Wire Retention Connector with Insulation Channeling
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Solution Overview
Problem
Existing wire connectors are prone to unintentional disengagement due to pulling and twisting, leading to electrical disconnection issues, especially in applications where crimping tools are not available.
Innovation Solution
A wire retaining system that uses a connector body with a wire retention member and a blade arranged perpendicular to the axis, forming a channel in the insulation to resist rotation and disconnection, allowing poke-in connections without the need for crimping or special tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a poke-in connector is used to simplify wire connection without crimping tools, then ease of operation is improved, but reliability deteriorates due to unintentional disengagement from pulling and twisting
Solution Approach 1:
The wire retention mechanism is segmented into multiple independent elements: a wire retention member with retention surfaces, and multiple blades positioned at different locations. Each blade engages the insulation at different points along the wire, distributing the retention force and preventing disengagement through rotation or pulling.
Solution Approach 2:
The retention mechanism transitions from simple linear engagement to three-dimensional engagement by positioning blades at different angular positions around the wire and creating channels at different depths in the insulation. This multi-dimensional engagement prevents rotation and pulling in multiple directions simultaneously.
2Reliability
If wire retention members with engagement surfaces are used to hold wires, then wire retention is improved, but device complexity increases due to additional components
Solution Approach 1:
The wire retention member and blades are merged into a single integrated component formed from the connector body itself. The retention surfaces and blades are created as unified structural features during connector manufacturing, eliminating the need for separate wire retention components and reducing assembly steps.
Solution Approach 2:
The connector body serves multiple functions: it provides the structural housing, creates the engagement opening, forms the wire retention member with retention surfaces, and positions the blades. This multi-functionality reduces the total number of components needed while maintaining reliable wire retention.
3Reliability
If blades form channels in insulation to resist rotation, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The blades are pre-positioned and pre-formed as integral features of the connector body during manufacturing. The channels in the insulation are created during the normal wire insertion process itself, rather than requiring separate precision positioning steps. This preliminary action ensures consistent blade-to-insulation engagement without requiring high-precision post-manufacturing adjustments.
Solution Approach 2:
The wire insertion process itself serves to create the engagement channels in the insulation by forcing the pre-positioned blades to cut or deform the insulation material. The system uses the insertion force to automatically form the retention channels, eliminating the need for separate channel-forming operations and reducing manufacturing precision requirements.
Data Source
AI summary
A wire retaining connector, connector system and method of connecting wires to connectors to reduce or eliminate unintentional wire disconnection from wire connectors, including disconnection of poke-in connectors. The connectors and connector systems include a connector body having at least one opening configured to receive a wire, the wire including a partially exposed conductor and insulation. The connector body further includes a wire retention member having at least one surface onto which a wire may be engaged. A cutting projection may also be provided on the wire connector to form a channel in the insulation during insertion of the wire into the connector. The wire retention member or the projection provides sufficient retention of the wire to resist disconnection of the wire from the connector body. A method for connecting wires to the connectors is also provided.