Mains Power Wire Connector with Puncturing Clamping Ends
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Solution Overview
Problem
Current methods for connecting mains power wires are complex, labor-intensive, and prone to conductor damage, leading to unreliable electrical connections and resource waste, as they require removing insulation layers and twisting conductors.
Innovation Solution
A mains power wire connection assembly featuring a connector with insulation body, button, and conductive connection terminal, allowing wires to be clamped without removing insulation, using puncturing clamping ends and elastic locking blocks for secure and reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conventional method of removing insulation layers and twisting conductors is used, then electrical connection can be achieved, but the process becomes complex and labor-intensive
Solution Approach 1:
The patent extracts the insulation removal step from the connection process by designing a connector with puncturing clamping ends that can penetrate the insulation layer directly. This allows the connector to access the conductor without requiring manual insulation removal, thereby simplifying the connection process while maintaining reliable electrical connection.
Solution Approach 2:
The connector is segmented into distinct functional components: puncturing clamping ends for penetrating insulation and clamping conductors, insulating bodies for electrical isolation, and locking mechanisms for mechanical fixation. This segmentation allows each component to perform its specific function efficiently, reducing overall process complexity.
2Ease of operation
If insulation layers are removed manually, then conductor access is achieved, but conductor damage occurs and resources are wasted
Solution Approach 1:
The connector extracts only the necessary function of insulation removal through its puncturing clamping ends, which are designed to penetrate the insulation layer precisely and access the conductor without causing damage. This selective extraction avoids the harmful effects of manual insulation removal while maintaining conductor accessibility.
Solution Approach 2:
The puncturing clamping ends are pre-configured with sharp edges and appropriate geometry to cleanly penetrate the insulation layer before contact with the conductor. This preliminary action ensures that the insulation is removed in a controlled manner that prevents conductor damage, eliminating resource waste.
3Reliability
If conductors are twisted together, then electrical connection is established, but tensile performance is reduced due to deformation
Solution Approach 1:
The patent replaces the twisting mechanical system with a clamping system. The puncturing clamping ends establish electrical connection through direct contact with the conductor after puncturing the insulation, without requiring twisting deformation. This substitution maintains electrical reliability while preserving the conductor's tensile performance.
Solution Approach 2:
The connection function is segmented into separate stages: insulation puncturing, conductor clamping, and mechanical locking. This segmentation eliminates the need for twisting as a single-step solution, allowing each stage to optimize for its specific function without compromising tensile strength.
4Object-affected harmful factors
If insulating tape is used to wrap twist joints, then sealing and protection are achieved, but mechanical fixing is not firm and may break
Solution Approach 1:
The connector extracts the protection function from the insulating tape wrapping process and integrates it directly into the connector structure. The insulating bodies are designed to provide electrical isolation and protection without requiring external tape wrapping, thereby eliminating the mechanical weakness of tape-based fixing while maintaining electrical safety.
Solution Approach 2:
The electrical isolation function and mechanical fixation function are merged into a single integrated connector structure. The insulating bodies simultaneously provide electrical protection and mechanical support, eliminating the need for separate tape wrapping and creating a more reliable mechanical connection.
5Reliability
If multiple manual operations are performed for wire connection, then connection can be achieved, but operator load increases and efficiency decreases
Solution Approach 1:
The patent merges multiple manual operations (insulation removal, conductor twisting, tape wrapping, and securing) into a single integrated connector that performs all functions simultaneously through one insertion and locking action. This consolidation dramatically improves connection efficiency while maintaining reliable electrical and mechanical connection.
Solution Approach 2:
The connector is designed to perform its own installation functions without requiring manual intervention for each step. The puncturing clamping ends automatically penetrate insulation and clamp conductors, while the locking mechanism self-secures the connection, reducing operator load and increasing productivity.
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 quick, reliable, and efficient electrical and mechanical connections between mains power wires, reducing operator load and avoiding resource waste by eliminating the need for insulation removal and minimizing tensile performance loss.
Implementation Method 1
elastic locking blocks
Data Source
AI summary
A mains power wire connection assembly (100) using a button to push a first wire and a second wire to move toward the direction of clamping slots, and the inner walls of the clamping slots puncture the first wire and second wires and clamp the same. The button and the insulation body are locked and fixed with respect to each other.