Electrical Connector With Clamping Metallization for Tool-Free Wiring
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Solution Overview
Problem
Existing methods for connecting wires to circuits, such as soldering, conductive gluing, and crimping, often fail to meet the requirements of simplicity, reliability, and cost-effectiveness, particularly in constrained field operations.
Innovation Solution
An electrical connector design featuring an uninsulated wire segment and an adjacent insulated segment, housed in a channel within a connector body made of insulating material, which can transition from an open to a closed configuration to establish a secure mechanical and electrical connection without tools, using a clamping structure and metallization for reliable contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering, conductive gluing, or crimping methods are used to connect wires to circuits, then electrical connection can be achieved, but the assembly process becomes complex, time-consuming, and requires additional tools
Solution Approach 1:
The patent combines the electrical connection function and mechanical fixation function into a single integrated connector component. The connector body with conductive elements and clamping structure eliminates the need for separate soldering or crimping operations, achieving both electrical connectivity and mechanical securing in one step.
Solution Approach 2:
The connector is designed to perform its own connection function without requiring external tools or additional processing steps. The clamping structure automatically secures the wire when the connector is assembled, and the conductive elements establish electrical contact through the same assembly action, making the system self-sufficient.
2Reliability
If traditional wire connection methods are used, then electrical connection can be established, but the assembly time and production efficiency are reduced
Solution Approach 1:
The connector is pre-configured with conductive elements and clamping structures in specific positions and orientations. The wire is pre-prepared with stripped insulation at the end. When assembled, these pre-configured elements automatically align and engage, eliminating the need for complex assembly steps and significantly reducing production time.
3Ease of operation
If field operations require one-handed work due to space constraints, then portability is improved, but the difficulty of performing connection tasks increases
Solution Approach 1:
The connector design allows the connection action to be accomplished through a simple insertion and closing motion that can be performed with one hand. The clamping structure and conductive elements are positioned to automatically engage the wire without requiring precise manual manipulation or multiple steps, making it suitable for field operations with space constraints.
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 enables efficient, reliable, and cost-effective one-step connection of wires, suitable for field operations, with high mechanical and electrical stability, and allows for easy disconnection without additional tools.
Implementation Method 1
The electrical connection element has a wire contact surface arranged in the channel for contacting the uninsulated wire segment
Implementation Method 2
The clamping structure is designed to deform the uninsulated wire segment during the transition from the open to the closed configuration
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention discloses an electrical connector (1) for a wire (2) having a wire end (22), where an uninsulated wire segment (211) extending out of the wire end (22) and an insulated wire segment (212) adjoining the uninsulated wire segment (211) together form an insertion section (21). The electrical connector comprises a connector body, the connector body having a channel (111) for receiving the insertion section (21). The connector further comprises an electrical connection element, wherein the electrical connection element has a wire contact area (131), arranged in the channel (11), for making contact with the uninsulated wire segment (211) and a connection area (132) arranged on the outside of the connector body (11), wherein the electrical connection element is formed by metallization, in particular a partial metallization (13), of the connector body (11). The electrical connector further comprises a cover element (12), the cover element (12) having a clamping structure. The clamping structure (122) does not project into the channel (111) in an open configuration and projects into the channel (111) from the open channel top side (111o) in a closed configuration. The clamping structure is designed to clamp, in the closed configuration, the insertion section (12) between the channel base (111a) and the clamping structure and to keep the uninsulated wire segment (211) in contact with the wire contact area (131).