Wire Terminating Post With Dual Apertures For Gauge Transition
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Solution Overview
Problem
The transition from small gauge wires to larger gauge wires in electronic devices is problematic, leading to damage and rendering expensive components unusable due to inadequate isolation during handling and assembly.
Innovation Solution
A wire terminating post with a conductive material design featuring a first end for interlocking with electrical components, a second end with apertures of different diameters, and notch portions for secure wire placement, allowing for robust electrical and mechanical connections resistant to mechanical loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If small gauge wires are directly joined to larger gauge wires, then electrical connection is achieved, but the small wires are not adequately isolated and are susceptible to damage during handling and assembly
Solution Approach 1:
The wire joining structure is segmented into distinct sections: a header portion, a body portion with apertures, and separate wire receiving areas. This segmentation isolates the fragile small gauge wires within the protected body portion, separating them from direct exposure to external mechanical forces while maintaining electrical connectivity.
Solution Approach 2:
The wire terminating post acts as an intermediary component between the small gauge wires and the larger gauge wires. It provides a protected transition zone where small wires can be securely held and connected to larger wires without direct exposure to handling and assembly loads, thus mediating the mechanical stress between different wire gauges.
2Ease of operation
If a simple wire connection method is used, then assembly is quick and easy, but the connection does not provide adequate protection against mechanical loads
Solution Approach 1:
The wire terminating post is pre-formed with integrated apertures, notches, and structural features that facilitate wire insertion and securing. This preliminary preparation of the connection structure allows for quick wire placement while ensuring robust mechanical and electrical connections without requiring complex assembly steps.
Solution Approach 2:
The wire terminating post is formed from conductive material that provides both electrical conductivity and mechanical strength. The composite structure integrates electrical connection pathways with mechanical support features, allowing a single component to fulfill both electrical and structural functions while resisting mechanical loads.
3Device complexity
If small gauge wires are exposed during handling, then wire routing is simple, but the wires are susceptible to damage rendering expensive components unusable
Solution Approach 1:
The small gauge wires are nested within the protected body portion of the wire terminating post, which houses them in a secure environment. This nesting arrangement protects the fragile wires from external damage while maintaining simple wire routing paths, allowing wires to be guided through predefined apertures and notches without exposing them to handling risks.
Data Source
AI summary
A wire terminating post formed from a conductive material includes a first end structured to interlock with a portion of an electrical component and a second end disposed opposite the first end. The second end includes a first aperture defined therethrough, the first aperture having a first diameter, and a second aperture defined therethrough, the second aperture have a second diameter less than the first diameter.