Compact Lever Connector Layout for Ergonomic Wire Clamping
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Solution Overview
Problem
Existing electrical connectors with release levers are not compact, do not provide ergonomic operation, and lack visibility and versatility for wire connection and testing.
Innovation Solution
A compact, low-profile electrical connector design with reversed lever actuation, clear housing for visibility, and test ports, accommodating a range of wire sizes, and featuring spring contact units and actuating members for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional in-line release lever quick connectors are used, then electrical connection functionality is provided, but the connector size is large and not compact
Solution Approach 1:
The patent inverts the conventional lever actuation direction by positioning the lever actuation end away from the wire insertion end. This reversal allows the lever to be operated with one hand while the other hand manages wire insertion, improving ergonomics in compact configurations.
Solution Approach 2:
The patent transitions from an in-line configuration to a stacked multi-port configuration, arranging connection ports vertically rather than horizontally. This dimensional change reduces the connector's footprint in tight electrical boxes while maintaining multiple connection capabilities.
2Loss of information
If conventional opaque housing connectors are used, then structural integrity is maintained, but visibility of conductor seating is not provided
Solution Approach 1:
The patent applies transparency (an optical property change) to the housing material, allowing users to visually confirm conductor seating and connection status without adding mechanical indicators or windows, thus maintaining structural simplicity while improving visibility.
3Adaptability or versatility
If single-port connectors are used, then simple construction is maintained, but versatility for multiple wire connections is not provided
Solution Approach 1:
The patent designs a stacked multi-port connector where multiple connection ports share a common housing and structural framework. This allows a single connector unit to perform multiple wire connection functions simultaneously, reducing the total number of connectors needed while maintaining construction efficiency.
Solution Approach 2:
The patent combines multiple connection ports into a single integrated connector body, merging what would traditionally be separate single-port connectors into one unified component that handles multiple wires through stacked ports.
4Ease of operation
If levers are positioned near wire insertion end, then compact leverage is achieved, but ergonomic two-handed operation is not possible
Solution Approach 1:
The patent positions the lever actuation end away from the wire insertion end, inverting the conventional arrangement. This allows the user's non-dominant hand to manage wire insertion at one end while the dominant hand operates the lever at the opposite end, enabling ergonomic two-handed operation without significantly increasing connector profile.
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
Ensures secure, positive connections with ergonomic operation, visibility for correct seating, and versatility for various wire sizes, enhancing user confidence and efficiency in tight spaces.
Implementation Method 1
a cantilevered contact arm extending between the pair of surfaces to clamp a conductor against one of the pair of surfaces, the contact arm movable between an initial position wherein a conductor of a predetermined size cannot be freely inserted between the contact portion and the contact surface and an inserting position wherein the conductor of a predetermined size can be freely inserted between the contact portion and the contact surface, the contact arm being spring biased to the initial position
Data Source
AI summary
An electrical connector is provided for electrically connecting a pair of conductors and includes: a housing made of an electrical insulating material, the housing having a pair of conductor insertion openings; a busbar component mounted in the housing between the insertion openings; a pair of cantilevered contact arms, each arm positioned on a side of the busbar opposite from the other contact arm to clamp a conductor against the busbar; and a pair of actuating member, each of the actuating members mounted on opposite sides of the busbar to actuate a corresponding one of the contact arms from an initial position to an inserting position as the actuating member is moved from a closed position to an open position.