Insulation-Piercing Busbar Connector for Fast Solar Cable Taps
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Solution Overview
Problem
Existing methods for connecting multiple cables to a larger cable are cumbersome and require extensive training and specialized tools, making them inefficient for quick and easy implementation in solar array applications.
Innovation Solution
An insulation piercing electrical connector system using a central busbar with sharp connection ends that penetrate the insulation of a larger cable to establish electrical connections, combined with mechanisms like pivoted torque arms, cradle and nut combinations, snap-in locking straps, or clamshell designs for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable connection methods are used, then reliable electrical connection is achieved, but installation complexity and time increase significantly
Solution Approach 1:
The connector is divided into distinct functional segments: an insulation piercing element with sharp piercing members for penetrating cable insulation, a central busbar for electrical connection, and a separate clamping mechanism. This segmentation allows each component to perform its specific function efficiently, enabling quick insulation piercing and cable attachment without complex multi-step processes
Solution Approach 2:
The insulation piercing members are pre-formed as sharp protrusions on the connector body, ready to penetrate cable insulation immediately upon insertion. The central busbar is pre-positioned to make electrical contact with the conductor as soon as the insulation is pierced, eliminating the need for separate stripping and connection steps
2Reliability
If traditional cable connection methods are used, then secure electrical connection is achieved, but operator skill requirements increase
Solution Approach 1:
The connector performs the insulation piercing action automatically through its own structural design. The sharp piercing members on the connector body self-inflict the insulation breach when the cable is inserted, eliminating the need for operators to manually strip insulation or use separate piercing tools. The clamping mechanism also self-adjusts to secure the cable connection
Solution Approach 2:
The connector uses a sharpness parameter change in the piercing members to transform from a non-penetrating state to an active penetration state. The extreme sharpness of the piercing members allows them to concentrate force on a minimal area, enabling automatic insulation penetration without requiring operator skill for manual stripping or cutting
3Productivity
If insulation piercing connectors are used, then installation speed increases, but connection stability may be compromised
Solution Approach 1:
The connector merges three essential functions into a single integrated component: insulation piercing, electrical connection, and mechanical clamping. The insulation piercing members, central busbar, and clamping mechanism work together as one unified device, ensuring that all three functions are performed simultaneously and stably in a single installation action
Solution Approach 2:
The connector employs composite construction with conductive materials for the central busbar and piercing members, and insulating materials for the connector body and clamping elements. This composite structure provides both the electrical conductivity needed for power transmission and the mechanical strength needed for stable, long-term connection security
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
Facilitates quick and easy cable connections with minimal training, reducing installation time and costs, particularly suitable for large solar fields where modular cable grouping is necessary.
Implementation Method 1
the at least one connection end is sharp such that it is capable of penetrating through the insulation of the larger cable
Data Source
AI summary
In one or more embodiments, an insulation piercing electrical connector device, a system for connecting one or more cables to a larger sized cable via central busbar and a method for providing an insulation piercing electrical connector or a system for connecting one or more cables to a larger sized cable via central busbar are disclosed. The system for connecting one or more cables to a larger cable via central busbar includes a central busbar provided with at least one connection end, wherein the central busbar is also connected to one or more cables, and wherein at least one connection end is sharp such that it is capable of penetrating the insulation of the larger cable and makes an electrical connection between the one or more cables to the larger cable via central busbar when penetrated in the insulation of the larger cable.