical systems. This is especially advantageous in industrial, utility, and renewable energy applications, where consistent and efficient power delivery is essential to maintaining operations and preventing disruptions.
7. Environmental Sustainability:
o The reduction in disposal costs and waste associated with single-use connectors contributes to environmental sustainability. The re-usable design supports eco-friendly practices by decreasing the amount of discarded materials, aligning with industry trends towards sustainable solutions.
8. Versatility Across Applications:
o The connector's design and performance make it suitable for a wide range of applications, including industrial, utility, and renewable energy sectors. Its versatility ensures that it can meet the demands of diverse environments and operational requirements, providing a reliable solution for various electrical systems.
Overall, the invention offers a comprehensive set of advantages that address the challenges associated with traditional connectors, providing a reliable, efficient, and cost-effective solution for modern electrical systems.

The descriptions and illustrations provided in this document are intended to explain the principles of the invention and its best mode of working. They are not intended to limit the scope of the invention, which is defined by the claims. Variations and modifications to the described embodiments may be made without departing from the scope of the invention. The specific embodiments described in this document are examples of the invention and are not intended to limit the scope of the claims. The claims should be interpreted broadly to cover all equivalent structures and methods that fall within the scope of the invention. The technical specifications and details provided in this document are for illustrative purposes only. Actual implementations of the invention may vary based on specific design requirements, manufacturing processes, and application needs.

Any references to prior art documents, patents, or publications are provided for informational purposes only. The inclusion of such references does not imply that the present invention is limited by or dependent on the prior art.
, Claims:WE CLAIM

1. An electrical connector for low voltage applications, comprising:
a. a connector body providing enhanced conductivity and corrosion resistance;
b. a re-usable Allen screw mechanism integrated into the connector body, configured to secure electrical conductors without damaging the screw threads, allowing for multiple uses;
c. a barrel portion within the connector body adapted to prevent oxidation and ensure a low-resistance electrical connection;
d. a special palm or pin designed to fit securely into terminals of various makes and models of miniature circuit breakers (MCBs) and/or energy meters, providing a firm connection and low resistance path;
e. a copper and tin plating on the connector body, enabling compatibility with both aluminum and copper conductors, thereby reducing galvanic corrosion;
f. an increased cross-sectional area compared to conventional lugs, facilitating improved heat dissipation and reducing thermal hotspots;
wherein the connector is configured to be installed without the need for specialized tools, such as crimping machines, and is suitable for a range of conductor sizes, thereby simplifying the installation process and reducing technical losses in electrical systems.
2. The electrical connector of claim 1, wherein the connector body is made from an aluminum alloy, preferably 6082-T6.
3. The electrical connector of claim 1, wherein the connector body is insulated with thin wall EPDM tubes to ensure creepage protection and enhance safety during operation.
4. The electrical connector of claim 1, wherein the Allen screw mechanism is designed to accommodate conductor sizes ranging from 4 to 50 square millimeters, providing versatility in application.

5. The electrical connector of claim 1, wherein the connector is tested according to IS 5561 standards, demonstrating a temperature rise significantly below the limit of 45 degrees Celsius.
6. The electrical connector of claim 1, wherein the connector body is designed to fit universally into terminals of all makes of 63A and 100A MCBs, eliminating the need for multiple types of connectors.
7. The electrical connector of claim 1, wherein the connector is designed to reduce installation time by approximately 15 minutes per circuit compared to conventional lugs and ferrules.
8. The electrical connector of claim 1, wherein the connector is configured to reduce contact resistance, thereby minimizing the occurrence of hot spots and fire cases in electrical installations.
9. The electrical connector of claim 1, wherein the barrel portion is coated from inside with non-oxidizing grease.
10. The electrical connector of claim 1, wherein the connector is designed to be cost-competitive compared to traditional tubular lugs, offering a more economical solution for electrical connections.
11. The electrical connector of claim 1, wherein the connector is suitable for use in both single-phase and three-phase energy meters, providing a universal solution for various electrical systems.
12. The electrical connector of claim 1, wherein the connector is designed to enhance customer satisfaction by improving the reliability of low voltage assets and reducing customer hour loss (CHL).
13. The electrical connector of claim 1, wherein the connector is configured to facilitate knowledge sharing and skill development among installation staff, contributing to a more competent workforce.
14. The electrical connector of claim 1, wherein the connector is designed to support long-term sustainability by integrating advanced diagnostic tools and predictive maintenance strategies.

15. The electrical connector of claim 1, wherein the connector is suitable for commercial deployment in utilities, industrial plants, and data centers, offering a robust and reliable connection solution.
16. The electrical connector of claim 1, wherein the connector is designed to be exported as a substitute for tubular lugs, providing an international market opportunity.
17. The electrical connector of claim 1, wherein the connector is configured to be part of a joint collaboration and franchisee model for manufacturing, marketing, and sales.
18. The electrical connector of claim 1, wherein the connector is offered as part of a value-added service package, including installation and maintenance services to enhance customer experience.

Dated this 17th day of April 2025