Parallel-Blade Insulation Piercing Connector for Mixed Cable Diameters
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Solution Overview
Problem
Existing electrical connectors for connecting conductors of varying diameters lack efficient mechanisms for making secure connections without stripping the insulation, and they often require complex assembly processes.
Innovation Solution
The electrical connector design features a pair of pads with grooves for conductor reception, connected by a fastener and equipped with insulation displacing contacts and gaskets. These components allow for secure engagement and piercing of conductor insulation, enabling connection without stripping, and facilitate easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional parallel cable clamps are used to connect conductors of varying diameters, then the connection can be made permanently or temporarily, but the device complexity increases due to requiring top and bottom halves with multiple grooves and mechanical fasteners
Solution Approach 1:
The connector is divided into a first pad and a second pad that can be movably connected by a fastener. Each pad has its own contact and gasket assembly, allowing independent adjustment and simplifying the overall structure. This segmentation enables the connector to adapt to different conductor diameters without requiring a completely complex multi-groove design.
Solution Approach 2:
The connector design with multiple grooves on each pad (first groove, second groove on first pad; third groove, fourth groove on second pad) allows a single device to handle multiple conductor configurations and diameters. The universal design enables the same connector structure to accommodate various conductor sizes through the parallel groove arrangement.
2Reliability
If insulation stripping is used to make conductor connections, then secure electrical connection can be achieved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The connector includes insulation displacing contacts with teeth that are pre-configured to pierce and displace insulation automatically during the connection process. This preliminary action eliminates the need for separate insulation stripping steps, as the insulation is displaced as part of the normal connector assembly process, thereby simplifying manufacturing while maintaining connection reliability.
Solution Approach 2:
The contact gasket serves as an intermediary component between the contact and the conductor. The gasket is positioned over the contact and works in conjunction with the teeth to pierce insulation and establish electrical connection. This intermediary mechanism enables secure connection without requiring complex insulation stripping operations.
3Reliability
If complex assembly processes are used to ensure reliable connections, then connection reliability improves, but the assembly time and complexity increase
Solution Approach 1:
The connector design allows the components to self-align and self-assemble to a程度. The movably connected pads with integrated contacts and gaskets can be assembled in a straightforward sequence, reducing the need for complex alignment procedures. The fastener system enables straightforward assembly while maintaining reliable connections, thereby reducing assembly time.
Solution Approach 2:
The insulation displacing contacts are pre-configured with teeth that automatically engage and pierce insulation during assembly. This preliminary configuration of the contact mechanism ensures that insulation displacement occurs automatically as part of the assembly process rather than requiring separate complex operations, thereby maintaining reliability while reducing assembly time.
Data Source
AI summary
An electrical connector includes a first pad with a first conductor groove and a second conductor groove. A second pad having a third conductor groove and a fourth conductor groove is movably connected to the first pad by a fastener. A first contact is connected to the first pad. The first contact has a first set of teeth that extend into the first groove and a second set of teeth that extend into the second groove. A first contact gasket is connected to the first pad and positioned over the first contact. A second contact is connected to the second pad. The second contact has a third set of teeth that extend into the third groove and a fourth set of teeth that extend into the fourth groove. A second contact gasket is connected to the second pad and positioned over the second contact.