Wire connector with the capability of connecting without cutting the wire

Abstract

Electricity has become an indispensable part of human life. In the field of electrical wiring, it is often necessary to take branches from the main wire that carries electric current for various uses. The fundamental problem arises in how to branch off from the wires, which is a major cause of fires and electric shocks. This is because the insulation of the wire at the desired point needs to be stripped (removed) in order to connect a side wire using various methods. The wire connector that allows for insulation stripping-free connection is a simple, practical, and cost- effective device. It enables the connection of a side wire to a live wire without causing significant damage to the insulation or stripping it away. In other words, this connector is used for connecting a wire along the path of the main wire carrying electricity with minimal damage to the insulation, ensuring that it is neither stripped nor cut.

Description

[0001] Description of the Invention

[0002] Title of the Invention: Wire Connector with the Capability of Connecting without Cutting the Wire Insulation

[0003] Technical Field of the Invention :

[0004] This invention pertains to the field of electricity and electrical wiring, which can establish a connection between two wires without causing serious damage to the wire insulation (the outer covering of the wire) and transfer electrical current from the main wire to the branch wire.

[0005] Technical Problem and Objectives of the Invention :

[0006] In traditional methods of connecting two wires, it is necessary to use techniques such as cutting or stripping the desired section of the wire, which leads to the degradation of the wire insulation. This, in turn, poses risks such as fire hazards, electric shock, reduced safety, and the inability to reuse the wire for other applications, resulting in increased costs.

[0007] In contrast, the current invention allows for the connection between two wires and the establishment of electrical current without cutting or stripping the wire. This eliminates the dangers and disadvantages associated with traditional methods, enhances safety by preventing fire hazards, reduces costs, and facilitates the reuse of wires for other purposes. Most importantly, the connecting method is much simpler and faster.

[0008] Description of Prior Art and Background of Advances Related to the Claimed Invention:

[0009] Connections are one of the essential components in the electrical industry. For this reason, various connectors have been introduced to the market, each offering different methods for connecting wires . In the prior art, all these connectors cause damage to the wire insulation (the insulation is stripped), and wires are connected through various methods such as male-female connections, screw connections, or quick connect methods .

[0010] One connector in the prior art bears some similarity to our inventive approach; this is the "T-Connector," which can be described as follows: In this connector, the wire is placed in a designated area, and a blade suitable for the wire size is positioned over it. The connection is then established through a compression action exerted by an external lever, such as a pair of pliers, which presses the blade onto the wire. Simultaneously, the branch wire is inserted into a terminal, insulated, and fed into the connector blade.

[0011] Despite its functionality, this connector has not been widely adopted by users primarily due to certain drawbacks, which I will outline later. As a result, users generally prefer alternative connection methods instead of utilizing this connector.

[0012] The T- Connector available in the market has several disadvantages, which are outlined below:1. Size-Specific Connectors: Different connectors must be used for wires of various sizes, as the size of the blade used in each connector corresponds to the wire size. For instance, if the blue connector is used for a size 0.5 wire, it will not establish a proper connection because the blade opening is designed for the larger size wires of 1.5 - 2.5. Conversely, if the blue connector is used for a size 3 wire, the blade opening will be too narrow and will damage both the insulation and the wire itself, potentially cutting through the wire. Therefore, each wire has its specific connector.

[0013] 2. Damage to Insulation: Since our primary goal is to minimize damage to the insulation or stripping the wire, the T-Connector blade removes the insulation at the connection point, essentially exposing the wire similar to previous methods.

[0014] 3. External Pressure Lever: The compression lever in this model is typically an external object (such as pliers). If insufficient pressure is applied, a connection is not made; however, excessive pressure may risk damaging the connector.

[0015] 4. Sensitivity to Vibration: When exposed to severe or continuous vibrations, T-Connectors may become loose, leading to poor connections.

[0016] 5. Unsuitable for Corrosive Environments: In environments with high humidity, chemicals, or corrosive elements, metal T-Connectors may corrode over time.

[0017] 6. Loss of Functionality with Multiple Uses: These connectors lose their effectiveness with repeated use because their bodies are made of hard plastic. When reused with tools like pliers, the connector may break or become damaged under pressure.

[0018] 7. Disposable Nature of Connectors: The branch wire is inserted into a terminal, which is then crimped using pliers. A plastic insulation cover is placed on it. Upon reuse, a separate terminal must be procured, as the previous terminal cannot be reused. In other words, these terminals are essentially single -use.

[0019] These disadvantages highlight the limitations of the T-Connector and indicate a need for an improved solution, which our invention aims to provide.

