Connector Assembly With Piercing Pins For Insulated Wires
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Solution Overview
Problem
Existing methods for electrically coupling separate electronic components are often labor-intensive, require specialized tools, and result in unreliable connections prone to environmental damage and aesthetics issues.
Innovation Solution
A connector assembly featuring a housing with a channel for insulated conductive wires, a hinged cover, and conductive pins that pierce the insulation to create a secure and sealed electrical connection, using a sealing material to prevent contamination and a clip mechanism for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire splicing is performed by removing insulating material and soldering or twisting wires together, then electrical connection can be established, but the process becomes labor-intensive, time-consuming, and requires specialized tools and skills
Solution Approach 1:
The connector is divided into distinct components: a housing that receives the insulated wire, a hinged cover for access, and integrated conductive pins. This segmentation allows the wire to be connected while remaining insulated, eliminating the need to remove insulating material and significantly reducing connection time and skill requirements.
Solution Approach 2:
The conductive pins act as intermediaries that pierce through the insulating material to establish electrical contact with the wire. This intermediary mechanism allows electrical connection without requiring wire stripping or soldering, making the process faster and less skill-intensive while maintaining reliability.
2Reliability
If wires are soldered or twisted together to create electrical connection, then connection can be established, but the mechanical and electrical connection becomes prone to breaking and vulnerable to environmental contaminants
Solution Approach 1:
The housing and cover form a protective enclosure around the wire and conductive pins, creating a sealed environment that shields the electrical connection from environmental contaminants such as moisture and dust, while allowing the wire to pass through with its insulating material intact.
Solution Approach 2:
The conductive pins serve as intermediaries that pierce the insulating material to establish electrical contact, then remain enclosed within the housing. This intermediary approach creates a protected junction that is mechanically stronger and resistant to environmental factors compared to exposed wire splices.
3Reliability
If traditional wire splicing methods are used, then electrical connection can be made, but the result is aesthetically unattractive and requires multiple tools and additional materials
Solution Approach 1:
The housing, cover, and conductive pins are merged into an integrated connector assembly that performs multiple functions: receiving the insulated wire, providing electrical contact through pin penetration, and offering environmental protection. This consolidation eliminates the need for separate tools and materials required for traditional splicing methods.
Solution Approach 2:
The connector assembly serves multiple functions simultaneously: it provides electrical connection, mechanical protection, and environmental sealing all within a single device. This multi-functionality simplifies the overall process compared to traditional methods that require separate operations for each function.
Data Source
AI summary
A connector assembly for providing electrical connection to an insulated conductive wire, the connector assembly including: a housing defining a channel for receiving the insulated conductive wire; a cover hinged to the housing and configured to close over the channel to cover the insulated conductive wire; and an electrically conductive pin having a first end in the channel and a second end in the housing beneath the channel.