Insulated Conductor Coupling with Movable Stud and Water Seal
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Solution Overview
Problem
Existing insulation displacement connectors (IDCs) face limitations in accommodating varying conductor sizes and types, and are not suitable for use in moist environments due to water penetration issues.
Innovation Solution
A connector system with a conductive stud and insulative body that allows for adjustable conductor alignment and secure electrical contact, using a conductive stud with threads that penetrate insulation and engage with a conductive surface, while the insulative body is designed to prevent water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If prior IDCs use a blade configuration to couple conductors, then electrical connection is achieved, but the device cannot accommodate a large variation of conductor sizes
Solution Approach 1:
The connector uses a movable coupling element that can be positioned at different locations along the conductor aperture to accommodate conductors of different sizes. The coupling element can move between a first position for smaller conductors and a second position for larger conductors, providing dynamic adaptability without requiring multiple fixed-structure connectors.
Solution Approach 2:
The connector body is divided into distinct functional components: a stationary body with conductor aperture, a movable coupling element, and a separate locking mechanism. This segmentation allows each component to be optimized independently, with the coupling element specifically designed to handle size variations while the body provides structural support.
2Adaptability or versatility
If prior IDCs use a blade configuration to couple conductors, then electrical connection is achieved, but the device cannot accommodate conductors of different constructions
Solution Approach 1:
The movable coupling element can be positioned at different locations along the conductor aperture, allowing it to adapt to different conductor constructions (solid, stranded, coiled, coaxial). The dynamic positioning enables the same connector structure to handle various conductor types by adjusting where the coupling element makes contact.
3Reliability
If prior IDC housings are locked to form electrical connection, then conductor coupling is achieved, but water and water vapor can penetrate through unsealed housing cracks or joints
Solution Approach 1:
The connector incorporates a seal member that forms a flexible barrier between the conductor aperture and the external environment. This seal member can be a gasket, O-ring, or flexible membrane that conformally seals around the conductor and coupling element, preventing water and vapor penetration while allowing the connector to remain locked for stable electrical connection.
4Adaptability or versatility
If a connector uses a movable coupling element to accommodate different conductor sizes, then adaptability is improved, but the device complexity increases
Solution Approach 1:
The connector merges the coupling element and locking mechanism into an integrated assembly where the coupling element's movement is directly linked to the locking action. This combination reduces the number of separate components and simplifies the overall structure while maintaining the ability to accommodate different conductor sizes through the movable coupling element.
Data Source
AI summary
Systems and methods are provided fir coupling a plurality of electrical conductors, such as wires. A connector is provided including a plurality of bores or channels formed into a preferably unitary connector body, wherein at least a portion of one or more of the bores or channels intersects at least a portion of another of the bores or channels. The bores or channels are preferably formed along bore axes, which may be coplanar. A method according to the present invention includes inserting an insulated electrical conductor into a connector body and rotating a conductive rotational member threaded into a bore or channel formed in a connector body so as to electrically contact the conductive portion of the insulated conductor and at least one other electrically conductive surface.