Push-In Spring Electrical Connector for PV Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connector systems for photovoltaic power transmission require direct handling of conductive members for permanent affixation, posing safety risks and inefficiencies in field installations.
Innovation Solution
A mating pair of male and female electrical connectors with releasable barbed prongs and complementary slots, allowing for secure connection without direct contact with conductive members, featuring push-in, spring-type connectors and gasket seals for moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct handling of conductive members is used for permanent affixation, then the connection can be permanently secured, but safety risks increase and installation efficiency decreases
Solution Approach 1:
The patent introduces an intermediary mechanism (the connector housing with integrated contact members and crimping structure) that mediates between the installer and the conductive members. The housing contains shielding members and positioning features that allow the conductor to be secured without the installer directly handling exposed conductive parts, thus maintaining reliability while improving safety and ease of operation
Solution Approach 2:
The connector is designed to be self-contained and self-securing. The housing includes integrated crimping structures and positioning features that automatically secure the conductor in place during installation without requiring separate tools or direct manual handling of conductive members. The connector performs its own securing function through its built-in mechanical features
2Ease of operation
If releasable barbed prongs and complementary slots are used, then connection and disconnection become easier, but device complexity increases
Solution Approach 1:
The connector is divided into distinct functional segments: the housing structure, the barbed prong elements, the complementary slots, and the contact members. This segmentation allows each component to perform its specific function independently while working together as a system, making the overall device easier to manufacture and assemble despite the increased functionality
Solution Approach 2:
Instead of using traditional locking mechanisms that require complex assembly, the patent employs barbed prongs that engage with complementary slots in an inverted fashion - the bars insert into slots and the barbs prevent removal without deliberate action. This inverted approach simplifies the connection process while maintaining security
3Strength
If push-in spring type connectors are used, then conductor grip is improved, but manufacturing precision requirements increase
Solution Approach 1:
The spring-type connector utilizes elastic deformation and spring force as key parameters to achieve secure conductor grip. By designing the spring with appropriate material properties and geometric parameters (wire diameter, coil spacing, free length), the connector can accommodate normal manufacturing tolerances while still providing sufficient gripping force. The elastic nature of the spring allows it to conform to slight variations in conductor size and shape
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 efficient field installation of electrical connectors without direct contact with conductive members, ensuring reliable and moisture-resistant connections for photovoltaic power transmission.
Implementation Method 1
a push-in, spring type connector configured to insertably receive and non-releasably grip the bared end of a conductor
Implementation Method 2
gasket seals for moisture resistance
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electrical connector system and method for making same, for joining adjacent ends of electrical power conductors, including a female connector assembly and a male connector assembly. Each of the female and male connector assemblies is provided with push-in type, spring mechanism to facilitate the insertion of a bared end of an electrical conductor, into the respective female or male connector housing for secured engagement of the bared end of the electrical conductor, without the assembler having to make physical contact with any electrically conductive structures.