Wire Connection Boot Assembly with Cinching Adapter
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Solution Overview
Problem
Existing wire and cable connectors are prone to loose connections due to improper installation or environmental stress, leading to safety and liability concerns, as they often require significant physical effort and can be costly and inefficient.
Innovation Solution
A cinching adapter system with a flexible cinching device that securely attaches wires to connectors, using a combination of insulating housings, clipping mechanisms, and removable fasteners to prevent wires from becoming loose or falling out, while being easy to use and manufacture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If twist-on wire connectors are used to join wires, then the connection process is simple and quick, but the wires may become loose or fall out due to improper installation or vibration
Solution Approach 1:
The connector is divided into two functional parts: a twist-on mechanism for easy installation and a separate locking mechanism with a locking member that engages with a recess to prevent wire loosening. This segmentation allows each part to specialize in its function while working together to solve the contradiction between ease of operation and connection stability.
Solution Approach 2:
The locking member is pre-positioned within the connector body, ready to engage with the wire insulation recess immediately upon installation. This preliminary positioning ensures that as soon as the wire is inserted and twisted, the locking mechanism is already in place to prevent loosening, eliminating the need for separate locking steps while maintaining reliability.
2Reliability
If crimp connectors are used to join wires, then the connection is secure, but significant physical effort and pressure are required for installation
Solution Approach 1:
The traditional crimping mechanical system that requires significant compression force is replaced with a twist-on engagement system combined with a locking mechanism. The locking member engages with the wire insulation through a simple twisting motion followed by automatic locking, eliminating the need for high-pressure crimping tools and manual force while maintaining secure connection stability.
3Reliability
If wire connectors require adequate rotation turns for proper installation, then the connection is secure, but the installation time increases and improper installation may still occur
Solution Approach 1:
The locking mechanism is designed to be self-actuating during the twisting process. As the user rotates the connector to secure the wire, the locking member automatically engages with the recess in the wire insulation at the appropriate point in the rotation. This self-service feature eliminates the need for the user to count or control the number of turns, reducing installation time while ensuring reliable locking occurs automatically when properly installed.
4Manufacturing precision
If tools are used to install wire connectors, then the installation precision is improved, but the cost increases and improper tool use can still cause wires to fall out
Solution Approach 1:
The locking member acts as an intermediary between the installer and the wire connection. Instead of requiring complex tools to ensure proper installation, the locking member provides a simple mechanical interface that works with both manual and automated installation methods. The locking mechanism ensures precision and reliability through its mechanical engagement design, eliminating the need for specialized installation tools while maintaining high installation precision.
Data Source
AI summary
The invention relates to a method of connecting electrical wires, conductors, or connections together by rotating the connector ends in an enclosure to tightly twist the wire ends together and also includes a clamping mechanism to prevent the wires from untwisting, becoming loose, or falling out of the enclosure. The present invention increases the holding ability of current rotating tools for electrical wires and connections.