Electrical Wire Connector With Teeth And Silicone For Watertight Sealing
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Solution Overview
Problem
Existing electrical connectors, such as wire nut style connectors, apply excessive stress to copper wires and can lead to fraying or loose connections if not properly secured, resulting in electrical resistance points or loose connections.
Innovation Solution
An electrical wire connector with a cavity and teeth to secure partially sheathed wires, using a bolt to displace silicone and create a watertight compartment when tightened, ensuring a secure and waterproof connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire nut style connectors are used to tighten onto bare copper wires, then the connection is secured, but excessive stress is applied to the copper causing fraying and potential loose connections
Solution Approach 1:
The patent introduces an intermediary mechanism (the cavity with silicone and teeth structure) between the connector and the wire. Instead of directly tightening onto the wire like traditional wire nuts, the connector secures the wire insulation within the cavity, using the silicone and teeth to prevent movement without concentrating stress on the copper conductor itself.
Solution Approach 2:
The connector is divided into functional segments: a cavity for receiving the wire connection, silicone material for sealing and cushioning, and teeth for gripping the insulation. This segmentation allows each component to perform its specific function without the entire structure applying concentrated force to the wire, distributing the securing action across multiple elements.
2Ease of manufacture
If traditional connectors are used without proper sealing, then assembly is simple, but electrical resistance points or loose connections can occur
Solution Approach 1:
The silicone within the cavity performs multiple functions automatically: it seals the connection area, cushions the wire insulation, and prevents movement. When the connector is assembled, the silicone self-adjusts to fill gaps and secure the wire connection, providing both sealing and mechanical retention without requiring additional steps or components.
3Reliability
If a deep cavity with silicone is used to ensure watertight connection, then connection security is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated cavity structure: wire reception, connection securing, sealing, and protection. The silicone is integrated directly into the cavity rather than being a separate component, and the teeth are formed as part of the cavity structure. This consolidation achieves watertight connections without proportionally increasing overall device complexity.
Data Source
AI summary
An electrical wire connector is configured to secure at least two electrical wires partially covered in sheaths. The electrical wire connector includes a body further comprising a cavity with a port configured to receive the at least two electrical wires twisted to form an electrical wire connection. Teeth are on a bottom surface of the electrical wire connection; wherein the teeth obstruct movement of the sheaths. A bolt, is detachably coupled to the body. Silicone fills the cavity with the at least two electrical wires. Tightening the bolt onto the sheaths into the teeth displaces some of the silicone from the cavity and creates a watertight compartment for the at least two electrical wires.