Crimp Connection Device With Segmented Conductive Envelope
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Solution Overview
Problem
Existing connection devices for electric cables with insulated strands, such as Continuously Transposed Conductors, require removal of insulating coatings for crimping, which is difficult and expensive, and do not ensure electrical continuity due to incompatibility with crimp connection devices.
Innovation Solution
A connection device with a conductive envelope featuring multiple housings separated by a longitudinal wall, allowing for direct contact between the conductive envelope and the cable core without breaking the insulating coating, enabling electrical continuity without prior removal of the insulating coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional crimp connection devices are used on cables with insulated strands, then mechanical connection is achieved, but electrical continuity cannot be obtained due to insulating coating blocking contact
Solution Approach 1:
The conductive envelope is segmented into multiple housings separated by longitudinal walls, with each housing receiving individual cable strands. The longitudinal walls create multiple contact surfaces that collectively penetrate through insulating coatings on different strands, ensuring electrical continuity without requiring complete coating removal.
Solution Approach 2:
The longitudinal walls extend along the length of the housings, creating contact surfaces in the longitudinal dimension rather than relying solely on radial contact. This dimensional approach allows the walls to progressively penetrate and break through insulating coatings as the connection device is crimped onto the cable.
2Reliability
If insulating coating is removed from cable strands, then electrical continuity can be achieved, but the process becomes difficult and expensive
Solution Approach 1:
The connection device performs the insulating coating removal function automatically during the crimping process. The longitudinal walls of the housings act as cutting edges that self-act to penetrate and break through the insulating coatings on the cable strands, eliminating the need for separate manual coating removal operations.
Solution Approach 2:
The longitudinal walls serve as intermediary elements between the conductive envelope and the cable strands. These walls mediate the interaction by mechanically penetrating the insulating coating barrier, allowing electrical contact to be established without direct manual intervention to remove the coating.
3Reliability
If a single-housing envelope is used, then the device structure is simple, but contact surface area with cable strands is insufficient for reliable electrical continuity
Solution Approach 1:
The envelope is divided into multiple housings separated by longitudinal walls, creating multiple contact zones. Each housing receives and contacts individual cable strands, with the longitudinal walls providing additional contact surfaces that collectively increase the total contact area with the strands.
Solution Approach 2:
Multiple housings and longitudinal walls are merged into a single integrated conductive envelope structure. This unified structure simultaneously provides mechanical support, electrical contact, and insulating coating penetration functions across all cable strands, achieving reliable electrical continuity without requiring separate components for each function.
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 device achieves electrical continuity between the cable strands and the connection device, simplifying the installation process and reducing costs by eliminating the need to remove insulating coatings, while maintaining the integrity of the insulating enamel coating.
Implementation Method 1
The sheath is configured to receive the terminal section of cable, and more specifically, the aluminum core of this terminal section. The sheath has multiple perforations and is made of a material harder than aluminum, so that the sheath is able to deform the core of the terminal section of cable when the tubular portion and the sheath are crimped onto the core
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
The connection device comprises a conducting element (31) exhibiting a tubular portion (33) and comprising a conducting sheath (21) which is perforated with distributed perforations according to a predetermined solid-void pattern, said tubular portion (33) and said sheath (21) being configured in such a way that the sheath (21) can be placed inside the tubular portion (33) with the end section positioned inside the sheath (21) and so that the tubular portion (33) and the sheath (21) can then be crimped onto the end section; characterized in that the sheath (21) comprises at least one longitudinal wall separating two distinct housings each configured to accept one respective longitudinal portion (11) of said end section of cable (10).