Linearized Magnet Wire Connector With Piercing Projections
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Solution Overview
Problem
Existing wire connectors struggle to efficiently connect larger bundles of magnet wires without the need for brazing, which is time-consuming and prone to errors, due to the difficulty in piercing the tough enamel insulation.
Innovation Solution
A wire connector design featuring a channel with projections that pierce the enamel insulation, allowing for the crimping of multiple magnet wires in a linear arrangement, enabling efficient conductive coupling without brazing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire connectors are used to connect magnet wires, then the connection can be made, but the tough enamel insulation coating prevents reliable electrical contact and requires time-consuming brazing operations
Solution Approach 1:
The connector features localized piercing elements (projections or spikes) with high hardness and sharp tips positioned at specific locations within the channel. These elements are specifically designed to pierce the enamel insulation coating, creating conductive pathways through the insulation to the underlying wire conductor, thereby solving the problem of unreliable electrical contact caused by the tough enamel coating.
Solution Approach 2:
The piercing elements are pre-formed on the connector before assembly. When wires are inserted into the channel, the projections automatically pierce the enamel insulation coating during the crimping process, eliminating the need for separate insulation removal or brazing operations. This preliminary preparation of piercing capability streamlines the manufacturing process.
2Productivity
If brazing is used to connect magnet wires, then reliable electrical contact is achieved, but the process is time-consuming and prone to errors
Solution Approach 1:
The invention replaces the thermal brazing process with a mechanical piercing and crimping system. The projections mechanically pierce the enamel insulation and embed into the wire conductor, creating electrical contact through direct metal-to-metal contact. The crimping action secures the wires to the connector body, providing both mechanical support and electrical connection without requiring heat application, thereby significantly reducing connection time and eliminating brazing-related errors.
Solution Approach 2:
The connector utilizes material property changes, specifically the hardness difference between the piercing elements and the enamel insulation coating. The projections are made of harder material that can easily penetrate the softer enamel coating under crimping pressure, enabling rapid insulation penetration and conductor contact without the time-consuming thermal process of brazing.
3Quantity of substance
If the channel size is increased to accommodate larger bundles of wires, then more wires can be connected, but the connector complexity increases
Solution Approach 1:
The connector channel is designed with segmented or modular piercing elements arranged in rows or groups along the channel length. Each piercing element independently pierces one or more wires, allowing the channel to accommodate varying numbers and sizes of wires by simply adjusting the number and spacing of projections, rather than redesigning the entire connector structure.
Solution Approach 2:
The connector channel and piercing elements are designed to handle multiple wire sizes and bundle configurations through a single standardized design. The projections can pierce through single or multiple wires simultaneously, and the channel geometry accommodates different wire diameters, making the connector universally applicable to various wire bundle sizes without increasing structural complexity.
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 faster and more reliable connection of larger numbers of magnet wires by piercing the enamel insulation, reducing the risk of faulty connections and eliminating the need for brazing operations.
Implementation Method 1
the plurality of projections are configured to pierce an enamel insulation coating of a wire
Implementation Method 2
the member is made of copper having a tin coating
Data Source
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AI summary
A wire connector includes a member and a channel. A size of the channel is configured to correspond to a width of a largest wire to be connected by the wire connector. The wire connector includes a plurality of projections. The plurality of projections extend from at least one wall forming the channel.