Axial Nested Cable Connector Structure for Miniaturization
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Solution Overview
Problem
Existing high-voltage cable connection systems are bulky due to the alignment of cable connector parts and direct-joint devices, necessitating a miniaturization solution.
Innovation Solution
A cable connection structure featuring two connector-equipped cables with a housing including a first portion for cable insertion and a second tubular portion on the outer periphery, allowing axial fitting and electrical connection, along with a relay member for mechanical and electrical relay, reducing overall size and interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable connector parts and direct-joint devices are aligned in the alignment direction, then electrical connection is achieved, but the device size increases
Solution Approach 1:
The patent applies nesting by placing the first cable connector part inside the second cable connector part in the axial direction. The first connector part is inserted into the hollow interior of the second connector part, creating a nested configuration that significantly reduces the overall device size while maintaining electrical connection functionality between the two cables.
Solution Approach 2:
The patent transitions from a lateral alignment configuration to an axial nested configuration. Instead of aligning connector parts side-by-side in the alignment direction, the invention repositions them along the axial direction of the cable, utilizing the third dimension (depth/length of the connector housing) to achieve connection, thereby reducing the footprint in the alignment direction.
2Ease of operation
If connector parts are arranged in alignment direction, then connection functionality is maintained, but vertical protrusion increases
Solution Approach 1:
The first cable connector part is nested within the second cable connector part along the axial direction, which confines the connector assembly within a compact cylindrical envelope. This nesting eliminates vertical protrusion because both connectors are contained within the outer dimensions of the second connector part, allowing the cable to pass through without exceeding the connector housing boundaries.
3Reliability
If direct-joint device is used to connect two high-voltage cables, then electrical connection is achieved, but device complexity increases
Solution Approach 1:
The patent merges the functions of the direct-joint device and the cable connector parts into a single integrated structure. The housing of the second cable connector part serves dual purposes: it provides the connector housing and simultaneously acts as the joint device that connects to the first cable connector part. This integration eliminates separate components and simplifies the overall device structure.
Data Source
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AI summary
A connector-equipped cable (2) is composed of a cable (3), and a connector (5) attached to an end of the cable (3). The connector (5) includes a housing (51) including a first portion (511) to which the end of the cable (3) is inserted and a tubular second portion (512) formed on an outer periphery side of the first portion (511). A cable connection structure (1) is composed of two connector-equipped cables (2, 2). The two connector-equipped cables (2, 2) are fitted with each other in an axial direction (X) of the cable (3) to electrically connect the two connector-equipped cables (2, 2) to each other.