Crimpless Electrical Connector With Tines And Threaded Activation

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Solution Overview

Problem

Existing electrical connectors require crimping to establish connections, which can deform conductors and necessitate specialized tools, limiting ease of assembly and disassembly, as well as conductor reuse.

Innovation Solution

A crimpless connector assembly that uses a crimpless contact with tines and an outer housing, along with an anti-rotation pin and activation unit, allowing for secure electrical connections without deformation and enabling easy assembly and disassembly without specialized tools, using threaded components for adjustable compression and secure conductor gripping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If crimping is used to establish electrical connections, then connection strength is improved, but conductor deformation occurs and specialized tools are required

Engineering Contradiction:

Improveconnection strengthVSAvoidease of assembly

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The connector is divided into separate components: a reusable outer housing and a disposable contact assembly with integrated tines. This segmentation allows the contact assembly to be pre-formed with deformation-resistant tines that provide connection strength without requiring field crimping operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The traditional crimping mechanical system (crimping tools applying compressive force) is replaced with a pre-deformed tine structure that provides mechanical engagement through its geometry alone. The tines are formed during manufacturing with built-in deformation characteristics that provide gripping force without requiring additional mechanical compression devices.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If crimping is used to establish connections, then electrical connection reliability is improved, but conductor reuse becomes difficult

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidconductor reuse

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The connector system is segmented into a permanent outer housing and a disposable contact assembly. This allows the conductor to remain intact and reusable while the contact assembly, which performs the connection function, is replaced. The tines are contained within the contact assembly and do not deform the conductor.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of deforming the conductor to create the connection (traditional approach), the invention inverts the approach by having the contact assembly deform its own tines during assembly to create the connection. The conductor remains undeformed and can be reused, while the disposable contact assembly absorbs the deformation.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If threaded components are used for adjustable compression, then ease of assembly is improved, but device complexity increases

Engineering Contradiction:

Improveease of assemblyVSAvoiddevice complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The threaded mechanism serves multiple functions: it provides adjustable compression force on the tines, enables easy assembly and disassembly of the contact assembly from the outer housing, and allows for precise positioning of the contact assembly within the housing. This multi-functionality justifies the added complexity by consolidating several adjustment needs into a single mechanism.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables secure, reusable electrical connections without conductor deformation, allowing for easy assembly and disassembly, and uniform pressure application, facilitating efficient transmission of power or data without the need for crimping tools.

Implementation Method 1

The tines can be elastically deformed in the second configuration and/or various intermediate configurations under the applied compression

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

The outer housing can include a tapered lumen which modulates the compression depending on the distance the crimpless contact is inserted into the tapered lumen

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

Some of the components can comprise threaded shafts configured to mate with threaded lumens or channels of another component, and can be easily assembled by screwing the components together

Methodology Applied

Scientific EffectThreaded connection: Screw

Data Source

PatentUS9843113B1Crimpless electrical connectors

Publication Date: 2017.12.12 ITT MANUFACTURING ENTERPRISES LLC

AI summary

Various crimpless electrical connector assemblies are disclosed. The crimpless connector can include a crimpless contact configured to join two electrical conductors. A portion of the crimpless contact can be received in an outer housing that comprises a tapered lumen. The crimpless contact can be coupled to an activation unit, such as with a threaded connection. Rotation of the activation unit can cause the crimpless contact to translate within the outer housing and the tines to be compressed against the first conductor, thereby physically securing the first conductor in the crimpless connector.