Cable Housing Slot and Hinge Design for Fast Cable Splicing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable housing systems face challenges in efficiently splicing cables due to complex assembly processes, potential for poor connections, and the need for additional manufacturing steps and materials, particularly with the use of metal busbars.
Innovation Solution
A cable housing system with a design that includes a cable mounting slot with a cable-insertion portion and a cable-retention portion, allowing for easy insertion and retention of cables without additional fixation elements, and featuring a fixation device with a living hinge for improved cable retention and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If all terminals are mounted to one housing, then a single assembly is achieved, but production becomes difficult and automation is complicated
Solution Approach 1:
The housing is divided into a first housing portion and a second housing portion that can be separately assembled. Terminals are distributed across these portions, allowing modular assembly and simplifying production processes while maintaining a complete functional assembly.
2Reliability
If an intermediate metal busbar is used to establish electric connection, then connections between terminals are achieved, but connection quality deteriorates with poor connections and increased resistances
Solution Approach 1:
The metal busbar intermediate element is completely removed from the system. Terminals are directly connected through the housing structure and conductive pathways integrated into the housing portions, eliminating the source of poor connections and increased resistance.
3Reliability
If a metal busbar is provided for establishing connections, then electric connectivity is achieved, but additional manufacturing steps and material requirements increase
Solution Approach 1:
The housing structure is merged with the electrical connection function. The housing portions themselves provide both mechanical support and conductive pathways, integrating structural and electrical functions into a single component system, thereby eliminating separate busbars and reducing manufacturing complexity.
4Reliability
If extensive fixation operations and additional fixation elements are used, then cable retention is improved, but assembly complexity and time increase
Solution Approach 1:
The cable retention system utilizes the natural elasticity and deformation of the housing material itself. The housing portions are designed to flex and grip cables automatically upon insertion, eliminating the need for separate fixation elements and reducing assembly complexity while maintaining reliable retention.
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 proposed cable housing system simplifies the cable splicing process, reduces the risk of poor connections, eliminates the need for metal busbars, and enhances assembly efficiency, making it suitable for automotive applications.
Implementation Method 1
The cable-retention portion is configured to retain the cable by force fit and/or form fit
Implementation Method 2
The fixation device includes a living hinge
Data Source
AI summary
The present invention relates to a cable housing, in particular a splice saver, for accommodating two cables. The cable housing includes a cable mounting slot in a wall of the cable housing. The slot comprises a cable-insertion portion configured to receive a cable. The cable-insertion portion comprises a first width. The slot further comprises a cable-retention portion configured to retain the cable by force fit and/or form fit. Moreover, the cable-retention portion comprises a second width which is smaller than the first width. Further, the cable-retention portion comprises a knife edge configured to retain the cable by means of force fit and/or form fit.