Cable Connector With Sliding Cap for Repeatable Piercing Force
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing insulation piercing connectors require manual force application, leading to ergonomic issues and inconsistency in piercing force, and are often complex and costly.
Innovation Solution
A connector design comprising a base part and a pressure applying cap with lateral recesses and projections that allow for a predetermined and repeatable force application during cable piercing, reducing manual effort and simplifying the mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual force is applied by the user to pierce the cable, then the connector can be connected, but the force application is inconsistent and causes ergonomic issues
Solution Approach 1:
The connector is designed to pierce the cable insulation automatically when the cap is pressed onto the base, without requiring the user to manually apply piercing force. The spring mechanism self-actuates to drive the piercing element through the insulation, making the system serve itself rather than relying on inconsistent user force application.
Solution Approach 2:
The connector incorporates a spring mechanism that dynamically applies controlled force during the piercing operation. The spring compresses as the cap is pressed and automatically releases stored energy to drive the piercing element through the cable insulation with consistent force, transforming static manual pressure into dynamic automated action.
2Reliability
If complex mechanisms with springs and moving parts are used to automate piercing, then force consistency improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The connector is divided into two separate functional components: a base part containing the piercing element and electrical contacts, and a cap containing the spring mechanism. This segmentation allows each part to be optimized independently and simplifies manufacturing while maintaining reliable automated piercing function.
Solution Approach 2:
The spring mechanism is extracted as a separate component within the cap, distinct from the base piercing mechanism. This extraction allows the spring to be pre-loaded and contained in the cap, which is then simply pressed onto the base, reducing overall device complexity while maintaining force consistency.
3Ease of manufacture
If simpler connectors with fewer moving parts are designed, then manufacturing cost decreases, but piercing force reliability may be compromised
Solution Approach 1:
The spring mechanism and cap are merged into a single integrated component that is molded as one piece. This combining of functions reduces the total number of parts, simplifies assembly, and lowers manufacturing cost while maintaining the reliable automated piercing function through the spring's consistent force application.
Solution Approach 2:
The cap serves multiple functions: it houses the spring mechanism, provides the pressing surface for user operation, and acts as a protective cover for the piercing element. This multi-functionality reduces the need for separate components, simplifying the overall design while maintaining piercing reliability.
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 design ensures consistent and predictable piercing of insulated cables with reduced manual force, improving ergonomics and potentially lowering manufacturing costs.
Implementation Method 1
The pressure applying cap 20 is slidable with respect to the base part 10 such that the force applied to the cable 3 increases as the cap 20 slides within the base part 10
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A connector (1) for an electrical cable (3) comprising a base part (10) and a pressure applying cap (20), said base part (10) comprising a seat (11) for receiving the electrical cable (3), the base part (10) comprising a pair of lateral recesses (12) for slidably receiving a pair of lateral projections (21) on the pressure applying cap (20), each of the 5lateral recesses (12) extending longitudinally along the base part (10) at an angle with respect to the seat (11) such that a region proximal a first end (14) of the base (10) is at a height H1 from the seat, and a region of the recess (12) distal the first end (14) of the base part (10) is at a height H2, wherein, the height H2 is less than the height H1, and wherein the pressure applying cap is slidable with respect to the base part such that the force 0applied to the cable (3) by the cap and the base part (10) increases as the cap (20) slides within the base part (10).