Bifurcated Wire Compression Connector Locking Mechanism
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Solution Overview
Problem
Standard C-tap compression connectors fail under high voltage or mechanical tension, leading to disconnection of wires and potential hazards due to their inability to withstand pullout tensions.
Innovation Solution
A compression connector design featuring two slidably coupled connector components that deform and lock in place when crimped, providing enhanced resistance to failure without requiring special crimping dies, and can be customized for different wire sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a standard C-tap compression connector is used, then the connector is simple to manufacture and install, but it fails under high voltage or mechanical tension, leading to wire disconnection
Solution Approach 1:
The compression connector is divided into two separate components: a C-shaped component and a bar component. These two components are inserted into the crimping tool separately and work together to achieve the compression and locking function, thereby increasing reliability without requiring a completely new complex single-piece design
Solution Approach 2:
The connector components are designed to deform dynamically during crimping. The C-shaped component bends and the bar component rotates to engage with the C-shaped component, creating a locked configuration that provides resistance to pullout tension while maintaining manufacturing simplicity
2Strength
If the connector deforms to lock in place, then resistance to failure increases three times, but the manufacturing process becomes more complex
Solution Approach 1:
By separating the connector into two components, each component can be manufactured using existing simple processes. The C-shaped component is formed by bending a strip of material, and the bar component is a separate simple bar, both of which can be produced with standard equipment
Solution Approach 2:
The two separately manufactured components are combined during the crimping process itself. The bar component is inserted through the C-shaped component and they lock together through deformation, achieving high strength without requiring complex manufacturing processes for either component
3Reliability
If the connector is designed to withstand high tension, then reliability improves, but compatibility with existing crimping dies is lost
Solution Approach 1:
The connector components are designed to deform dynamically during crimping to achieve the locked configuration. This dynamic deformation allows the connector to adapt to the existing crimping die geometry while still achieving the high tension resistance through the final locked state
Solution Approach 2:
The two-component design maintains compatibility with existing crimping dies by using standard crimping motion and geometry. The C-shaped component fits within the existing die cavity and the bar component passes through it, allowing the use of existing crimping tools while achieving enhanced reliability
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 connector exhibits significantly increased resistance to failure, withstanding at least three times the force of standard C-tap connectors, and maintains a secure connection without the risk of opening, ensuring reliable wire connection even under high tension.
Implementation Method 1
When crimped, the compression connector deforms such that it locks in place and is resistant to failure
Implementation Method 2
a crimping tool that applies pressure to the outside of the compression connector causing it to deform around the wires
Data Source
AI summary
A compression connector for connecting two wires is disclosed. The compression connector is made of either a single bifurcated connector body or two individual connector components that are slidably coupled and then crimped. As the compression connector is crimped, structural features on the connector components are pushed into a locked state in the two component embodiment. Bifurcated embodiments allow for more than one crimping act on the compression connectors resulting in a more reliable compression connection. The compression connector that results is much more resistant to failure compared to known C-shaped compression connectors.