Tool-Free Electrical Connection Kit with Piercing Teeth
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connection kits for motor vehicle conductors often damage the core when attempting to cut through the insulating sheath and require the use of a tool for the guillotine effect, which is inconvenient.
Innovation Solution
An electrical connection kit with a connection lug featuring aligned teeth that pierce the sheath of the first conductor when folded, eliminating the need for a tool and minimizing core damage, and incorporating a support stop and locking mechanism for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a blade is used to cut the sheath of the conductor during tightening, then the sheath can be severed, but the core may be damaged by unwanted cutting
Solution Approach 1:
The patent introduces an intermediary element (the specialized connection piece with cutting edge) that performs the sheath cutting function separately from the core contact function. This intermediary structure allows the sheath to be cut without the clamping force directly affecting the core, as the cutting action is distributed along the length of the connection piece rather than concentrated at a single blade contact point.
Solution Approach 2:
The connection piece is segmented into multiple contact points along its length, with cutting edges distributed at specific positions. This segmentation allows the cutting function to be performed at multiple locations along the sheath without requiring a single aggressive blade action that could damage the core. The core remains protected while the sheath is progressively cut away.
2Reliability
If a tool is used to achieve the guillotine effect for cutting the sheath, then the sheath can be cut effectively, but the operation becomes complex and requires additional equipment
Solution Approach 1:
The connection piece is designed to perform the sheath cutting function automatically during the normal connection process. When the connector is assembled and tightened, the cutting edges on the connection piece automatically engage and cut the sheath without requiring any separate tool or additional operation. The connection mechanism itself provides the cutting function, eliminating the need for external cutting tools.
Solution Approach 2:
The patent merges the sheath cutting function with the electrical connection function into a single integrated component. The connection piece simultaneously serves as both the electrical conductor and the sheath cutting tool, combining what were previously separate operations (cutting and connecting) into one unified action that reduces device complexity.
3Ease of operation
If manual folding of the connection box is used, then no tool is required, but sufficient force may not be applied to pierce the sheath
Solution Approach 1:
The connection piece is pre-configured with cutting edges and positioning features that prepare the sheath for cutting before the final tightening action. The sheath is positioned and pre-pierced by the structured contact points during initial assembly, so that the final manual folding action only needs to apply sufficient force to complete the connection rather than starting the piercing from scratch.
Solution Approach 2:
The connection mechanism incorporates dynamic elements that allow the force application to be optimized during the folding process. The connection piece can deform or adjust its position during tightening, concentrating force at the cutting edges at the right moment while distributing force elsewhere during the assembly process, enabling effective sheath piercing with manual force.
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
The kit provides a reliable, tool-free electrical connection between conductors with reduced risk of core damage, allowing for a simple hand gesture to achieve a good quality connection.
Implementation Method 1
the teeth of the terminal occasionally pierce the sheath of the first conductor and come into contact with the core. The pressure exerted by the hand of an operator is sufficient to pierce the sheath of the first conductor.
Data Source
Figure 1~4
Figure 5~8
AI summary
The invention relates to an electrical connection kit (18) for two electrical conductors (11, 12), comprising a connection housing (20) with two parts (21, 22) that fold one onto the other. The first part (21) has a receiving groove and a support housing extending in the same longitudinal direction, such that the receiving groove and the support housing are superimposed. The kit (18) further includes a connection lug crimped onto the second electrical conductor (12) at one end, and having aligned teeth of electrically conductive material at its other end.The kit (18) is configured so that, once the connecting lug is housed in the support housing, the teeth are aligned in the longitudinal direction, and that, once the first electrical conductor (11) is placed in the receiving groove, the folding of the parts causes the sheath of the first conductor (11) to be pierced by the teeth.