Twist Lock Connector Assembly Tool-Free Sealing
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Solution Overview
Problem
Existing jumper cable plug connections require additional components and tools, such as screws and screwdrivers, which can damage the materials, allow water ingress, and complicate maintenance, especially in poor weather conditions.
Innovation Solution
A self-connecting jumper cable plug design where a cylindrical housing and electrical terminal holder are locked by twisting, using ridges and keyways or slots and protrusions to secure the components without external tools, and incorporating a seal to prevent moisture and debris entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a screw is used to secure the electrical terminal holder to the cylindrical housing, then the connection is secure, but the screw may damage or wear the material of the electrical terminal holder and cylindrical housing, and the hole through which the screw passes may allow water or debris to enter into the plug
Solution Approach 1:
The invention removes the screw and screwdriver components from the connection system entirely. Instead, it uses a twist-lock mechanism where the electrical terminal holder is inserted into the cylindrical housing and secured by rotating it to engage ridges with keyways, eliminating the need for holes that would allow water or debris entry.
Solution Approach 2:
The connection mechanism is self-securing through the twist-lock action. The operator simply inserts the terminal holder and rotates it; the ridges automatically engage with the keyways to secure the connection without requiring additional tools or components like screws.
2Strength
If a screw is used to secure the electrical terminal holder, then the connection is secure, but it requires a screw driver that the truck operator might not have, and adds time and difficulty in poor weather conditions
Solution Approach 1:
The twist-lock mechanism allows the electrical terminal holder to be secured and released using only the operator's hand. The ridges engage with the keyways through simple rotation, eliminating the need for external tools like screwdrivers and making the operation straightforward in any weather condition.
Solution Approach 2:
The invention extracts the screwdriver tool requirement from the connection process. By using the twist-lock mechanism with ridges and keyways, the system achieves secure connection without needing any external tools, improving ease of operation significantly.
3Strength
If a screw is used to secure the electrical terminal holder, then the connection is secure, but if the screw is dropped or lost, the plug may be unusable until a replacement screw is found
Solution Approach 1:
The invention removes the loose screw component from the system entirely. The twist-lock mechanism integrates the securing function into the structural design of the terminal holder and housing, eliminating the risk of losing small fastening components and ensuring the plug remains usable indefinitely.
Solution Approach 2:
The securing mechanism is merged into the structural components themselves. The ridges on the terminal holder and corresponding keyways in the housing are integral parts of these components, combining the fastening function with the structural design rather than using separate loose fasteners.
4Strength
If the electrical terminal holder is inserted into the cylindrical housing and secured with a screw, then the connection is secure, but it complicates maintenance and repair operations
Solution Approach 1:
The invention removes the screw and screwdriver from the maintenance process. The electrical terminal holder can be quickly released by rotating it to disengage the ridges from the keyways, allowing for rapid maintenance and repair operations without tool requirements.
Data Source
AI summary
An electrical connector including a substantially tubular housing for housing an electrical terminal, and a substantially cylindrical electrical terminal holder configured to be inserted into the housing, the electrical terminal holder being configured to hold the electrical terminal, wherein the electrical terminal holder and the housing are configured to be mechanically engaged by twisting the electrical terminal holder with respect to the housing after being inserted therein.