Insulation-Hooking Busbar Teeth for Fast Cable Piercing Contact
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Solution Overview
Problem
Existing electrical connectors face challenges in efficiently and securely connecting busbars to cables, particularly in ensuring a stable electrical connection while piercing through insulation without damaging the conductor.
Innovation Solution
The use of angled teeth with a skinny body and curved tip that can pierce through insulation, bend underneath, and create voids or slide between conductor strands to establish a secure electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional connectors are used to connect busbars to cables, then the connection process is complex and time-consuming, but the angled teeth design enables quick and easy connection
Solution Approach 1:
The connector is segmented into distinct functional elements: the busbar body and multiple angled teeth protruding from it. This segmentation allows the teeth to independently pierce the insulation and engage the conductor, simplifying the overall connection process while maintaining high productivity
Solution Approach 2:
The angled teeth are pre-positioned on the busbar in a ready-to-pierce configuration. When the busbar is inserted into the cable, the teeth automatically pierce the insulation and engage the conductor without requiring additional manual steps, enabling quick connection
2Strength
If the teeth are made sharp to pierce through insulation, then piercing capability is improved, but the risk of damaging the conductor increases
Solution Approach 1:
The teeth exhibit local quality variation: the tips are sharp to pierce insulation effectively, while the bodies are substantial and curved to provide structural support and control the piercing action. This localized differentiation allows strong piercing capability without excessive sharpness that could damage the conductor
Solution Approach 2:
The teeth are designed with curved tips rather than straight sharp edges. This curvature allows the teeth to follow the natural path of least resistance through the insulation and conductor, distributing the piercing force more evenly and reducing the risk of conductor damage while maintaining effective piercing capability
3Strength
If the teeth are made rigid to maintain piercing ability, then piercing strength is improved, but the ability to bend and slide underneath insulation is reduced
Solution Approach 1:
The teeth are designed with dynamic characteristics: they have sufficient rigidity to pierce insulation but incorporate curvature and dimensional proportions that allow them to bend and slide underneath the insulation layer. This dynamic design enables the teeth to adapt to different cable configurations while maintaining piercing strength
Solution Approach 2:
The teeth parameters (dimensions, curvature radius, material properties) are optimized to achieve a balance between rigidity and flexibility. The skinny body with curved tip configuration creates a specific stiffness-to-strength ratio that allows bending and sliding motion while maintaining the ability to pierce through insulation when proper force is applied
4Productivity
If the teeth pierce through insulation directly, then electrical connection is established quickly, but insulation integrity is compromised
Solution Approach 1:
The teeth are designed to first pierce the insulation layer before engaging the conductor. This preliminary action through the insulation is controlled and localized, creating minimal openings that are immediately sealed by the insulation's elastic recovery, thus maintaining overall insulation integrity while enabling quick electrical connection
Solution Approach 2:
The piercing action, which could be considered harmful to insulation integrity, is converted into a beneficial feature: the controlled piercing creates precise contact points with the conductor while the surrounding insulation remains intact and provides continued protection. The harm of piercing is transformed into the benefit of reliable electrical contact
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 connection between busbars and cables, simulating crimping force with thousands of pounds of pressure, ensuring a stable electrical connection without compromising insulation integrity.
Implementation Method 1
the one or more angled teeth are sharp enough to pierce through an insulation part of a cable including the insulation part and a conductor part
Implementation Method 2
the one or more angled teeth are capable of bending and hence facilitate bending and sliding motion underneath the surface of the insulation part
Implementation Method 3
the one or more angled teeth create one or more voids in the conductor part of the cable and follow the created one or more voids until the one or more angled teeth are embedded in the conductor part of the cable
Data Source
AI summary
In one or more embodiments, aligned insulation hooking busbar, and a method for providing the same are disclosed. The aligned insulation hooking busbar includes at least one connection end including one or more angled teeth, wherein the one or more angled teeth are sharp enough to pierce through an insulation part of a cable including the insulation part and a conductor part, wherein the one or more angled teeth are structured with a skinny body and a curved tip without compromising the ability of the one or more angled teeth to pierce through the insulation part of the cable when proper force is applied, and wherein the one or more angled teeth make an electrical connection between the busbar and the conductor part of the cable when in contact with the conductor part of the cable.