Conductive Spiral Electrical Connector for Wire Gripping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical connectors, such as crimp connectors and threaded wire connectors, often fail due to inadequate pressure during crimping or threading, leading to unreliable connections with small surface areas, and it is difficult to visually inspect the quality of the connection.
Innovation Solution
A conductive spiral connector that can be manually tightened around stripped wires to create a secure electrical connection, with a larger diameter configuration allowing easy insertion and then reducing to a smaller diameter for substantial force exertion, ensuring a reliable and permanent connection with a large contact surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional crimp connectors are used, then electrical connection is achieved, but the connection quality varies greatly depending on crimping skill and pressure
Solution Approach 1:
The spiral connector is designed to automatically tighten around the wire bundle when twisted, creating its own securing force without requiring external crimping tools or operator skill. The spiral's geometry converts rotational motion into radial compression, self-generating the necessary connection force.
Solution Approach 2:
The spiral connector changes its diameter parameter from a larger initial state (for easy wire insertion) to a smaller final state (for secure wire gripping). This parameter transformation is achieved through manual twisting, allowing the same component to serve multiple functional states.
2Reliability
If crimping is used to secure wires, then connection is formed, but the contact surface area is small and inspection is difficult
Solution Approach 1:
The connector transitions from a two-dimensional crimping action to a three-dimensional spiral wrapping around the wire bundle. This dimensional change creates extensive circumferential contact surface area and allows visual verification of the wrapping integrity.
Solution Approach 2:
The spiral connector uses curved, helical geometry to wrap around the wire bundle, creating continuous circumferential contact rather than point or line contact. This curvature provides both mechanical security and visual indication of proper installation.
3Strength
If the connector diameter is small for secure gripping, then connection strength is high, but wire insertion becomes difficult
Solution Approach 1:
The spiral connector is designed with dynamic adjustability, allowing its diameter to change from a larger state during insertion to a smaller state during securing. The user twists the spiral to dynamically transform its geometry, optimizing for insertion first, then for gripping.
Solution Approach 2:
The connector is initially provided in a larger diameter configuration that facilitates easy wire bundle insertion. Only after insertion is complete does the user tighten the spiral to the smaller gripping configuration, separating the insertion and securing actions.
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 conductive spiral connector provides a reliable, secure, and easy-to-use electrical connection with a large contact surface area, eliminating the need for crimping tools and ensuring consistent connection quality without visual inspection difficulties.
Implementation Method 1
the conductive spiral is manually tightened into a smaller-diameter configuration that creates electrical contact between said conductive spiral and the stripped wire(s)
Implementation Method 2
after said insertion, the conductive spiral is manually tightened into a smaller-diameter configuration that creates electrical contact
Data Source
AI summary
An electrical connector forms electrical contact by tightening a movable, electrically-conductive spiral around un-insulated wire(s). The spiral coils around the wire(s) multiple times and tightens on the wire(s) when either one or the other end, or both ends, of the spiral is/are rotated relative to the other. One region of the spiral is preferably fixed to an insulating housing or otherwise retained from movement in the housing, while another region of the spiral is rotated and latched to retain the spiral in the tightened condition. Multiple spirals may be provided in one connector, including spirals that tighten around separate wires at opposite ends/side of the connector. Modular connectors that include spiral(s) may be assembled in multiple combinations.