Cable Connector Grounding Offset for Last-Disconnect Safety

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Solution Overview

Problem

Existing cable connectors face risks of mechanical stress leading to disconnection and potential short circuits due to the grounding line being torn away from the pin, which can cause damage or electric shock, and require additional work to ensure the grounding cable is longer than other conductors.

Innovation Solution

A cable connector design with a mechanically lockable plug connection featuring a grounding coupling section closer to the cable entry opening, ensuring the grounding connection is maintained last under tension, and a clamping mechanism for secure wire contact, eliminating the need for additional work to lengthen the grounding cable.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the grounding wire is made longer than other conductors to ensure it disconnects last, then safety is improved, but installation complexity increases

Engineering Contradiction:
ImprovesafetyVSAvoidinstallation complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent pre-configures the grounding coupling section to be positioned closer to the cable entry opening than other coupling sections. This preliminary structural arrangement automatically ensures that the grounding wire disconnects last during pull-out events without requiring installers to manually lengthen the grounding wire or perform additional preparation steps, thus maintaining safety while simplifying installation.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The connector structure itself provides the safety function through its geometric design. The offset positioning of the grounding coupling section creates a self-regulating mechanism where the grounding wire's effective length is determined by the connector geometry rather than manual wire preparation, allowing the system to self-ensure safety without external intervention during installation.

Inventive Principle:
Principle #25Self-service

2Reliability

If manual wire preparation is required to ensure grounding wire length, then safety is improved, but installation time increases

Engineering Contradiction:
ImprovesafetyVSAvoidinstallation time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The grounding coupling section is pre-positioned closer to the cable entry opening during connector manufacturing. This preliminary action eliminates the need for installers to perform time-consuming manual wire length adjustments, while still ensuring the grounding connection is maintained until all other conductors disconnect, thus improving safety without increasing installation time.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The connector structure automatically provides the required wire length differential through its geometric design. The grounding coupling section's offset position creates a built-in mechanism that self-regulates wire engagement and disengagement sequence, eliminating the need for manual wire preparation and reducing installation time while maintaining safety.

Inventive Principle:
Principle #25Self-service

3Reliability

If the grounding coupling section is positioned closer to the cable entry opening, then the grounding connection is maintained last under tension, but the connector structure becomes more complex

Engineering Contradiction:
Improvegrounding connection stabilityVSAvoidconnector structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies local quality by positioning only the grounding coupling section closer to the cable entry opening, while other coupling sections remain at standard positions. This localized structural modification creates the necessary wire length differential for safety without requiring complex overall redesign of the connector, thus improving grounding stability with minimal increase in structural complexity.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The solution addresses the wire length issue by changing the spatial dimension of the grounding coupling section's position along the connector's length. By offsetting this specific coupling section closer to the cable entry opening, the patent creates a geometric solution that ensures grounding connection stability without adding mechanical complexity or requiring additional components.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

4Reliability

If mechanical locking mechanisms are added to prevent disconnection, then reliability is improved, but device complexity increases

Engineering Contradiction:
Improveconnection stabilityVSAvoidlocking mechanism
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent pre-configures the grounding coupling section's position to be closer to the cable entry opening, creating a built-in mechanical advantage that passively ensures grounding connection stability during pull-out events. This preliminary structural arrangement provides connection reliability through geometry rather than active locking mechanisms, thus improving reliability without significantly increasing device complexity.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent converts the potentially harmful effect of pull-out forces into a beneficial sequence where the grounding wire's offset positioning ensures it engages and disengages at different points along its length. This transforms the mechanical stress that could cause failure into a safety feature where the grounding connection is maintained last, improving reliability without adding complex locking mechanisms.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentEP4465455A1Cable connector with offset coupling area for the protective conductor
Publication Date: 2024.11.20 NEUTRIK
  • EP4465455A1 patent drawingFigure 1A~1C
  • EP4465455A1 patent drawingFigure 2
  • EP4465455A1 patent drawingFigure 3A~3B

AI summary

The present invention relates to a cable connector 1, wherein the cable connector 1 comprises a mechanical retention element, a locking slider 4, mechanical key elements 3, 3', a cable entry opening 7, a live conductor contact element 10, a neutral conductor contact element 23, and a protective conductor contact element 11, wherein the live conductor contact element 10 is provided in a first coupling section 20 to provide an electrically conductive connection with a conductor end of the live conductor 16, the neutral conductor contact element 23 is provided in a second coupling section 24 to provide an electrically conductive connection with a conductor end of the neutral conductor 22, and the protective conductor contact element 11 is provided in a third coupling section 21, hereinafter referred to as the grounding coupling section 21, to provide an electrically conductive connection with a conductor end of the protective conductor 17.wherein the electrically conductive connections within the respective coupling section 20, 21, 24 are provided by contacting and thereby fixing the respective conductor end of the individual conductor 16, 17, 22 at at least one contact point, wherein a cable entry opening-side end of the earthing coupling section 21, in particular the at least one contact point with the conductor end of the protective conductor 17, is arranged in the insertion direction of the power cable 18 into the cable entry opening 7 at a shorter distance from the cable entry opening 7 than a cable entry opening-side end of the first and a cable entry opening-side end of the second coupling section 20, 24, in particular than the at least one contact point with the live conductor and the at least one contact point with the neutral conductor.