Electric Wire Connector with Segmented Housing and Movable Cover
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Solution Overview
Problem
Existing electric wire connectors are not suitable for high wire diameters, particularly in solar systems, requiring high bending forces for termination and increasing system complexity and size, with multiple connectors needed for each wire.
Innovation Solution
A compact electric wire connector with a housing base divided into compartments and a linearly movable housing cover, featuring adaptable wire receiving openings sealed with a gel material, insulation displacement contacts, and a biasing spring for secure and efficient connection of wires without stripping, suitable for a wide range of wire sizes and environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single connector is used to connect multiple wires, then the device complexity and number of components are reduced, but the connector housing volume and wire receiving opening size must increase to accommodate high wire diameters
Solution Approach 1:
The connector housing is divided into multiple compartments, with each compartment designed to receive and terminate a wire independently. This segmentation allows the housing to accommodate multiple high-diameter wires simultaneously while maintaining organized separation, reducing the need for multiple separate connectors.
Solution Approach 2:
The single connector housing is designed with multiple wire receiving openings and contact terminals that can accommodate various wire diameters (2.5 to 10 mm²). The housing serves multiple functions: receiving multiple wires, providing electrical connection through contact terminals, and sealing against environmental factors, replacing what would traditionally require multiple separate connectors.
2Reliability
If the wire receiving opening is sealed to prevent humidity and dirt entry, then the reliability in harsh environments is improved, but the ease of wire insertion and adaptability to different wire sizes deteriorates
Solution Approach 1:
A gel sealing material is used to seal the wire receiving opening. The gel has flexible, deformable properties that allow it to be penetrated by wires of different diameters during insertion. Once the wire is in place, the gel conforms around the wire to create an effective seal, preventing humidity and dirt from entering the housing while maintaining ease of insertion.
Solution Approach 2:
The sealing material transitions from an unsealed or loosely sealed state during insertion to a sealed state after insertion. The gel material changes its physical state from deformable (allowing wire penetration) to conformal (providing seal), adapting its parameters based on the insertion process stage.
3Strength
If high bending forces are applied to terminate high diameter wires, then the connection strength is improved, but the ease of operation and potential for wire damage increases
Solution Approach 1:
The connector housing and contact terminals are designed to automatically provide the necessary clamping force to secure high-diameter wires. The contact terminals are configured to engage with the wires and provide sufficient termination strength without requiring external tools or high bending forces from the operator. The housing structure itself supports the wire termination process.
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 simplifies the connection process, reduces the number of components needed, prevents high bending forces, and ensures secure, reliable connections for high current applications, even in harsh environments, by using a single connector for multiple wires and providing protection against humidity and dirt.
Implementation Method 1
the at least one wire receiving opening is filled with a sealing material
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an electric wire connector (1) for connecting at least two wires (10), particularly solar wires (34). The electric wire connector (1) comprises a connector housing (2) with a housing base (6) and at least one housing cover (4), the housing base (6) being divided into at least two compartments (8); and at least two contact terminals (53), each arranged in a different compartment (8), the at least two contact terminals (53) being connected to one another by an electrically conductive member (57). The at least one housing cover (4) comprises at least one wire receiving opening (12) for receiving one of the at least two wires (10) in an insertion direction (S) and the at least one housing cover (4) is linearly movable relative to the housing base (6) from an open position (14) for receiving at least one of the wires (10) to a closed position (16) for terminating the inserted wire (10).