[0020] Proposed Solution for the Existing Technical Problem along with a Detailed and Comprehensive Description of the Invention

[0021] The proposed invention (1)(2) consists of several components, including the body (3), input and output wires (4), core (5), electrical terminal (6), and bolts and nuts (7). This device is designed to connect a wire in line with the main power-carrying wire while minimizing damage to the wire insulation. The insulation covering the main wire carrying electric current is neither stripped nor cut.

[0022] The components of this device are as follows:

[0023] -Body (8): The body is divided into two separate sections, which attached together by with bolts and nuts.

[0024] -Core (5): Made of copper, this part serves as high conductivity conductor for transferring electricity.

[0025] -Electrical Terminal (6): This acts as the interface between the core and the branch wire.

[0026] -Bolts and Nuts (7): These are used to connect the upper part of the device to the lower part at the front and rear of the body.-Wires (4): One is the main wire carrying electrical current, and the other is a branch wire that distributes electricity.

[0027] Each electrical connection has two lines, phase, and neutral, and the wire connector with the capability of connecting without cutting the insulation is intended for separate use with each. This means that the inventive device must be connected for each electrical line individually.

[0028] Body (8)

[0029] This component consists of two parts: upper and lower .

[0030] 1. Lower Section (9)

[0031] This part is constructed to be 5 cm long, 12 mm wide, and 12 mm deep, divided into four segments (10)

[0032] 1.1 First Section: This segment measures 12 mm in length and serves as a space for the bolts and nuts to connect to the upper section.

[0033] 1.2 Second Section: A 9 mm long compartment designated for housing the core.

[0034] 1.3 Third Section: This section is dedicated to the electrical terminal, measuring 18 mm in length and 9 mm in width, designed to accommodate the terminal securely. It features 1.5 mm high walls on both sides to ensure that the terminal is firmly held in place.

[0035] 1.4 Fourth Section: The last section measures 11 mm in length and has a groove the width of 0.5 mm wire, designed for connection to the upper section (10)

[0036] Summary of the Invention:

[0037] This innovative design resolves the existing issues associated with traditional wire connectors by allowing effective electrical connections without the need to strip or cut the insulation. The use of quality materials, such as copper for the core, ensures efficient electrical conductivity while minimizing risks associated with conventional methods that leave wires exposed .

[0038] Each feature of the design aims to enhance usability, safety, and reliability, while also ensuring that the device is user-friendly and provides a secure connection. This eliminates the need for specialized connectors for different wire sizes and allows for repeated use without damage, addressing the drawbacks associated with existing connectors in the market.2-Upper Section (11)(12)

[0039] The upper section is also 5 cm long, 12 mm wide, and 13 mm high, divided into four parts (13) First Part: This section, measuring 12 mm in length, serves as a space for the bolts and nuts, which connect it to the lower section.

[0040] Second Part: This section is designed to accommodate wires of various thicknesses. It measures 9 mm in length and 4.4 mm in height (10.4 mm from the top edge). This part is adaptable, allowing for changes in design according to specific dimensional requirements.

[0041] Third Part: This section is entirely open in the middle to house the terminal, measuring 18 mm in length. A 0.2 mm wall is present to securely hold the terminal in place, and the top is open for access to the terminal's connection screws.

[0042] Fourth Part: Designed for connection to the lower section, this part measures 11 mm in length and 13 mm in height. It fits inside the lower section and is secured through bolts and nuts.

[0043] Core (5)

[0044] The core (5) is the most critical part of the assembly, designed in the shape of a brush. It is constructed of copper, making it an excellent conductor of electricity. The dimensions of the core are 6 mm x 7 mm, with a handle of 8 mm in length and 2 mm in thickness for connection to the terminal (6) (1-5). The core features a series of 18 needles arranged in a grid pattern of 3 x 6, each with a height of 3 mm and a pointed end. When a wire is placed on these needles, the pressure applied from the upper and lower bodies punctures the wire insulation, allowing the electrical connection to transfer to the core and subsequently to the terminal (l-5.(

[0045] Advantages of Core (5)

[0046] 1. Simple and Efficient Design: The core's straightforward configuration allows for effective operation.

[0047] 2. High Durability: The core is securely fastened to the terminal on one side and rests on the lower body, requiring no frequent disassembly or reassembly, thus remaining stable.

[0048] 3. Adjustable Size: The dimensions of the core are flexible, compatible with recommended sizes, such as 9 mm, and can be modified (e.g., arranging needles in a 5 x 3 layout)

[0049] 4. No Additional Force Required: The design does not require extra driving force to insert the wire into the core; tightening the bolts in the body generates adequate pressure for insertion.

[0050] 5. Cost-Effectiveness: The construction of the core is economical, free from excessive costs.

