Insulation Piercing Connector for Electrical Wiring

Solution Overview

Problem

The installation of tap connectors is time-consuming and costly due to the need to strip insulation from electrical wires, which disrupts the electrically conductive path between main and branch conductors.

Innovation Solution

The development of insulation piercing connectors with a removable cap and screws featuring insulation piercing members that can pierce through the conductor insulation, creating an electrically conductive path without the need for manual stripping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional metal tap connectors are used with manual insulation stripping, then reliable electrical connection is achieved, but installation time and cost increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The connector is divided into functionally distinct components: the connector body with conductive path, removable cap for insulation management, and screws with integrated insulation piercing members. This segmentation allows each component to perform its specific function efficiently while maintaining overall connection reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulation piercing function is merged directly into the screw fastening mechanism. The screws contain integrated insulation piercing members that automatically pierce the insulation during the fastening operation, combining two previously separate operations (insulation removal and mechanical fastening) into a single action.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If insulation stripping is performed manually before connection, then proper electrical contact is ensured, but installation complexity and cost increase

Engineering Contradiction:

Improveelectrical contact qualityVSAvoidinstallation process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulation piercing function is merged directly into the screw fastening mechanism. The screws contain integrated insulation piercing members that automatically pierce the insulation during the fastening operation, combining two previously separate operations (insulation removal and mechanical fastening) into a single action.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector system performs the insulation piercing operation automatically during installation without requiring external tools or manual stripping. The insulation piercing members on the screws self-service the insulation removal function as part of the fastening process itself.

Inventive Principle:

Principle #25Self-service

3Productivity

If insulation piercing features are integrated into the connector, then installation speed increases, but connector structure becomes more complex

Engineering Contradiction:

Improveinstallation speedVSAvoidconnector structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The connector is divided into functionally distinct components: the connector body with conductive path, removable cap for insulation management, and screws with integrated insulation piercing members. This segmentation allows each component to perform its specific function efficiently while maintaining overall connection reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The screws serve multiple functions: they provide mechanical fastening, create electrical contact, and pierce the insulation barrier. This multi-functionality reduces the number of separate components and operations needed, offsetting the increased complexity of individual components with overall system simplification.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11264736B2Insulation piercing connector

Publication Date: 2022.03.01 HUBBELL INC

AI summary

Mechanical-type electrical connectors having insulation piercing screws used to create an electrically conductive path between a run conductor secured to the connector and a branch conductor secured to the connector are provided.