Tracer Wire Connector with Insulation Piercing for Reliable Splices
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Solution Overview
Problem
Existing tracer wire connectors fail to effectively maintain an electrically conductive path between tracer wires, particularly when connecting multiple tracer wires, including through and dead-end types, leading to inefficiencies in locating non-conductive underground objects.
Innovation Solution
A tracer wire connector comprising a base and a cover with cradles and insulation piercing members that pierce through the insulating jacket of tracer wires to establish an electrically conductive path, using snap-fit assemblies for secure attachment and a water-resistant design to accommodate both through and dead-end tracer wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing tracer wire connectors are used to connect multiple tracer wires, then the connection of tracer wires is achieved, but the electrical conductive path is not reliably maintained
Solution Approach 1:
The connector is divided into distinct functional components: a body housing, multiple cradles for positioning different types of tracer wires, and individual insulation piercing members for each wire. This segmentation allows each component to be optimized for its specific function while maintaining overall reliability of the electrical connection.
Solution Approach 2:
Insulation piercing members are introduced as intermediary elements that penetrate the insulating jackets of tracer wires to establish direct electrical contact with the conductors. These piercing members act as mediators between the tracer wires and the connector's electrical pathway, ensuring reliable conductive connection while accommodating the insulating material.
2Adaptability or versatility
If a connector accommodates both through and dead-end tracer wires, then versatility is improved, but device complexity increases
Solution Approach 1:
The connector body is designed with multiple cradles that can accommodate different types of tracer wire configurations (through wires and dead-end wires) within a single device. This multi-functional design allows the same connector to handle various installation scenarios without requiring multiple specialized connectors, thereby improving versatility while controlling complexity through standardized components.
Solution Approach 2:
The cradles are designed to flexibly position tracer wires according to their specific configuration requirements. The dynamic adjustment capability of the cradles allows them to adapt to different wire types and installation methods, enabling the connector to handle both through and dead-end wires effectively without requiring fixed, specialized structures for each configuration.
3Reliability
If insulation piercing members are used to establish electrical contact, then electrical conductivity is improved, but risk of insulation damage increases
Solution Approach 1:
The insulation piercing members are specifically designed with localized piercing points that concentrate the electrical contact function at precise locations on the tracer wires. This local quality approach ensures that the piercing action is confined to small, controlled areas, minimizing damage to the surrounding insulation while establishing reliable electrical contact at the necessary points.
Solution Approach 2:
The insulation piercing members are designed to self-align and self-position during the connection process, automatically finding the correct location on the tracer wire insulation. This self-service mechanism reduces the risk of improper piercing and accidental damage to the insulation, as the system guides the piercing action to appropriate locations without requiring precise manual positioning.
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 connector ensures reliable electrical connection between tracer wires, enhancing the ability to locate non-conductive underground objects by maintaining a continuous electrical path, while providing a water-resistant seal and ease of installation.
Implementation Method 1
at least two insulation piercing members positioned within the cavity. The at least two insulation piercing members are electrically conductive and electrically coupled to each other
Data Source
AI summary
Trace wire connectors that include a cover that can be attached to a base and used to electrically interconnect two or more tracer wires without having to remove insulation from the tracer wires. The cover has multiple portals that permit one or more tracer wires to pass into an inner cavity of the cover. The base has multiple cradles on which tracer wires passing into the cavity can rest. The cover can be oriented relative to the base for use with a through tracer wire and a dead-end tracer wire, or for use with multiple dead-end tracer wires.