Splice Assembly Brush for Conductor Surface Cleaning
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Solution Overview
Problem
Existing wire splicing connectors face inefficiencies due to the need for manual cleaning of oxidized or dirty conductor surfaces, which is time-consuming and often not done effectively, affecting the reliability of electrical connections.
Innovation Solution
A brush assembly integrated with the wire splice connector, featuring a housing with a cavity and bore, and a brush member with bristles that extend inwardly, is designed to engage and clean the conductor as it is inserted, ensuring effective contact without requiring a dedicated cleaning tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning of conductor surfaces is performed using a dedicated tool, then cleaning effectiveness is improved, but operation time and process complexity increase
Solution Approach 1:
The brush member is integrated directly into the wire splice connector body, combining the cleaning function with the connector function. This eliminates the need for a separate dedicated cleaning tool and reduces operation time while maintaining cleaning effectiveness through the bristle structure that contacts the conductor during insertion.
Solution Approach 2:
The brush member is positioned within the connector body to perform cleaning action automatically as the conductor is inserted. The cleaning action occurs preliminarily during the insertion process itself, before the connector fully engages, eliminating the need for a separate post-insertion cleaning step.
2Reliability
If manual cleaning of conductor surfaces is performed, then connection quality is improved, but process complexity increases
Solution Approach 1:
The cleaning function is merged with the connector body by integrating the brush member directly into the housing. This single integrated component performs both connection and cleaning functions, simplifying the overall process while maintaining connection quality through effective conductor surface cleaning.
3Reliability
If a dedicated cleaning tool is used, then cleaning thoroughness is improved, but ease of operation deteriorates
Solution Approach 1:
The brush member is integrated into the connector body, combining cleaning and connecting operations into a single action. Users simply insert the conductor into the connector, and the brush automatically cleans the surface during insertion, maintaining thoroughness while dramatically improving ease of operation.
Solution Approach 2:
The brush member automatically performs cleaning action as the conductor passes through it during insertion. The system serves itself by integrating the cleaning mechanism directly into the insertion path, eliminating the need for separate manual cleaning operations.
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 brush assembly effectively cleans the conductor surfaces during insertion, enhancing the reliability and speed of electrical connections by integrating cleaning into the splicing process, reducing the need for additional cleaning steps and improving connection quality.
Implementation Method 1
The brush member includes a plurality of bristles extending inwardly toward the housing axis... The brush assembly effectively cleans the conductor surfaces during insertion
Implementation Method 2
The conductors that are connected by wire splice connectors often have oxidized or dirty outer surfaces. To ensure an effective electrical connection, the conductor must be cleaned
Data Source
AI summary
A splice assembly for engaging a conductor includes a brush configured to engage the conductor. The brush includes a housing having a first portion and a second portion. The housing defines a housing axis extending between the first portion and the second portion. The first portion defines a cavity having an open end. The second portion defines a bore. A diameter of the cavity is larger than a diameter of the bore. The cavity and the bore are configured to receive the conductor therethrough. The brush further includes a brush member secured within the cavity and positioned proximate the open end.