Universal Electrical Connector with Interchangeable Jaw Segments
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Solution Overview
Problem
Conventional electrical connectors for core and stranded (C-S) cables require a large and expensive inventory of different sizes to accommodate various cable diameters, and they can cause excessive compression of the cable core during installation, which is labor-intensive and potentially damaging.
Innovation Solution
An electrical connector with a crimpable tubular portion and partially cylindrical jaw segments of varying inner diameters, facilitated by a nose guide with a flange and circumferentially extending rib, allows for secure retention of cable cores of different diameters using a universal body with interchangeable jaw segments, reducing inventory needs and preventing core compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional electrical connectors are manufactured with various inside diameters to accommodate different cable diameters, then all cable sizes can be connected, but a large and expensive inventory of connectors is required
Solution Approach 1:
The electrical connector is divided into a body and interchangeable jaw segments. The jaw segments are removable and can be replaced based on the cable diameter being connected. This segmentation allows a single connector body to accommodate multiple cable sizes by simply changing the jaw segments, eliminating the need to maintain an inventory of multiple complete connector sizes.
Solution Approach 2:
The connector body is designed as a universal component that can work with different jaw segments to accommodate various cable diameters. The body includes a bore and positioning features that are compatible with multiple jaw segment types, making the body itself multi-functional and applicable to different cable sizes without requiring multiple specialized bodies.
2Reliability
If screw-on inner sleeves are used to prevent excessive compression on composite core, then core damage is prevented, but installation becomes labor intensive
Solution Approach 1:
The inner sleeve function is extracted and integrated directly into the jaw segments. The jaw segments themselves provide the protective function previously requiring a separate inner sleeve component. This eliminates the need for the additional screw-on inner sleeve step during installation, reducing labor intensity while maintaining the core protection function.
Solution Approach 2:
The jaw segments are designed to automatically provide the protective function for the composite core through their own structural design. The jaw segments include features such as tapered surfaces and controlled crimping characteristics that prevent excessive compression of the core, making the system self-sufficient without requiring additional protective components or complex installation procedures.
3Quantity of substance
If a single electrical connector body is used with interchangeable jaw segments, then inventory costs are reduced, but the connector must accommodate varying jaw segment thicknesses
Solution Approach 1:
The jaw segments are nested within the bore of the connector body during installation. The bore is designed to accommodate the nested arrangement of multiple jaw segments around the cable core. This nesting approach allows the body to universally receive different jaw segment configurations and thicknesses while maintaining proper positioning and function.
Solution Approach 2:
The connector design allows for dynamic adaptation to different jaw segment thicknesses through features such as the nose guide with adjustable positioning and the bore design that can accommodate varying jaw segment dimensions. The system is designed to be flexible in its acceptance of different jaw segment configurations, allowing the same body to work with multiple jaw segment types having different thicknesses.
Data Source
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AI summary
An electrical connector includes a body having a crimpable tubular portion. A bore is formed in the tubular portion. A plurality of partially cylindrical jaw segments are disposable in the bore. The plurality of jaw segments form an opening for receiving a cable. A nose guide is disposable in the bore to facilitate retaining the plurality of jaw segments in the body.