One-Handed Electrical Connector for Exothermic Welding Igniters
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Solution Overview
Problem
Conventional electrical connectors for exothermic welding require two-hand mating and do not provide a secure connection, making it difficult to establish reliable operations, especially when connecting an igniter strip to a power source.
Innovation Solution
An electrical connector design with a movable conductor that can be actuated manually to securely engage and disengage an igniter strip, allowing for one-handed operation and a robust connection between the igniter and power source, featuring a non-conductive housing with metal electrodes and a thermoplastic or ceramic material resistant to heat, and an actuator to move conductors between resting and actuated orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional electrical connectors are used for exothermic welding, then the connection can be established between power source and igniter, but the connector requires two-hand mating and does not provide secure connection
Solution Approach 1:
The connector employs a movable conductor that can shift between a first position (for insertion) and a second position (for secure engagement). This dynamic element allows the connector to transition from a receptive state to a locked state, enabling one-handed operation while ensuring secure connection. The movable conductor is actuated by a button that shifts its position to either make or break electrical contact with the igniter.
Solution Approach 2:
The connector design allows the movable conductor to automatically engage with the igniter when inserted, securing it in place without requiring additional manual fastening steps. The spring element provides automatic return to the engaged position after actuation, making the connection process self-completing and eliminating the need for two-hand operation.
2Object-affected harmful factors
If the connector housing is made from heat-resistant material for exothermic welding application, then thermal resistance is improved, but the housing complexity increases
Solution Approach 1:
The connector housing is constructed from composite materials including thermoplastic and ceramic components. The thermoplastic housing provides structural integrity and electrical insulation, while ceramic elements (such as the insulator surrounding the movable conductor) provide superior heat resistance. This composite approach achieves the required thermal resistance for exothermic welding applications while maintaining a relatively simple monolithic housing structure.
3Ease of operation
If the second conductor is made movable to enable one-handed operation, then ease of operation is improved, but the device complexity increases
Solution Approach 1:
The second conductor is designed as a movable element that can shift between a first position (disengaged) and a second position (engaged with igniter). This dynamic capability enables one-handed operation by allowing the user to insert the igniter and then actuate the button to secure the connection. The movement is constrained to a simple linear or rotational path, minimizing mechanical complexity while achieving the desired operational ease.
Solution Approach 2:
A button serves as an intermediary element that translates user pressure into movement of the second conductor. When the button is pressed, it actuates the movable conductor to shift positions and engage or disengage from the igniter. This intermediary mechanism provides mechanical advantage and control, enabling one-handed operation without requiring complex direct manipulation of the conductor itself.
Data Source
AI summary
An electrical connector can be provided for connecting a power source to an insertable conductor, including an igniter for exothermic weld material. One or more conductors can be disposed within a housing that is configured to receive the insertable conductor. An actuator can be engaged from outside the housing to move at least one of the conductors within the housing between resting and actuated orientations.