Wire-to-Wire Connector with Integrated Actuators
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Solution Overview
Problem
Existing wire-to-wire connectors often require complex assembly processes and occupy significant space, making them impractical for applications where secure but temporary connections are needed.
Innovation Solution
A simple, in-line wire-to-wire connector with a box-shaped body and C-shaped contact elements, featuring actuators that allow easy insertion and secure connection of coaxially aligned wires without the need for tooling, and optional redundant contact elements for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional press fit connectors with blade and receptacle terminals are used, then secure electrical connection is achieved, but numerous processing and assembly steps are required
Solution Approach 1:
The patent combines the blade terminal, receptacle terminal, and housing into a single integrated connector body. The insulative body houses both male and female contact elements internally, eliminating the need for separate assembly steps to attach terminals to housings. This merging of components directly reduces assembly complexity while maintaining secure electrical connection.
2Reliability
If traditional connectors with separate housings are used, then reliable connection is achieved, but the connectors occupy relatively large space
Solution Approach 1:
The patent integrates both the insulative housing and contact terminals into a single compact body structure. The male and female contact elements are housed within the same insulative body, allowing the connector to occupy minimal space while maintaining reliable electrical connection. This eliminates the need for separate housing components that会增加 overall connector volume.
3Reliability
If permanent splice connectors are used, then secure connection is achieved, but the connections cannot be released or reconfigured
Solution Approach 1:
The patent employs spring-loaded contact elements that can dynamically transition between engaged and disengaged states. The resilient nature of the spring contacts allows the connector to maintain secure connection during use while enabling easy release and reconfiguration. This dynamic mechanism provides both reliability and adaptability, allowing the connection to be permanent during operation but easily modifiable when needed.
4Ease of manufacture
If in-line IDC splice connectors with caps are used, then wires can be spliced together, but tooling is required for operation
Solution Approach 1:
The patent designs the connector with self-contained features that eliminate the need for external tools. The spring-loaded contact elements automatically engage and secure the wire conductors upon insertion, and the same mechanism enables easy release without requiring crimping tools, strippers, or other specialized equipment. The connector performs all functions—wire insertion, electrical contact, and release—through its own integrated mechanisms.
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 connector provides a secure, space-efficient, and easy-to-use solution for connecting multiple wires, allowing for quick insertion and withdrawal without complex assembly, while ensuring reliable electrical contact through biased contact tabs and redundant paths.
Implementation Method 1
A first contact element is disposed in the connector position coaxial with the wire insertion openings... The first contact element generally has opposite end portions with a respective contact tab configured thereon, the contact tabs biased to a closed position across the respective wire insertion opening
Implementation Method 2
The actuators are depressible (manually or with a tool) to move the contact tabs to an open position for insertion of a conductive core of a wire into the wire insertion opening beyond the contact tab
Implementation Method 3
upon release and return of the actuators, the contact tabs are biased against the conductive cores of the wires and the first contact element defines a conductive bridge between the terminal ends of the coaxially aligned wires
Data Source
AI summary
A wire-to-wire electrical connector includes an insulative body member and an internal connector position. A wire insertion opening is defined in each end wall of the body member at the connector position. A first contact element is disposed in the connector position coaxial with the wire insertion openings and includes opposite end portions with a respective contact tab configured thereon. The contact tabs are biased to a closed position across the respective wire insertion opening. An actuator is configured with each wire insertion opening. The actuators are movably displaceable through an opening in a wall of the body member and include an engagement end in contact with a respective end portion of the first contact element. The actuators are manually depressible to move the contact tabs to an open position for insertion of a conductive core of a wire into the wire insertion opening beyond the contact tab, whereby upon release and return of the actuators, the contact tabs are biased against the conductive cores of opposite wires.