Twist-on Wire Connector With Segmented Driving Features
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Solution Overview
Problem
Existing twist-on wire connectors and application tools lack efficient mechanisms for secure and versatile attachment to electrical conductors, particularly in accommodating different sizes and requiring manual or tool-assisted methods that are not always effective.
Innovation Solution
The design incorporates complimentary driving features with engagement and slip surfaces on both the twist-on wire connector and the application tool, allowing the tool to move independently in one direction and engage the connector in the opposite direction for secure attachment, enabling easy application and adjustment to various conductor sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If diametrically opposed wings are provided to the housing shell to provide leverage for twisting, then the connector can be manually attached, but the connector cannot be easily adjusted or removed
Solution Approach 1:
The housing shell is divided into two functional zones: gripping features (such as wings or ribs) that engage with the application tool, and a smooth cylindrical surface that allows independent rotation of the connector relative to the tool during installation. This segmentation enables the tool to apply torque through the gripping features while the smooth surface permits the connector to rotate freely, facilitating both manual attachment and subsequent adjustment or removal operations
2Productivity
If the tool and connector are rigidly connected during rotation, then the connector can be applied to conductors, but the tool cannot be independently positioned or adjusted
Solution Approach 1:
The connection between the application tool and connector transitions from rigid to dynamic during the installation process. The smooth cylindrical surface allows the connector to rotate independently relative to the tool, creating a dynamic relationship that enables the tool to be positioned and oriented freely before engagement, while still transmitting rotational force effectively during the application operation
3Adaptability or versatility
If the connector housing is entirely smooth, then the connector can rotate freely, but the application tool cannot grip or apply torque effectively
Solution Approach 1:
The housing shell exhibits local quality variation with distinct functional zones: localized gripping features (wings, ribs, or other engagement structures) provide high friction and mechanical interlocking for effective torque transmission from the tool, while the remaining smooth cylindrical surface provides low friction for free rotation. This spatial differentiation of surface properties allows simultaneous achievement of secure tool engagement and rotation freedom
Data Source
AI summary
A twist-on wire connector is releasably engageable with a tool. The connector and the tool are provided with complimentary driving features which allow the tool to be moved independent of and relative to the connector when the tool is moved in one rotational direction and which place the tool and connector into driving engagement when the tool is moved in the opposite rotational direction such that the connector is moved with the tool to apply the connector onto a plurality of electrical conductors. The complimentary driving features are provided to the tool and the connector by providing to each of the tool and the connector one or more engagement surfaces positioned adjacent to a slipping surface.