Stranded Wire Connection Using Ratcheting Crimping and Gel Sealing
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Solution Overview
Problem
Existing methods for attaching stranded electrical wires fail to create secure, waterproof connections that withstand stress forces and the heating and cooling effects caused by energizing and de-energizing cycles, leading to premature failure.
Innovation Solution
A method using a ratcheting crimping tool to compress stranded wires into a metallic barrel, followed by insertion into a dielectric gel-filled connector tube with a snap cover, eliminating spaces between strands and providing a permanent, waterproof connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual twisting or compression methods are used to connect stranded wires, then the connection process is simple and quick, but the connection is not secure and will fail due to expansion and contraction during energizing cycles
Solution Approach 1:
The wire strands are pre-twisted together before insertion into the barrel, creating a unified structure that resists separation during crimping and eliminates spaces that would allow expansion and contraction
Solution Approach 2:
The crimping process applies progressive compression force to the barrel, transforming it from a loose fit around the wires to a tightly compressed connection that eliminates all spaces between strands and barrel interior
2Ease of operation
If inconsistent tightening and crimping techniques are used, then the connection process is easier and faster, but the heating and cooling effect during operation destroys the wires in a short period
Solution Approach 1:
The ratcheting crimping tool automatically maintains consistent compression force throughout the crimping process, eliminating the need for operator skill or judgment to achieve proper tightness. The tool self-regulates the compression to eliminate all spaces uniformly
Solution Approach 2:
The ratcheting mechanism provides tactile feedback through distinct clicking sensations, allowing the operator to know when the barrel is fully compressed and when to stop, ensuring consistent results without requiring experience or judgment
3Force
If spaces remain between wire strands after connection, then the connection process requires less compression force, but the spaces allow expansion and contraction that deteriorates the wires over time
Solution Approach 1:
Twisting the strands together before crimping creates a compact, space-free structure that eliminates voids where expansion and contraction could occur, ensuring long-term stability
Solution Approach 2:
The controlled compression process progressively reduces the barrel volume, forcing elimination of all spaces between strands and barrel interior through uniform radial compression
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 creates a secure, waterproof connection that prevents expansion and contraction, ensuring longevity and reliability of the electrical connection, suitable for low-voltage applications including LED lamps and lighting fixtures.
Implementation Method 1
applying ratcheting pressure to the barrel member to compress the barrel member over each end of the stranded wires
Implementation Method 2
inserted into a dielectric gel filled connector tube
Data Source
AI summary
A method of stranded electrical wire connection involves stripping the insulation of the ends of stranded wire and inserting a compression member over the ends of the wire, and applying constant, irreversible ratcheting pressure to the compression member to compress the compression member over each end of the stranded wires. The compressed stranded wires and compression member are then inserted into a tube connector which is filled with a dielectric gel. The tube connector has a cover with a snap connector member. When the compressed wire connection is fully encased within the connector tube, the cover is closed over the top of the connector tube and snapped and locked shut, to ensure for a waterproof electrical connection.