Axial Electrical Connectors for Modular Artificial Tree Assembly
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Solution Overview
Problem
Existing artificial tree systems lack efficient mechanisms for easy assembly, disassembly, and multi-channel signal transmission, leading to complexity and potential electrical safety hazards during the connection of trunk segments and branch segments.
Innovation Solution
The implementation of axial electrical connectors that allow trunk segments to connect in any radial orientation, enabling easy assembly and disassembly, while also facilitating the transmission of multiple independent command signals and power through the tree column, using self-aligning electro-mechanical interfaces and multi-channel electromagnetic coupling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional connection mechanisms are used for trunk segments, then mechanical strength is maintained, but assembly complexity and time increase significantly
Solution Approach 1:
The artificial tree is divided into modular trunk segments that can be independently assembled. Each segment contains integrated electrical connectors and mechanical coupling features, allowing rapid assembly without complex external wiring or alignment mechanisms. The segmentation enables parallel assembly operations and reduces the skill level required for installation.
Solution Approach 2:
The patent combines mechanical connection, electrical connection, and signal transmission functions into a single integrated coupling interface. The electrical connectors are embedded within the mechanical coupling structure, eliminating the need for separate wiring harnesses and reducing assembly steps. This merging of functions directly addresses the contradiction by simplifying the overall connection mechanism while maintaining mechanical strength.
2Ease of operation
If radial alignment is required for connector engagement, then electrical contact reliability is improved, but ergonomic safety and assembly ease deteriorate
Solution Approach 1:
The connector design incorporates asymmetric features that guide proper alignment during assembly. The male and female connectors have complementary asymmetric geometries that naturally orient themselves during insertion, ensuring reliable electrical contact without requiring precise radial alignment. This asymmetric design provides tactile feedback and mechanical guidance that maintains reliability while improving ease of operation.
Solution Approach 2:
The connectors are designed to self-align and self-engage during the assembly process. The mechanical coupling features include guiding surfaces and alignment pins that automatically position the connectors in the correct orientation as the trunk segments are brought together. This self-aligning mechanism eliminates the need for manual radial alignment, improving ergonomic safety while maintaining electrical contact reliability.
3Adaptability or versatility
If multiple independent command signals are transmitted through the column, then control capability is enhanced, but device complexity and electrical hazard potential increase
Solution Approach 1:
The electrical connector design supports multiple independent command signals along with power transmission through a single integrated interface. The connector includes multiple contact elements that can carry different signal types (power, data, control commands) simultaneously. This multi-functional capability enables enhanced control of branch segments and lighting elements without requiring separate wiring for each signal type, thereby reducing overall system complexity.
Solution Approach 2:
The signal transmission system uses a nested architecture where multiple signal channels are organized hierarchically within the connector structure. Power lines form the outer layer, while data and control signals are nested within inner contact elements. This nested arrangement allows for systematic organization of multiple signals, reducing wiring complexity and improving maintainability while enabling sophisticated control capabilities.
4Ease of repair
If trunk segments are designed for easy disassembly, then productivity and maintenance ease are improved, but mechanical strength and structural stability may worsen
Solution Approach 1:
The mechanical coupling system incorporates dynamic elements such as spring-loaded locking features and reversible engagement mechanisms. These elements provide strong holding force during normal operation to ensure structural integrity, while allowing easy release through a simple disengagement action. The dynamic design enables the connection to adapt between two states: a locked, high-strength state for operational stability and an unlocked, easy-to-assemble state for maintenance and reconfiguration.
Data Source
AI summary
Disclosed is an artificial tree having a plurality of electrified tree sections that couple together to provide power and/or command signals to devices connected thereto. One or more tree sections may have a trunk portion, one or more electrical connectors having a plurality of terminals, branches, a light string, and an electrical distribution system located at least partially within the trunk portion. A first tree section may be configured to couple to a second tree section such that an electrical connector of the first tree section is in electrical connection with an electrical connector of the second tree section, thereby mechanically and electrically connecting the first tree section to the second tree section such that power and/or the control data are transmitted to the second tree section. Further, each trunk segment may include an axial electrical connector that permits adjacent trunk segments to connect in a plurality of radial orientations relative to each other.