Tool-Free Electrical Connector With Self-Actuating Jaw
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connectors require substantial tensile force to form a reliable mechanical and electrical coupling with conductors, which can be cumbersome and inefficient, especially in high-voltage applications where additional tools are often needed to actuate the connection.
Innovation Solution
The development of an electrical connector featuring a tubular housing with jaw members and a spring mechanism that automatically clamps conductors upon insertion, utilizing a sealant containment membrane to ensure environmental protection and secure contact without the need for external tension or tools, compliant with ANSI standards for zero-tension connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If substantial tensile force is applied to form a reliable mechanical and electrical coupling, then connection reliability is improved, but operation complexity and tool requirements increase
Solution Approach 1:
The connector utilizes the conductor's own tensile force to drive the wedge member and form the connection, eliminating the need for external tensioning tools. The system serves itself by using the installed conductor to create the clamping action through its inherent tension
Solution Approach 2:
Instead of applying external tension to create the connection, the invention inverts the approach by using the conductor's existing tension to drive the connection formation. The wedge member is pushed by the conductor itself rather than by an external actuator
2Reliability
If substantial tensile force is applied to form a reliable mechanical and electrical coupling, then connection reliability is improved, but additional tools are required
Solution Approach 1:
The connector is designed to use the conductor's own tension to drive the wedge member, eliminating the need for external tensioning tools. The system is self-actuating and requires no additional equipment beyond the conductor itself
Solution Approach 2:
The invention extracts the tensioning function from external tools and transfers it to the conductor itself. The conductor's inherent tension is harnessed to perform the work that would otherwise require separate tensioning equipment
3Object-affected harmful factors
If sealant is applied to protect electrical contact engagement, then corrosion protection is improved, but connector complexity increases
Solution Approach 1:
A flexible sealant containment membrane is used to hold and apply sealant within the connector. This thin film structure provides effective corrosion protection while adding minimal complexity to the overall connector design
Solution Approach 2:
The sealant acts as an intermediary substance between the electrical contact surfaces, providing corrosion protection without requiring complex sealing mechanisms. The sealant fills and protects the interface where environmental contaminants would otherwise cause degradation
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 enables reliable, tool-free mechanical and electrical coupling of conductors with enhanced corrosion protection and compliance with ANSI standards, ensuring secure connections without the need for applied tension, thus simplifying high-voltage applications and improving connector reliability.
Implementation Method 1
a spring provided to force the at least one jaw member to clamp the conductor within the interior cavity
Implementation Method 2
a sealant contained in the sealant chamber in the interior cavity to environmentally protect an electrical contact engagement between the conductor and the electrical connector
Data Source
AI summary
An electrical connector for forming a mechanical and electrical coupling with an electrical conductor includes a tubular housing, at least one jaw member, a sealant containment membrane, and a sealant. The tubular housing has a connector axis. The housing defines a conductor receiving opening and an interior cavity each configured to receive the conductor along the connector axis. The at least one jaw member is configured to clamp the conductor within the interior cavity. The sealant containment membrane is disposed in the interior cavity and defines a sealant chamber. The sealant is contained in the sealant chamber in the interior cavity to environmentally protect an electrical contact engagement between the conductor and the electrical connector when the conductor is clamped in the interior cavity by the at least one jaw member.