Poke-in Electrical Connector with Push-Button Wire Release
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Solution Overview
Problem
Poke-in wire contacts in electrical connectors often require specialized tools for wire release, leading to potential damage and increased costs due to brittleness issues from heat exposure, making it difficult to remove wires without damaging the connector or wire.
Innovation Solution
An electrical connector design featuring a movable contact beam with a resiliently deflectable spring actuator that allows for easy engagement and disengagement of wires without specialized tools, using a push-button mechanism that can withstand heat without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible member made of plastic or similar material is used to push on the poke-in contact for wire release, then the wire can be released from the contact, but the flexible member becomes brittle when exposed to heat from solder reflow process, causing it to fracture or fail
Solution Approach 1:
The patent removes the flexible member component entirely from the housing and replaces it with a metal contact frame that provides the wire release function through its inherent elastic properties. The flexible member is extracted from the system and its function is transferred to the contact frame structure itself.
Solution Approach 2:
The patent employs a metal contact frame with elastic properties to replace the plastic flexible member. The metal material provides both the mechanical flexibility needed for wire release and the heat resistance required to withstand solder reflow processes, creating a composite solution that combines both required properties.
2Ease of operation
If a special dedicated tool is required to release the electrical wire from the poke-in contact, then the wire can be released, but the tool is not readily available in the field and may damage the connector if not used properly
Solution Approach 1:
The contact frame is designed to be self-actuating through its elastic properties. When external force is applied to the contact frame, it automatically deflects to release the wire without requiring a specialized tool. The structure serves itself by using its own elastic deformation to perform the release function.
Solution Approach 2:
The contact frame transitions from a static structure to a dynamic one that can deflect and return. The elastic contact frame can dynamically respond to applied forces by deflecting to release the wire and then returning to its original position, enabling repeated wire release operations without specialized tools.
3Reliability
If the contact beam is held firmly in the closed position to ensure reliable wire engagement, then the electrical connection is stable, but it becomes difficult to release the wire from the receptacle
Solution Approach 1:
The contact beam is designed as a dynamic elastic structure that can transition between closed and open positions. The elastic properties allow it to be firmly engaged in the closed position for reliable connection while enabling easy transition to the open position for wire release when external force is applied.
Solution Approach 2:
The contact beam is segmented into distinct functional zones: an engagement portion that provides firm contact with the wire, a deflectable portion that provides elastic movement, and a connection portion that attaches to the circuit board. This segmentation allows different parts to perform different functions - firm engagement and easy release.
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 safe and cost-effective repeated insertion and removal of wires without damaging the connector or wire, accommodating various wire sizes and reducing the risk of actuator failure from heat exposure.
Implementation Method 1
a push-button actuator having a resiliently deflectable spring that is configured to slidably engage the contact beam to thereby move the contact beam from the closed position to the open position
Implementation Method 2
the push-button actuator comprises a spring beam that is engaged in physical contact with the opposite side of the contact beam for biasing the contact beam to the closed position
Data Source
Figure 1
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Figure 3
AI summary
An electrical connector (10) includes a housing (16) having a receptacle (20) that is configured to receive an electrical wire (12) therein. An electrical contact (18) is held by the housing (16). The electrical contact (18) includes a contact beam (26) that includes a wire interface (28a, 28b) that is configured to engage the electrical wire (12). The contact beam (26) is movable between a closed position and an open position. The wire interface (28a, 28b) is configured to engage the electrical wire (12) when the contact beam (26) is in the closed position. The wire interface (28a, 28b) is configured to be disengaged from the electrical wire (12) when the contact beam (26) is in the open position. The electrical connector (10) includes a push-button actuator (30) having a resiliently deflectable spring (32) that is configured to slidably engage the contact beam (26) to thereby move the contact beam (26) from the closed position to the open position.