Compression Connector Single Tap Port Multiple Nests
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Solution Overview
Problem
Existing compression connectors are difficult to manufacture and lack sufficient wire pullout resistance and ease of access for tap wires of varying sizes, as they require multiple openings and complex configurations to accommodate different sizes.
Innovation Solution
A compression connector with a single tap wire port featuring multiple nests within the port, allowing for easy insertion and secure crimping of tap wires of varying sizes, utilizing a C-shaped body with ramps and hooks to provide high securing forces and ease of access through a single entrance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple openings are provided in the connector body to accommodate different sized tap wires, then adaptability to various wire sizes is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The single tap wire port is designed to perform multiple functions by accommodating different sized tap wires through a unified structure. The port includes multiple nests of varying sizes within it, allowing the same port to receive and secure tap wires of different diameters, thereby eliminating the need for multiple separate openings while maintaining adaptability across wire size ranges
Solution Approach 2:
Multiple nests are positioned within the single tap wire port, with each nest sized to receive specific ranges of tap wire sizes. This nested configuration allows smaller nests to be contained within the overall port structure, enabling a hierarchical arrangement where tap wires of different sizes can be sequentially accommodated within the same port entrance, simplifying the overall connector geometry
2Adaptability or versatility
If multiple openings are provided for different sized tap wires, then versatility is improved, but manufacturing ease deteriorates
Solution Approach 1:
Multiple separate openings for different wire sizes are merged into a single integrated tap wire port. This consolidation reduces the number of discrete features that must be formed during manufacturing, simplifying the molding or fabrication process while maintaining the capability to accommodate various tap wire sizes through the unified port structure with internal nests
3Ease of operation
If a single tap wire port is used to accommodate various sized wires, then ease of operation is improved, but wire pullout resistance may deteriorate
Solution Approach 1:
Different regions within the single tap wire port are designed with locally optimized characteristics to match specific wire sizes. Each nest within the port has dimensions and geometries tailored to its intended wire size range, providing appropriate friction and mechanical interlocking for each wire type. This localized optimization ensures high pullout resistance for each wire size while maintaining a unified port entrance for ease of operation
Data Source
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AI summary
A compression connector for crimping and securing a tap wire of various sizes within a range of tap wire sizes to a main line wire, the compression connector has a body portion including a first hook and a first ramp extending from the compression connector body part. The space between the hook and the ramp comprises a first opening for insertion of a main line wire into contact with the hook and ramp prior to crimping. The body portion also includes a second hook and a second ramp forming a second opening defining an entrance to a tap wire port. The body portion defining the second opening includes nest portions adapted to receive and accommodate different sizes of tap wires prior to crimping, and to hold the tap wires in place during crimping. Each nest portion is in communication with the second opening that forms a single entrance to the tap wire port.