Cable Spacing Element for Multi-Core Sheath Positioning
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Solution Overview
Problem
Existing methods for assembling multi-core sheathed cables face issues with undefined cable positioning, insufficient longitudinal sealing, and inadequate mechanical strength after cutting, particularly in preventing dust, water, and foreign matter ingress.
Innovation Solution
An expanding element with a tapered mandrel and a widened end featuring a stop and guide elements, such as a perforated disk, is used to separate and position individual cables within the sheath, which is then overmolded with plastic to create a sealed and strengthened cable end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the sheath is detached and individual cables are separated manually, then the cables can be accessed for connection, but the individual cables are not positioned in a defined manner and mechanical strength is insufficient
Solution Approach 1:
The patent introduces a mandrel as an intermediary tool with guide elements that temporarily holds and positions the individual cables during the assembly process. The mandrel features tapered sections and guide surfaces that automatically align cables into precise positions without requiring manual positioning, thereby achieving both ease of operation and manufacturing precision
Solution Approach 2:
The mandrel is inserted into the cable end before the connection assembly is completed, performing the preliminary action of separating and positioning all individual cables simultaneously. This preliminary positioning action ensures that subsequent connection steps can proceed with predefined cable positions, eliminating the need for manual positioning during final assembly
2Productivity
If simple sealing methods like insulating tape or hardening plastic compound are used, then sealing can be applied quickly, but longitudinal sealing is insufficient and foreign matter can still enter
Solution Approach 1:
The patent employs a flexible sealing element in the form of a conical sealing ring that can be inserted into the cable end. This sealing ring creates an effective longitudinal seal against dust and water ingress while maintaining a relatively simple application process, improving both sealing reliability and maintaining productivity
3Device complexity
If the cable end is left as-is after cutting, then no additional components are needed, but mechanical strength is insufficient when cables and sheathed cable are moved
Solution Approach 1:
The patent combines multiple functions into a single integrated connection assembly that includes the mandrel, sealing element, and connection terminals. This merged design provides mechanical strength enhancement while preventing foreign matter ingress, and can be installed as one unit, thereby improving strength without proportionally increasing device complexity
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 solution ensures precise positioning and sealing of individual cables, enhancing mechanical strength and preventing foreign matter ingress, while allowing for improved handling and sealing against dust, water, and air.
Implementation Method 1
an expanding element with a mandrel (1) having a tapered first end (3) and a widened second end (4) is proposed. The mandrel is inserted longitudinally into an end of a sheathed cable from which the sheath has been stripped until the stop abuts the remaining sheath. In this way, the strands are separated and positioned
Implementation Method 2
The positioning of the individual lines can also be improved by providing a guide element for accommodating the individual lines, which guide element extends radially to the longitudinal direction of the mandrel. In a particularly advantageous manner, the guide element can be designed as a perforated disc, with the individual lines being guided through the holes in the perforated disc
Implementation Method 3
the end with the expansion element is overmoulded with plastic material. Depending on the area of application, the encapsulation can take place in such a way that the guide element is flush with the encapsulated plastic material and the guide element thus forms part of an end cap, or that the guide element is completely embedded in the plastic material
Implementation Method 4
The mandrel is inserted longitudinally into an end of a sheathed cable from which the sheath has been stripped until the stop abuts the remaining sheath
Data Source
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AI summary
Spreading element for sheathed cables with multiple conductors such as cables, strands and the like, with a mandrel (1) for insertion into one end of the sheathed cable, wherein the mandrel has a tapered first end (3) and a flared second end (4) along a longitudinal direction, and with a stop (2) at the second end extending radially to the longitudinal direction, characterized in that the mandrel (1) has recesses (9) on its surface for receiving the conductors of the sheathed cable, the mandrel (1) has several wedges (7) or is composed of several wedges, and that a guide element (6) with recesses (8) for receiving the conductors is provided, extending radially to the longitudinal direction.