One-Way Locking Wire Connector With Hard Stops for Alignment
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Solution Overview
Problem
Existing wire connectors for tracer wires in utility lines suffer from alignment issues and over-rotation, leading to disconnection and inoperability, necessitating a connector with positive stops to ensure proper alignment and secure closure.
Innovation Solution
A wire connector with opposing stops and gripping tabs that align wire ports in the open position and prevent over-rotation, featuring a one-way rotation mechanism to ensure a secure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rotating connector is used to pierce insulation and connect wires, then wire connection is achieved, but alignment issues occur due to rotation capability
Solution Approach 1:
The connector is divided into two separate portions: a first portion with through-bores for wire insertion and alignment, and a second portion with insulation-piercing elements for connection. This segmentation allows each portion to perform its specific function independently, ensuring both alignment precision and connection capability.
Solution Approach 2:
The first portion is positioned and aligned with the wires before the connection action occurs. The through-bores are pre-aligned with the wire positions, and the insulation is positioned within the piercing elements before rotation begins, ensuring precise alignment is maintained throughout the connection process.
2Ease of operation
If a rotating connector is used to connect wires, then connection is made, but over-rotation can occur causing disconnection and inoperability
Solution Approach 1:
The design incorporates features that prevent over-rotation before it can occur. The relative rotation between portions is constrained to a specific range, and the connector reaches a predetermined closed position where further rotation is blocked, preventing disconnection and maintaining reliability.
Solution Approach 2:
The connector transitions from a static design to a dynamic one with controlled rotation. The connector rotates from an open position to a closed position, but the rotation is limited and controlled rather than free, allowing the connector to adapt its position while maintaining reliability through predetermined stop points.
3Ease of operation
If a connector allows rotation for connection, then wire connection is enabled, but alignment of wire ports with openings is difficult
Solution Approach 1:
The connector portions have asymmetric features including non-circular cross-sections and specifically positioned through-bores and gripping tabs. This asymmetry provides inherent alignment cues and mechanical constraints that guide proper orientation during installation, simplifying the alignment process without adding complex alignment mechanisms.
Data Source
AI summary
A wire connector configured to connect at least two wires includes a first portion and a second portion rotatably connected to the first portion. The first portion includes a plurality of spaced apart through bores in the first main body and opposing first stops extending from the exterior surface. The second portion includes a combination insulation piercing and wire connecting member having a plurality of apertures with arcuate slots extending from each of the plurality of apertures and opposing second gripping tabs, wherein opposing second gripping tabs are located about 180° from each other. When the opposing second gripping tabs abut each of the opposing first stops, the member is in a first position where wires can be positioned into the second portion through the member.