Wire Piercing Connector With Channel Disk For Secure Wire Alignment
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Solution Overview
Problem
Existing multi-circuit electrical connectors lack a secure means to retain and align multiple leads, leading to misalignment and potential disconnection issues due to the lack of secure wire retention and alignment before assembly.
Innovation Solution
A multi-circuit electrical connector featuring a disk with radially arranged channels and conductive protrusions, where wires are inserted through the channels and partially out, then the disk is inserted into a cavity with conductive protrusions that pierce the wires to establish connections, ensuring secure retention and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wires are laid in exterior slots prior to assembly, then wire insertion is simplified, but wires are not held securely and may become misaligned or make contact with one another
Solution Approach 1:
The patent applies preliminary action by forming channels in the connector body that guide wires into proper positions before the final compression connection is made. The channels pre-position the wires securely, preventing misalignment and contact with other wires, while still allowing easy insertion. This resolves the contradiction by preparing the wire paths in advance without compromising security.
Solution Approach 2:
The channels act as an intermediary structure between the exterior slots and the final compression contact point. They provide a controlled path that secures the wires during assembly, ensuring proper alignment and preventing unwanted contact, thus bridging the gap between easy insertion and secure retention.
2Reliability
If a compression member compresses leads into piercing engagement with barbs, then electrical connection is established, but the structure becomes complex
Solution Approach 1:
The patent merges the functions of wire guidance, retention, and electrical connection into a single integrated structure. The channels serve both as guides for wire insertion and as structures that facilitate the compression and piercing connection. This consolidation reduces the number of separate components and simplifies the overall connector structure while maintaining reliable electrical connections.
Solution Approach 2:
The channels perform multiple functions: they guide wire insertion, secure wire positioning, and facilitate the compression piercing connection. This multi-functionality eliminates the need for separate guidance structures and retention mechanisms, reducing device complexity while ensuring reliable electrical connections.
3Ease of manufacture
If wires are threaded through channels into recesses and contacted by shorting pin, then connection is made, but wires do not extend completely through and remain prone to falling out or becoming misaligned
Solution Approach 1:
The channels are formed to extend completely through the connector body, pre-establishing secure paths for the wires before assembly. This preliminary structuring ensures that wires remain securely positioned throughout the assembly process and do not fall out or become misaligned, while still allowing for easy manufacturing and assembly.
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 provides a reliable and secure method for establishing electrical connections for multiple circuits, minimizing the risk of misalignment and disconnection, while allowing for easy assembly and ensuring proper contact between wires and conductive protrusions.
Implementation Method 1
at least one of the conductive protrusions extends into the second opening of the channel and at least partially pierces the wire to establish an electrical connection
Data Source
AI summary
A wire piercing connector assembly, including a body including a cavity having two or more conductive protrusions, a disk connectable into the cavity, the disk including a first side and a second side, a plurality of channels extending from the first side to the second side of the disk, wherein each channel includes two first openings on the first side and one second opening on the second side, two or more wires, each wire extending into one of the first openings of one of the channels and at least partially out another of the first openings of the channel, and wherein at least one of the conductive protrusions extends into the second opening of the channel and at least partially pierces the wire to establish an electrical connection between the at least one conductive protrusion and the wire.