Solderless Wire Connector Grip and Insulation Overmold
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Solution Overview
Problem
Existing wire connectors lack effective grip and insulation features, leading to potential slippage and risks of electrical contact due to inadequate gripping surfaces and insufficient insulation, especially when exposed to moisture or contaminants.
Innovation Solution
A wire connector design featuring raised ribs with flexible rib caps, an annular base with textured surfaces, leverage wings, and a flexible wire skirt, all overmolded with materials like rubber or silicone, providing enhanced grip and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional wire connectors use smooth plastic surfaces, then manufacturing is simple, but user grip is insufficient leading to slippage
Solution Approach 1:
The patent applies local quality by adding textured surfaces and raised ribs only to specific gripping areas of the connector外壳, while other areas maintain smooth surfaces for manufacturing efficiency. This localized texturing provides enhanced friction and grip exactly where the user's fingers contact the connector, without complicating the entire structure.
Solution Approach 2:
The connector surface is segmented into multiple functional zones: smooth areas for manufacturing simplicity, raised ribs for structural reinforcement and grip, and textured regions for enhanced friction. This segmentation allows each zone to serve its specific purpose while collectively solving the grip problem without excessive complexity.
2Reliability
If wire connectors use standard plastic material, then manufacturing cost is low, but insulation performance is insufficient especially when exposed to moisture
Solution Approach 1:
The patent employs composite materials by combining a rigid plastic base material with an overmolded elastomeric material. The plastic provides structural integrity and basic insulation, while the elastomeric overmold adds moisture resistance and enhanced insulating properties. This composite approach improves reliability without making the manufacturing process excessively complex, as overmolding is a established manufacturing technique.
Solution Approach 2:
The patent changes the material parameters by selecting elastomeric materials with specific properties (high dielectric strength, moisture resistance) for the overmold layer. This parameter change in material selection enhances insulation performance while the overmolding process itself remains a standard manufacturing method, balancing reliability improvement with manufacturing feasibility.
3Object-affected harmful factors
If wire connectors lack flexible insulation layers, then device complexity is low, but protection against electrical contact is insufficient
Solution Approach 1:
The patent implements flexible shells by adding an elastomeric overmold layer that conformally coats the rigid plastic connector. This flexible layer provides continuous electrical insulation and protection against contact, while its flexibility allows it to accommodate the connector's shape and twisting motion during installation without cracking or compromising protection.
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 design enhances user grip and reduces slippage, improves insulation, and mitigates risks of electrical contact, ensuring secure and reliable wire connections.
Implementation Method 1
enhanced grip and reduces slippage
Implementation Method 2
overmolded with materials like rubber or silicone
Implementation Method 3
annular base with textured surfaces, providing enhanced grip
Implementation Method 4
improves insulation, and mitigates risks of electrical contact
Data Source
AI summary
A wire connector includes an outer shell with a wire cavity therein, a plurality of raised ribs on the surface of the outer shell, each of the raised ribs having a rib cap overmolded on to a top surface with a gap between the rib cap corresponding to each of the raised ribs and the rib cap corresponding to each adjacent raised rib. Two leverage wings may extend outward from the outer shell on opposing sides. A wire skirt may be overmolded around the open end of the outer shell, the wire skirt and plurality of rib caps formed of a material more flexible than a material used to form the outer shell. A wing rib may be overmolded onto a portion of the first side of each leverage wing. A base of the wire connector may include texture in the form of raised grip bumps of various shapes.