Compression Connector Hinge Mechanism for Conductor Retention
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Solution Overview
Problem
Existing compression-type electrical connectors often experience issues where wires or conductor strands 'pop out' of their slots during the crimping process, leading to incomplete connections.
Innovation Solution
The design incorporates a connector body with a run conductor portion and a branch conductor portion, featuring parallel side walls, a rounded bottom, and hinge portions that compress first to secure the branch conductors, along with insulation piercing members and a movable conductor retainer to ensure the conductors remain in place during crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior tap connectors are used during the crimping process, then the connector can be compressed to achieve connection, but wires or conductor strands pop out of their slots before crimping is complete
Solution Approach 1:
The connector body is pre-configured with hinge portions that are designed to compress before the conductors can pop out. The hinge portions act as a preliminary mechanical constraint that secures the conductors in place during the crimping process, preventing them from exiting their slots before the crimping tool can complete the connection.
Solution Approach 2:
The connector body is divided into distinct functional portions including hinge portions and conductor retention portions. The hinge portions are segmented elements that independently compress during crimping to secure conductors, while other portions of the connector body provide structural support and insulation. This segmentation allows different parts to perform specialized functions that collectively prevent conductor ejection.
2Reliability
If the connector body is designed with hinge portions that compress first, then branch conductors are secured effectively, but the device structure becomes more complex
Solution Approach 1:
The hinge portions are integrated directly into the connector body as a unified structure rather than being separate components. The hinge portions are formed as continuous elements within the connector body that leverage the compression force applied during crimping to secure conductors. This merging eliminates the need for separate hinge components while achieving the same conductor retention function.
Solution Approach 2:
The hinge portions utilize the compression force applied during the normal crimping process to automatically secure the conductors. The structural design of the hinge portions causes them to compress and lock conductors in place as a direct result of the crimping action, without requiring additional mechanisms or steps. The connector body's own compression serves the dual purpose of creating the electrical connection and securing the conductors.
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 solution effectively secures both branch and run conductors within their respective openings, preventing them from exiting and ensuring a reliable electrical connection upon crimping, thereby improving the connectivity and stability of the compression connector.
Implementation Method 1
when force is applied by the crimping tool to the connector body, the hinge portion of the connector body will compress first to secure the branch conductor to the connector body
Implementation Method 2
The insulation piercing members are provided to pierce or cut through insulation surrounding electrical wires in the run conductor or the branch conductor
Implementation Method 3
the compression connector includes a connector body of compressible material adapted to be inserted into a crimping tool having two opposed curved die surfaces for the compression of the connector
Data Source
AI summary
The present disclosure provides embodiments of compression-type electrical connectors used to connect one or more branch wires or conductors to one or more run wires or conductors.