Twist-on Wire Connector Finger Cushion Design
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Solution Overview
Problem
Existing twist-on wire connectors are uncomfortable to use over extended periods, leading to finger fatigue and injury due to their small size and requirement for both compressive and tangential forces, and existing cushioned grips are ineffective when grasped in non-designated areas or under cramped conditions.
Innovation Solution
A finger-friendly twist-on wire connector with a rigid shell and integral finger cushion material, featuring circumferentially dispersed ribs, riblets, and lobes, which provide a balanced grasping region that reduces finger fatigue and injury by distributing pressure and allowing feedback through direct contact with the rigid shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hard plastic shell is used for the wire connector, then the connector can effectively transmit compressive and tangential forces to form electrical connections, but the hard surface becomes painful and slippery on the fingers during repeated use
Solution Approach 1:
The wire connector combines a hard plastic shell with a soft cushioning material (such as rubber or elastomer) to create a composite structure. The hard shell maintains structural integrity and force transmission capability, while the soft material provides finger comfort and grip during repeated use, resolving the contradiction between strength and ease of operation.
Solution Approach 2:
The connector applies different material properties to different regions: the hard plastic shell is used where structural strength and force transmission are needed, while soft cushioning material is applied specifically on the gripping surfaces where finger contact occurs. This localized differentiation allows each region to optimize its function without compromising the other.
2Volume of moving object
If the wire connector size is reduced for better maneuverability in tight spaces, then the connector can be used in cramped conditions, but the small size makes it difficult to grasp and apply sufficient torque
Solution Approach 1:
A flexible cushioning material is applied to the connector body, creating a soft outer layer that can be easily compressed and grasped by fingers. This flexible layer allows the user to maintain a secure grip on the small connector, overcoming the difficulty of grasping tiny objects while preserving the compact size needed for working in tight spaces.
3Ease of operation
If a cushioned grip is placed only on the designated gripping portions, then the connector provides comfort for standard grasping, but it offers no benefit when users grasp in non-designated areas or under cramped conditions
Solution Approach 1:
The cushioning material is designed to cover multiple regions of the connector including the closed end section, skirt, and grip-mounting portion, making the comfort feature universally applicable regardless of where the user chooses to grasp the connector. This multi-regional coverage ensures the connector remains comfortable and effective whether grasped in standard or non-standard positions, and whether sufficient space is available.
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 comfortable and fatigue-free operation by distributing finger pressure across both resilient and rigid surfaces, enhancing grip security and reducing discomfort while maintaining effective wire engagement.
Implementation Method 1
distributing pressure and allowing feedback through direct contact with the rigid shell
Data Source
AI summary
A finger friendly twist-on wire connector having a spiral coil and an open end rigid shell secured to the spiral coil with the rigid shell having an outer surface with a circumferential band and a closed end supporting a finger cushion material integral to at least a portion of the outer surface of the rigid shell with the finger cushion material including a plurality of circumferentially spaced elongated ribs resiliently deformable in response to radially and tangential finger forces thereon as rotational finger forces are transmitted to the rigid shell through the finger cushion material to thereby inhibit finger fatigue and finger injury while allowing the user to maintain a feel of the wire engagement within the wire connector.