Cable Wire Brushing Connector for Oxidation Removal

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Solution Overview

Problem

Existing electrical cable connectors often fail to effectively remove contamination and oxidation from cable conductors before connection, leading to poor electrical contact and increased installation time.

Innovation Solution

An electrical connector with an integrated wire brush insert that cleans the cable conductor by rotating relative to it, ensuring effective removal of contaminants before securing the conductor, utilizing a cylindrical body with grooves and set screws for secure connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional cable connectors are used without integrated cleaning mechanism, then device complexity is reduced, but contamination and oxidation remain on cable conductors leading to poor electrical contact

Engineering Contradiction:

Improveelectrical contact qualityVSAvoidconnector structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The wire brush insert is integrated directly into the connector body, combining the cleaning function with the connector structure. The brush is positioned within a groove in the connector body and contacts the cable conductor during insertion, eliminating the need for separate cleaning operations or tools.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The wire brush performs cleaning action before the cable conductor is fully secured in the connector. The brush contacts the conductor surface during the insertion process, removing contamination and oxidation beforehand to ensure optimal electrical contact from the start.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If manual wire brushing is performed separately before connector installation, then electrical contact quality improves, but installation time increases

Engineering Contradiction:

Improveelectrical contact qualityVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The cleaning and connecting operations are merged into a single integrated action. As the cable is inserted into the connector, the wire brush automatically contacts and cleans the conductor surface, eliminating the need for separate brushing steps and reducing total installation time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector performs the cleaning function automatically during the insertion process itself. The wire brush is positioned to contact the conductor as it enters the connector body, so the cleaning action occurs self-service style without requiring additional manual intervention or separate tools.

Inventive Principle:

Principle #25Self-service

3Reliability

If wire brush bristles are made stiffer to remove corrosion more effectively, then cleaning ability improves, but risk of damaging cable conductor increases

Engineering Contradiction:

Improvecontamination removal effectivenessVSAvoidconductor damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The wire brush is positioned to contact only the outer surface of the cable conductor where contamination and oxidation are located. The bristles are arranged to engage the conductor surface in a controlled manner within the connector groove, providing effective cleaning while limiting contact to non-critical areas.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The bristle stiffness and arrangement are optimized to provide sufficient cleaning force for surface contamination while maintaining flexibility to conform to the conductor surface. The brush design allows effective removal of corrosion and oxidation without applying excessive point loads that could damage the conductor.

Inventive Principle:

Principle #35Parameter changes

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 integrated wire brush ensures reliable electrical connections by removing contamination and oxidation, reducing installation time and enhancing connection quality.

Implementation Method 1

Rotating the cable wire brushing connector relative to the cable conductor cleans the cable conductor prior to securing the cable conductor within the cable wire brushing connector

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentEP3062397B1Cable wire brushing connector and method thereof

Publication Date: 2018.10.10 THOMAS & BETTS INTERNATIONAL INC

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AI summary

An electrical connector (100) includes a body (102) having a bore (104) and an interior surface (110). The bore (104) is sized to receive a cable conductor (20) of an electrical power cable (14). The body (102) includes a groove (120) disposed along a length of the interior surface (110). A wire brush insert (140) is located within the groove (120) and includes a plurality of bristles (144) that extend into at least a portion of the bore (104). Rotating the cable wire brushing connector (100) relative to the cable conductor (20) cleans the cable conductor (20) prior to securing the cable conductor (20) within the cable wire brushing connector (100).