[0051] 4-Electrical Terminal (14)(15)

[0052] The design incorporates an input and output electrical terminal, connecting one end to the core and the other to the secondary wire intended for branching. This configuration ensures that the electrical connection is secure, efficient, and easy to handle, providing reliable performance while minimizing damage to the wire insulation.

[0053] 5- Bolts and Nuts (7)These are used to connect the upper and lower bodies and serve as a lever to apply pressure for inserting the core into the current-carrying wire.

[0054] 6- Wires (4)

[0055] There is one wire at the front of the device that receives power from the main electrical flow (1-4), and another wire at the back of the device, which is the branch wire intended for connection (2-4)

[0056] Method of Operation

[0057] The wire carrying electricity consists of two strands: phase and neutral. When we want to take a branch from the current-carrying wire, we first unscrew the front bolts of the device. Then, we place the phase wire in the upper section at part 2-2 of the upper section (13). This positioning puts the wire directly over the core in the lower section (16, a side view)

[0058] Next, we tighten the device's bolts. The pressure from tightening the bolts acts as a lever, connecting the upper section to the lower section, causing the needles on the core to pierce the current-carrying wire (17, a front view). It is essential to note that not all the needles on the core need to penetrate the wire; it is sufficient for one row of needles to enter the wire according to its diameter; the thicker the wire, the more needles will enter.

[0059] Simultaneously, the end of the core enters the terminal, transferring the current to the electrical terminal (15). The branch wire connected to the other side of the electrical terminal is then ready for use. In this way, we can transfer electricity to the branch wire without cutting or stripping the insulation of the main wire.

[0060] The same steps apply for the neutral wire as well.

[0061] In this inventive device, because we take the branch with minimal serious damage to the insulation of the current-carrying wire, it has a high safety factor (since the wire retains its original insulation, and the safety of the wire is not compromised). Issues like electric shock, which are common in this industry, and insulation failures — which, if not performed to standard, can lead to fire hazards and short-circuits (reports indicate that 50% of fires in the country are caused by electrical faults, and 35% of fires in Rasht are due to wiring connections) — are not a concern.

[0062] Moreover, due to the ease and speed of making connections, this device has high utility in the industry. Given that there is no need to strip the wire, it can be considered a new and innovative method in building wiring. Working with this device is straightforward, comfortable, and fast.

[0063] This device provides significant economic savings. In temporary wiring setups, it causes minimal serious damage to the insulation of the wire from which electricity is taken. After removing this device from the previous connection point, the wire can be reused in a new location, resulting in lesswaste. Additionally, for future projects, there is no need for new wires, as the same wire can be used multiple times without any damage to either the insulation or the wire itself.

[0064] Finally, electrical wire insulation typically consists of materials like plastic, polyethylene, polypropylene, PVC, and others, which are mostly non-recyclable. In traditional methods, the insulation is destroyed for connections, leading to these materials entering the environment and creating detrimental ecological impacts (albeit on a small scale). This inventive device does not destroy the insulation, leaving no harmful effects on the environment.

[0065] Explanation of Shapes, Diagrams, and Charts

[0066] Figure 1 and 2: These figures show a perspective view of the entire invention .

[0067] Figure 3: This figure shows the upper body section and the lower body section .

[0068] Figure 4: This figure represents the input and output wires, with wire 1 carrying the main current and wire 2 being the branch wire .

[0069] Figure 5: This figure illustrates the central core .

[0070] Figures 1-5: Display the precise dimensions of the core .

[0071] Figure 6: Shows the electrical terminal .

[0072] Figure 7 : Displays the screws and nuts used to connect the two bodies .

[0073] Figure 8: Shows the body in an opened position .

[0074] Figure 9: Depicts the lower body while also indicating the location of the electrical terminal, core, and branch wire .

[0075] Figure 10: Presents the lower body segmented into 4 areas with precise dimensions .

[0076] Figures 11 and 12: Show the upper section in a simple form .

[0077] Figure 13: Displays the upper section segmented into 4 distinct parts with precise dimensions . Figures 14 and 15: Represent the electrical terminal, indicating the entry point for the core and the exit for the branch wire .

[0078] Figure 16: A longitudinal section of the device showing how the wire enters the desired main core . Figure 17: A front section showing the wire's entry into the core .

[0079] Figures 18 and 19: Illustrate a practical example where a wire connector with the capability of making a connection without cutting the insulation connects one to the phase and the other to the neutral, with output wires going into the lighting panel. In section one, an execution method is described.

[0080] Clear and Precise Statement of the Advantages of the Claimed Invention Compared to Previous InventionsThis device can take electricity from the main wire without seriously damaging the wire's insulation or cutting the wire.

[0081] The advantages of this invention are as follows:

[0082] 1. The insulation of the wire is not stripped or cut, whereas in prior technologies, the insulation gets cut.

