Compression Connector Structure for Stable Wire Crimping
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Solution Overview
Problem
Existing compression connectors face issues with wires popping out of their slots during the crimping process, and the connectors becoming dislodged from the crimping tool, making it difficult for end users to achieve secure mechanical and electrical connections.
Innovation Solution
The design of the compression connector includes a connector body with distinct conductor portions and insulation piercing members, adapted to be inserted into a crimping tool, which ensures proper alignment and secure crimping by using die surfaces to compress the connector body, featuring varying wall thicknesses and insulation piercing members to pierce through the insulating jacket of the conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing compression connectors are used during crimping, then the connection between conductors can be established, but the wires tend to pop out of their slots and the connector becomes dislodged from the crimping tool
Solution Approach 1:
The connector body includes integrated wire retention features such as flanges or stops that preliminarily secure the wires in their proper slots before crimping begins. The connector is designed with alignment features that preliminarily position the connector within the crimping tool, preventing dislodgement during the crimping process.
Solution Approach 2:
The connector body acts as an intermediary element between the wires and the crimping tool, providing a structured interface that holds wires in place and interfaces with the tool's die surfaces. The integrated retention features serve as intermediate structures that prevent wire displacement during the connection process.
2Reliability
If multiple wires are held in proper position within the connector, then secure electrical connection can be achieved, but the complexity of maintaining wire and connector positioning increases
Solution Approach 1:
The connector integrates multiple functions into a single component: wire retention features are merged with the connector body structure, and alignment features are integrated into the same component. This consolidation reduces the number of separate parts and simplifies the overall assembly process while maintaining secure wire positioning.
Solution Approach 2:
The connector body features localized structural variations such as flanges, stops, or ribs at specific positions where wires need to be retained. These local structural enhancements provide targeted wire retention without requiring complex overall connector design, maintaining simplicity while achieving reliable wire positioning.
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 provides a secure mechanical and electrical connection by ensuring the conductors remain aligned during crimping, preventing wire displacement and ensuring a stable connection.
Implementation Method 1
at least one insulation piercing member... configured to pierce through an insulating jacket surrounding the run conductor
Implementation Method 2
two opposed die surfaces for the compression of the connector body
Data Source
AI summary
An electrical compression connector for connecting a plurality of conductors, the compression connector including a connector body of compressible material adapted to be inserted into a crimping tool having two opposed die surfaces for the compression of the connector body, the connector body including a first conductor portion and a second conductor portion. The first conductor portion includes a pair of side walls including a first side wall and a second side wall joined by a bottom wall, and a first conductor opening between the pair of side walls and the bottom wall and at least one insulation piercing member. The second conductor portion includes at least one second conductor opening extending at least partially through the connector body.