Stranded Wire Connection Using Ratcheting Crimping and Adhesive Sealing
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Solution Overview
Problem
Existing methods for attaching stranded electrical wires result in insecure connections that fail due to stress forces, particularly exacerbated by heating and cooling cycles caused by current flow, leading to premature deterioration.
Innovation Solution
A method using a ratcheting crimping tool to compress stranded wires into a metallic barrel, followed by a shrink tube with adhesive, which is heated to create a permanent, waterproof connection, eliminating expansion and contraction between strands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual twisting or compression methods are used to connect stranded wires, then the connection process is simple and quick, but the connection security and reliability deteriorate under stress forces and thermal cycling
Solution Approach 1:
The wire strands are pre-twisted together before insertion into the barrel member, creating an initial mechanical interlock that prevents strand separation during crimping and service. This preliminary action ensures consistent strand alignment and eliminates the need for complex multi-step securing processes.
Solution Approach 2:
The connection assembly combines multiple materials with complementary properties: a metallic barrel member for structural strength and electrical conductivity, adhesive material for bonding strands to the barrel interior surface, and shrink tube with adhesive for external sealing and reinforcement. This composite structure addresses both simplicity and reliability requirements.
2Productivity
If inconsistent tightening and crimping techniques are used, then the manufacturing process is faster and more flexible, but the connection durability deteriorates due to expansion and contraction during energizing cycles
Solution Approach 1:
The crimping process transforms the barrel member from a rigid cylindrical shape to a compressed oval or flattened shape, reducing internal volume and creating radial compression forces that firmly grip the wire strands. This parameter change ensures consistent, repeatable connections regardless of operator technique or crimping speed.
Solution Approach 2:
Adhesive material is introduced as an intermediary substance between the wire strands and the barrel member interior surface. The adhesive fills gaps and bonds the strands to the barrel, preventing relative movement during thermal expansion and contraction cycles, thereby ensuring long-term durability.
3Device complexity
If spaces remain between wire strands after connection, then the crimping process is less aggressive and simpler, but the connection fails prematurely due to differential expansion and contraction
Solution Approach 1:
The adhesive material is applied in a manner that fills voids and spaces between wire strands and around the barrel member, creating a continuous bonded matrix. This eliminates air pockets and differential movement zones that would cause premature failure during thermal cycling.
Solution Approach 2:
The wire strands are pre-twisted into a compact, uniform bundle before insertion into the barrel member. This preliminary compaction minimizes initial spaces and ensures consistent strand distribution, allowing the crimping process to achieve reliable compression without requiring excessive force or complexity.
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 method produces a secure, permanent connection that withstands stress forces and environmental conditions, ensuring longevity and reliability of electrical connections in low-voltage applications.
Implementation Method 1
the shrink tube, with its layer of adhesive, is heated, thus substantially eliminating any space between the shrink tube and the permanent connection
Implementation Method 2
applying ratcheting pressure to the barrel member to compress the barrel member over each end of the stranded wires
Data Source
AI summary
A method of stranded electrical wire connection involves stripping the insulation off the ends of stranded wire, inserting a metallic barrel member over the ends of the wire, applying ratcheting pressure to the barrel member to compress the barrel member over each end of the stranded wires, and then applying constant, irreversible ratcheting pressure to the wire containing barrel to substantially eliminate the spaces between the strands and to form a permanent barrel to wire connection between the lengths of wire. A shrink tube with an inner layer of adhesive is positioned over the permanent connection and the shrink tube, with its layer of adhesive, is heated, thus substantially eliminating any space between the shrink tube and the permanent connection. Utilizing the method of the present invention results in a permanent, waterproof connection between the stranded wire which eliminates all expansion and contraction within the permanent connection during use.