Tap Splice Electrical Connector with Wedging Interlock
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Solution Overview
Problem
Existing electrical connectors lack a reliable and modular solution for efficiently connecting and securing multiple conductors of varying sizes, often requiring complex assembly processes and additional locking mechanisms.
Innovation Solution
A tap or splice electrical connector comprising two one-piece members with hook-shaped sections and wedging interlock sections that interlock slidably, allowing for secure connection and clamping of conductors through angled wedging surfaces, enabling easy assembly and modular compatibility with different conductor sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used to connect conductors of varying sizes, then secure connection is achieved, but the assembly process becomes complex and additional locking mechanisms are required
Solution Approach 1:
The patent combines multiple functions into a single integrated connector body: the hook-shaped section for conductor retention, the wedging surface for mechanical interlocking, and the contact surface for electrical connection. This eliminates the need for separate locking mechanisms and simplifies the assembly process while maintaining secure connections for conductors of varying sizes
Solution Approach 2:
The connector is designed with universal applicability through its modular one-piece members that can accommodate different conductor sizes. The wedging surface and hook-shaped section work together to provide a universal solution that secures various conductor diameters without requiring different connector types or additional locking components
2Adaptability or versatility
If modular connector design is implemented for different conductor sizes, then versatility is improved, but connection security may be compromised
Solution Approach 1:
The connector utilizes parameter changes through its wedging surface geometry and hook-shaped section dimensions to accommodate different conductor sizes. By varying the physical parameters of the one-piece members while maintaining the fundamental interlocking mechanism, the connector achieves versatility across conductor sizes while preserving connection security through consistent mechanical interlocking principles
3Ease of operation
If simple assembly process is used, then ease of operation is improved, but reverse disconnection prevention may be insufficient
Solution Approach 1:
The connector employs asymmetric design in the wedging surface and hook-shaped section geometry. The wedging surface is angled to facilitate easy insertion and assembly, while the asymmetric interlocking features prevent reverse disconnection. This asymmetric configuration allows simple assembly in one direction while providing robust prevention against accidental disconnection in the reverse direction
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 solution provides a secure, modular, and efficient method for connecting conductors of various sizes, ensuring reliable electrical and mechanical contact while allowing for easy assembly and preventing reverse disconnection, thus enhancing the usability and versatility of electrical connectors.
Implementation Method 1
The first and second wedging interlock sections are shaped to move the first conductor contact surfaces of the first and second one-piece members towards each other when the first and second one-piece members are slid relative to each other
Data Source
AI summary
An electrical connector element including a first section and a second section. The first section has a general hook shape with a first conductor contact surface on an inward facing surface of the general hook shape. The second section is integrally formed with the first section. The second section has a first side forming a second conductor contact surface and an opposite second side. The second side faces the first conductor contact surface. The second side is sized and shaped to slidably interlock directly with another electrical connector element. The second side has at least one wedging surface.