Poke-In Electrical Connector Actuator Mechanism
Solution Overview
Problem
Poke-in wire contacts face difficulties in removing electrical wires without damaging them or the connector, leading to increased costs due to potential repair or replacement needs.
Innovation Solution
An electrical connector design featuring a housing with a slot for an actuator that moves contact beams from a closed to an open position, allowing easy insertion and removal of wires, with the actuator sliding parallel to the insertion axis to disengage the wire interface, facilitating multiple insertions and removals without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire interface engages the electrical wire in a poke-in contact, then secure electrical connection is achieved, but removal of the electrical wire becomes difficult without damaging the wire or contact
Solution Approach 1:
The contact beam is designed to be movable between a closed position (engaging the wire) and an open position (releasing the wire). This dynamic capability allows the contact to securely hold the wire during operation while enabling easy removal when needed, resolving the contradiction between connection security and removal ease.
Solution Approach 2:
An actuator serves as an intermediary mechanism that moves the contact beam between engaged and disengaged states. The actuator includes a wedge that interacts with the contact beam to facilitate controlled movement, allowing the wire to be securely held during normal operation and easily removed when the actuator is activated.
2Reliability
If the contact beam is held in a fixed closed position, then reliable wire engagement is maintained, but the wire cannot be removed or repositioned
Solution Approach 1:
The contact beam transitions from a static fixed position to a dynamic movable position, capable of switching between closed (engaged) and open (disengaged) states. This enables the system to maintain reliable engagement during operation while allowing wire installation and removal when actuated.
Solution Approach 2:
The contact beam is preliminarily positioned in the closed engaged state to ensure reliable wire connection. When wire installation or removal is needed, the actuator moves the contact beam to the open state, allowing the wire to be inserted or removed before the contact beam returns to its engaged position.
3Device complexity
If a simple poke-in contact design is used, then device complexity is reduced, but wire removal causes damage requiring repair or replacement
Solution Approach 1:
By making the contact beam movable rather than fixed, the design prevents wire damage during removal. The beam can open to release the wire cleanly without requiring forceful extraction that would damage either the wire or contact, thereby reducing repair and replacement needs while maintaining relatively simple structure.
Solution Approach 2:
The actuator serves as an intermediary that enables controlled movement of the contact beam. This mechanism allows the wire to be removed cleanly by actuating the beam to the open position, preventing damage to the wire or contact and eliminating the need for repair or replacement that would otherwise be required with fixed poke-in contacts.
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 secure electrical connections while allowing easy installation and removal of electrical wires, reducing the risk of damage and associated costs by ensuring the wire interface can be disengaged without damaging the wire or the connector.
Implementation Method 1
the contact beam is configured to be slidably engaged by an actuator along an actuation direction that is non-perpendicular to the insertion axis
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An electrical connector (10, 110, 210) includes a housing (16, 116, 216) having a receptacle (20, 120, 220) that is configured to receive an electrical wire (12) therein along an insertion axis (24, 124, 224). An electrical contact (18, 118, 218) is held by the housing. The electrical contact includes a contact beam (26, 126, 226) that includes a wire interface (48, 148, 248) that is configured to engage the electrical wire. The contact beam is movable between a closed position and an open position. The wire interface is configured to engage the electrical wire when the contact beam is in the closed position. The wire interface is configured to be disengaged from the electrical wire when the contact beam is in the open position. The contact beam is configured to be slidably engaged by an actuator (30, 130, 230) along an actuation direction that is non-perpendicular to the insertion axis to move the contact beam from the closed position to the open position.