Cable Connection Assembly With Crosslinked Injection-Molded Insulation
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Solution Overview
Problem
Conventional methods for connecting solar panels require multiple process steps, additional materials, and pose risks of solder joint failure, increased costs, and potential failure points due to imperfections like delaminations and leaks in cable connection assemblies.
Innovation Solution
A method involving surface treatment of the cable sheath to enable immediate and complete crosslinking with new plastic material during injection molding, forming an insulating sheath with improved moisture protection and mechanical resistance, eliminating the need for adhesion promoters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connection methods with multiple process steps are used, then electrical connections can be established, but manufacturing complexity and time increase
Solution Approach 1:
The patent combines multiple separate manufacturing steps (surface treatment, adhesion promoter application, and injection molding) into a single integrated injection molding process. The plastic material itself performs the surface treatment and bonding functions, eliminating the need for separate adhesion promoters and reducing manufacturing complexity while maintaining connection reliability.
Solution Approach 2:
The plastic material used in injection molding serves multiple functions simultaneously: it acts as the bonding agent, the insulating material, and the structural component. This multi-functionality reduces the number of separate materials and process steps needed, thereby reducing manufacturing complexity while ensuring reliable electrical connections.
2Strength
If adhesion promoters are used to bond cable sheath and plastic material, then bonding strength is improved, but additional materials and process steps are required
Solution Approach 1:
The patent extracts and eliminates the adhesion promoter step from the manufacturing process. Instead of applying a separate adhesion promoter, the plastic material is formulated to inherently bond with the cable sheath through surface treatment, thereby maintaining bonding strength while simplifying the manufacturing process.
Solution Approach 2:
The plastic material is designed to perform its own bonding function without requiring external adhesion promoters. The material contains built-in properties and surface treatment mechanisms that enable direct bonding to the cable sheath, eliminating the need for additional materials and process steps.
3Reliability
If casting compounds or epoxy resin coatings are used for protection, then insulation and protection are improved, but delaminations and leaks occur over time
Solution Approach 1:
The patent uses composite material construction where the plastic material is integrated with the cable sheath through surface treatment, creating a unified structure. This composite approach eliminates the interface between separate materials (cable sheath and casting compound) that causes delamination, thereby improving long-term reliability and service life while maintaining insulation protection.
4Strength
If surface treatment is applied to cable sheath, then crosslinking with plastic material is improved, but additional process step is added
Solution Approach 1:
The patent merges the surface treatment step with the injection molding process. The surface treatment is performed on the cable sheath in preparation for the injection molding, and the two steps are integrated into a continuous manufacturing flow without requiring separate equipment or operations, thereby improving crosslinking strength while maintaining manufacturing efficiency.
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 method results in a cable connection assembly with enhanced insulation resistance, mechanical strength, and moisture protection, ensuring a permanent and inseparable connection without residues, achieved through irreversible chemical bonding.
Implementation Method 1
the material of the cable sheath can immediately and completely crosslink with new plastic material supplied during an injection molding operation
Implementation Method 2
after being generated by heating from a plastic granule, when a circumferential surface layer of the respective cable sheath
Implementation Method 3
relatively thin surface areas of the cable sheath are removed circumferentially or are at least roughened in order to provide fresh surface areas
Data Source
AI summary
In a process for manufacturing an electric cable connection assembly 1 for connecting solar panels, a circumferential surface layer 6 of the respective cable sheath is partially removed by exposure to light at end portions of at least two individual cables which are connected to a respective exposed conductor end portion 5. After forming an electrically conductive connection between the cables 2, the cables 2 are introduced into the cavity 18 of an injection molding tool 15 and a heated, plastically deformable plastic granulate consisting of the same material as the cable sheath is injected into the cavity 18. The plastic material crosslinks homogeneously. An insulating sheath formed in this way is characterized by improved moisture protection and mechanical resistance.