Compression Connector Stranded Wire Conical Centerpost
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Solution Overview
Problem
Existing connectors for stranded conductive wires fail to securely hold the wire when tension is applied, especially after corrosion, due to gaps between strands and inadequate gripping mechanisms, leading to potential disengagement.
Innovation Solution
A compression-type connector with a conical centerpost and spiral thread that splays and traps the strands, providing resistance to disengagement, combined with a compression sleeve that locks in place to prevent retraction, ensuring secure attachment even under tension and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard crimping is used on stranded wire, then initial connection is achieved, but gaps between strands reduce over time due to vibration and corrosion, causing disengagement
Solution Approach 1:
The conical centerpost is inserted into the connector body in advance, positioned to contact and splay the wire strands before the compression sleeve is applied. This preliminary action ensures that when the sleeve is compressed, the strands are already positioned against the centerpost, preventing gap formation and maintaining stable strand spacing throughout the connector's service life.
2Reliability
If compression sleeve is added to lock wire, then resistance to disengagement improves, but device complexity increases
Solution Approach 1:
The connector combines multiple functions into a single integrated structure: the conical centerpost serves both as a strand-splaying element and as a positioning feature that maintains strand spacing, while the compression sleeve provides both mechanical compression and locking engagement. This merging of functions achieves high reliability without excessive complexity.
3Reliability
If conical centerpost is used to splay strands, then gripping mechanism improves, but manufacturing precision requirements increase
Solution Approach 1:
The conical centerpost uses a gradual taper ratio that balances gripping effectiveness with manufacturing feasibility. The cone angle is designed to be sufficient to splay strands effectively during compression, but not so steep as to require ultra-precise manufacturing. This parameter optimization allows standard manufacturing processes to produce reliable connectors.
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 effectively resists separation of the wire from the connector when tension is applied, maintaining secure attachment and preventing disengagement due to the conical centerpost's gripping mechanism and the locking compression sleeve.
Implementation Method 1
A conical centerpost having a circular base and a sharp apex is axially disposed within the axial cavity at the leading end thereof such that the base of the conical centerpost is disposed at the leading end of the cavity
Implementation Method 2
A compression sleeve having an axial bore is slidably mounted within the axial cavity of the connector body
Data Source
AI summary
Compression-type connectors for attaching wires ranging in size from #10-16 and having stranded conductors. The connector is similar to coaxial cable connectors in that it includes a connector terminal adapter, a connector body attached to the connector terminal adapter, the connector body having an axial cavity dimensioned to receive a wire in a trailing end thereof, a centerpost disposed within the axial cavity that has a conical tip projecting rearwardly, and a compression sleeve slidably mounted either within the trailing end of the cavity or overlying the trailing end of the connector body. In one embodiment the centerpost is conical with the base of the cone disposed at the leading end of the cavity and the apex of the cone projecting rearwardly and a threaded outer surface therebetween. In a preferred embodiment, the centerpost has a straight threaded shaft with a conical tip. The connector terminal adapter is operable for attachment to a variety of conductive terminals.