[0083] 2. It has a high safety factor (since the wire retains its original insulation, ensuring the safety of the wire is not compromised), and issues such as electric shock and insulation failure are not a concern .

[0084] 3. It has high utility in the industry; whereas in prior knowledge, connectors need to be made for each wire size, this product works for a variety of wire sizes.

[0085] 4. In previous technologies, pressure was applied using an external tool like pliers, which may not establish a connection if pressure is low and can damage the product if pressure is high. However, in this product, the pressure is applied via the screws and nuts of the body, which do not damage the product in any way.

[0086] 5. In previous technologies, vibrations could loosen connections and cause failures; in this product, connections can be broken simply by loosening the screws and nuts, and vibrations do not cause disconnection.

[0087] 6. In reusable applications, no damage occurs to the product because no pressure is applied; only the screws and nuts are tightened or loosened. In previous technologies, connectors are usually made of plastic, which becomes dry and brittle over time, especially when pressure is applied by an external tool (pliers). In repeated uses, a small amount of pressure may break the entire product or shatter parts of it.

[0088] 7. The final cost of the product is very reasonable .

[0089] 8. It has high economic efficiency because the wire is tapped with minimal serious damage to the insulation, allowing it to be reused in a new location after the connection is removed. In previous technologies, new plugs and insulation jackets must be obtained for reuse, but this method requires no additional components for future use.

[0090] 9. Working with this device is very easy and convenient.

[0091] 10. Regarding environmental impacts, although on a small scale, in the long term and on a larger scale, it significantly reduces the consumption of non-recyclable materials .

[0092] 11. . The core material of this product is made of copper, which is a good conductor and resistant to rust and corrosion, whereas the blades in previous technologies are made from aluminum and tin, which are more prone to corrosion.

[0093] Explanation of at Least One Implementation Method for Using the Invention

[0094] 1. Suppose we have a 15-meter wire that we want to convert into a lighting strip. At every halfmeter interval, it is sufficient to connect one wire connector, which allows for connection without stripping the insulation, to the phase and another to the neutral. This way, electricity can be effortlessly distributed in the shortest possible time. Whenever we no longer need the device, we can easily detach it, and the wire remains undamaged and can be used for other purposes. (Figures 18 and 19)2. For Renters: Imagine we rented a store that requires lighting. For example, we need 10 halogen lights and 5 ceiling panels, which must be installed at varying distances (let's assume 15 meters of wire is needed for the halogen lights and another 15 meters for the ceiling panels). In the rented property, a connection must be taken from the main power wire for each light (in other words, we need to strip or cut the main wire 10 times for the halogen lights and 5 times for the ceiling panels .

[0095] 3. With our inventive device, this can be achieved easily and without damaging the main wire.

[0096] By using connectors that do not require stripping, the lights can be connected to the main wire without harming it. After moving the store, the device can be detached and reinstalled in the new location according to the new wiring plan (which may differ from the previous plan), allowing the same main wires to be used without any damage.

[0097] 4. Overall, this device is highly efficient in any situation where branching from the main wire is needed for various purposes, or where temporary lighting is required, particularly when wiring plans change over time. It significantly reduces costs.

[0098] Explicit Statement of the Industrial Application of the Invention

[0099] -It can be used anywhere that requires taking a branch from the main wire carrying electrical current. -In building wiring: to facilitate wiring with a high safety factor, without the need for insulation, and for easy execution.

[0100] -In shop wiring: it is easy to implement, can be done by anyone without special skills, and does not require purchasing new wire when moving; thus, it saves on wiring costs. It also offers high safety. -In places where frequent changes to decor are needed, which require adjustments to the lighting plan each time, such as in retail displays, home interiors, and photography studio setups, etc.

Claims

Claim:What is claimed ■.A device for tapping electrical power from a main wire without causing significant damage to the wire's insulation or cutting the wire. The device consists of several components, including a body, a core, an electrical terminal, and screws and nuts. It is used to connect a branch wire along the path of a main wire carrying electrical current with minimal damage to the wire's insulation, ensuring that the insulation is not stripped or cut. The device comprises the following components ■.a. Body: Composed of two separate parts that are connected to each other using screws and nuts .b. Core: Made of copper, known for its excellent conductivity, facilitating efficient power transfer .c. Electrical Terminal: Acts as a connector between the core and the branch wire .d. Screws and Nuts: Used to join the upper and lower parts of the body and function as a pressure lever to press the core into the current-carrying wire .e. Wires: Includes a main current-carrying wire at the front of the device and a branch wire at the rear for power transfer .This device allows for safe and efficient electrical power tapping without compromising the integrity of the main wire's insulation

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