Ceramic Insulator Cable Connector Fireproof Termination
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Solution Overview
Problem
Existing cable connection methods in safety installations, such as those in tunnels and buildings, fail to maintain functional integrity during fires, particularly in accordance with standards like DIN 4102, as they do not ensure reliable electrical connections and protection from fire, water, and dust.
Innovation Solution
A cable connector and termination system utilizing a ceramic insulator with metal contact inserts and a heat shrink tube, which provides a fireproof, watertight, and dust-resistant connection between multicore cables, ensuring electrical insulation and mechanical stability even at high temperatures, and protecting against mechanical damage and liquid penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional cable connection methods are used, then ease of installation is improved, but functional integrity during fire is compromised
Solution Approach 1:
The connector combines ceramic insulator material with metallic contact inserts to create a composite structure that provides both mechanical stability and electrical conductivity while maintaining fire resistance. The ceramic body offers high-temperature stability and insulation, while the metal inserts provide reliable electrical contact even under thermal stress.
Solution Approach 2:
The ceramic insulator acts as an intermediary element between the metallic contact inserts and the external environment, providing thermal and electrical isolation. This mediator protects the conductive components from direct exposure to fire and moisture while maintaining electrical connectivity through the insulated metal inserts.
2Reliability
If ceramic insulator with metal contact inserts is used, then functional integrity during fire is improved, but device complexity increases
Solution Approach 1:
The invention merges multiple functions into a single integrated connector body: the ceramic insulator simultaneously provides electrical insulation, mechanical support, and fire resistance, while the embedded metal contact inserts provide electrical connectivity. This consolidation eliminates the need for separate insulation components and mounting structures.
Solution Approach 2:
The ceramic connector body serves multiple purposes: it acts as the insulating barrier, the structural framework, the mounting substrate for contact inserts, and the protective housing. This multi-functional design reduces the number of separate components needed while maintaining fire safety and electrical performance.
3Object-affected harmful factors
If heat shrink tube is added for protection, then protection against water and dust is improved, but manufacturing complexity increases
Solution Approach 1:
The heat shrink tube provides a flexible protective barrier that conforms to the connector shape and seals the interface between cables and the ceramic body. This thin film solution offers IP68-level protection against water and dust penetration without requiring rigid sealing mechanisms or complex gasket systems.
Solution Approach 2:
The heat shrink tube is pre-applied to the connector assembly before final installation, allowing the protective sealing function to be established in advance. This preliminary protection ensures that the internal components are sealed against environmental contaminants before the connector is put into service, simplifying the overall manufacturing process.
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 system maintains functional integrity class E90 during fires and provides IP68 protection against dust and liquids, ensuring reliable and safe electrical connections between flat and round cables.
Implementation Method 1
a heat shrink tube that envelops the entering portions of the cables and the clamping sleeve, and in the shrunken state lies tightly against an outer contour of the clamping sleeve and an outer contour of the portion of the cables that enter the clamping sleeve
Data Source
AI summary
Cable connectors for connecting two multicore cables are provided including a clamping sleeve, having a ceramic insulator with openings on each side of the sleeve, for accommodating core conductors. The clamping sleeve includes contact inserts passing through the clamping sleeve. Clamping elements are provided to clamp the core conductors to the contact inserts to electrically connect the multicore cables. The cable connector has a heat shrink tube that surrounds the clamping sleeve and the cables. Furthermore, cable termination including a clamping sleeve with a ceramic insulator with openings for core conductors is provided. Contact inserts are situated behind the openings to clamp the core conductors on the contact inserts establishing mechanical fixing of the core conductors on the clamping sleeve. The cable termination includes a heat shrink tube as according to the first aspect.