Insulation-Piercing Branch Connector for Sealed Main Line Taps
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Solution Overview
Problem
Existing methods for connecting main and branch lines in power systems are complex, time-consuming, and prone to aging, leading to potential short-circuits due to the use of adhesive tape and separate connecting members, which are unsuitable for large-scale tasks and compromise safety.
Innovation Solution
A branch connector comprising a first and second shell with piercing pieces that pierce through the insulation layer of the main line when buckled together, allowing quick and secure connection of branch and main lines using a buckle structure and spacer bars for stability and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tape and sealing materials are used to connect main line and branch line, then the connection can be achieved, but the sealing performance deteriorates over time due to aging
Solution Approach 1:
The patent replaces traditional adhesive tape and sealing materials with a disposable plastic shell structure. The shell is designed to be installed once and provides permanent sealing without degrading over time like adhesive materials. The piercing pieces are integrated into the shell and perform their function during initial installation, eliminating the need for ongoing maintenance of sealing materials.
Solution Approach 2:
The patent uses a composite structure combining plastic shell material with metal piercing pieces. The plastic shell provides insulation and sealing, while the metal piercing pieces provide mechanical penetration and electrical connection. This composite approach creates a durable connection that overcomes the limitations of single-material solutions like adhesive tape.
2Reliability
If traditional connection method with stripping insulation and adhesive tape is used, then connection can be achieved, but the installation process becomes complex and time-consuming
Solution Approach 1:
The patent merges multiple traditional connection steps into a single integrated device. The plastic shell combines the functions of insulation protection, sealing, and mechanical support, while the integrated piercing pieces combine the functions of insulation penetration and electrical contact. This eliminates the need for separate operations of stripping insulation, applying tape, and securing connections.
Solution Approach 2:
The piercing pieces are designed to automatically pierce the insulation layer when the shell is installed, without requiring manual stripping or preparation. The spring mechanism provides self-contained force for penetration, and the structure automatically positions the piercing pieces during installation, reducing the need for manual intervention and specialized tools.
3Reliability
If separate connecting members installed by pliers are used, then connection can be achieved, but the installation time increases
Solution Approach 1:
The patent combines the connecting members into a single integrated plastic shell structure. Instead of using separate connectors that require individual installation with pliers, the entire connection system is merged into one device that is installed as a single unit by clamping onto the main line, dramatically reducing installation time while maintaining connection stability.
Solution Approach 2:
The piercing pieces are designed with spring mechanisms that provide dynamic force during installation. The springs are compressed during the clamping installation process and then expand to push the piercing pieces through the insulation layer, providing the necessary penetration force without requiring manual effort with pliers. This dynamic mechanism enables quick installation while ensuring reliable electrical contact.
Data Source
AI summary
A branch connector for main lines, includes a first shell and a second shell. A groove for receiving a main line is formed in the first shell, mutually insulated piercing pieces are arranged on the first shell or the second shell, and each piercing piece has one end connected to a branch line and another end configured as a sharp piercing head for piercing through an insulation layer of the main line when the first shell and the second shell are buckled together. In use, the main line is placed in the groove of the first shell, then the first shell and the second shell are pressed to be buckled together, at this moment, the main line will be squeezed, and the insulation layer of the main line will be pierced by the piercing pieces, such that the main line and the branch line are electrically connected to each other.