Cold Shrink Electrical Connector Housing with Localized Material Segmentation
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Solution Overview
Problem
Existing electrical cable connectors, particularly loadbreak and deadbreak high voltage elbow connectors, face challenges in achieving a secure and watertight connection with power cables while balancing cost and performance, as they often require complex manufacturing processes and materials that are not optimized for different cold shrink performance levels.
Innovation Solution
The use of a power cable connector with a housing comprising two distinct portions of cold shrink materials, where the power cable receiving body is formed of cold shrink capable EPDM and the elbow body is made of conventional non-cold shrink material, allowing for a secure and watertight connection through a removable core that expands the connector to accommodate power cables of various sizes, and then collapses to secure them, while maintaining cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cold shrink capable material is used for the entire connector housing, then secure and watertight connection is achieved, but manufacturing cost increases
Solution Approach 1:
The connector housing is divided into two portions with different material properties: the power cable receiving body uses cold shrink capable material for secure engagement, while the elbow body uses conventional non-cold shrink material for cost reduction. This local differentiation allows each portion to have the specific properties needed for its function without incurring the cost of cold shrink material throughout the entire housing.
2Reliability
If cold shrink capable material is used for the entire connector housing, then watertight connection is achieved, but manufacturing complexity increases
Solution Approach 1:
The housing is segmented into two portions with different material characteristics. The power cable receiving body portion is formed from cold shrink capable material to provide the necessary elastic engagement and watertight seal, while the elbow body portion is formed from conventional material, simplifying the overall manufacturing process and reducing complexity.
3Ease of manufacture
If non-cold shrink material is used for the elbow body, then manufacturing cost is reduced, but rigidity and structural stability decrease
Solution Approach 1:
The elbow body portion is formed from conventional non-cold shrink material, providing adequate structural support and rigidity for the elbow connection function. The cold shrink capable material is reserved for the power cable receiving body where elastic engagement is critical, allowing cost reduction in portions where high rigidity is less critical.
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
This solution enables a secure, watertight, and cost-effective connection by utilizing the elastic properties of cold shrink materials to securely engage power cables, while the non-cold shrink material in the elbow body provides increased rigidity and reduced manufacturing costs, ensuring reliable performance in high voltage applications.
Implementation Method 1
the inner housing and/or the outer jacket are formed of a cold shrink capable material... allowing the power cable receiving body to collapse inwardly to secure the power cable within the connector
Implementation Method 2
a removable core is inserted through the power cable receiving body. The core is configured to expand the axial opening through the power cable receiving body
Data Source
AI summary
An electrical connector assembly configured to couple a power cable and at least one other electrical component, includes a housing body that includes a outer jacket, an insert portion, and an insulative inner housing positioned between at least a portion of the outer jacket and the insert portion. The housing body forms at least one bore for receiving the power cable. The outer jacket comprises a cable receiving jacket portion and a main body jacket portion. At least a portion of the cable receiving jacket portion is configured to engage the power cable received into the housing body. The cable receiving jacket portion comprises a cold shrink material configured to securely engage the power cable upon and the main body jack portion comprises a non-cold shrink material.