Crimped Coupling Sleeve With Nested Insulation
Solution Overview
Problem
Existing coupling sleeves for low-voltage conductor cables lack sufficient mechanical and electrical protection, and their implementation can be ergonomically unsatisfactory and costly, with risks of electrocution and burns due to inadequate insulation and the need for heating systems.
Innovation Solution
A coupling sleeve design featuring a conductive body with multiple insulating envelopes and crimping zones, eliminating the need for screwing systems and providing enhanced electrical insulation and sealing through a single crimping operation, reducing manufacturing costs and improving ergonomics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single insulating layer is used in the coupling sleeve, then the manufacturing cost is reduced and the structure is simplified, but the electrical insulation and mechanical protection are insufficient, creating a risk of electrocution
Solution Approach 1:
The patent implements a nested multi-layer insulating structure where an inner insulating layer and an outer insulating layer are positioned concentrically around the conductive body. The inner layer provides primary insulation close to the conductor, while the outer layer provides additional protection and mechanical strength. This nested arrangement maximizes insulation effectiveness within a compact structure, resolving the contradiction between reliability and complexity by organizing insulating layers in a space-efficient, hierarchical manner.
Solution Approach 2:
The patent employs different insulating materials for the inner and outer layers, each selected for specific properties. The inner layer may use materials with superior electrical insulation properties close to the conductor, while the outer layer uses materials providing enhanced mechanical protection, environmental resistance, or flame retardancy. This composite material approach allows optimization of each layer for its specific function, achieving high overall reliability without requiring a single overly complex material system.
2Strength
If a screw system is used to hold cables in the coupling sleeve, then the mechanical connection is secure, but the assembly becomes complex and ergonomically unsatisfactory with increased manufacturing cost
Solution Approach 1:
The patent extracts and eliminates the screw system entirely from the coupling sleeve design. Instead of using separate fastening components, the cable holding function is integrated directly into the coupling sleeve structure through crimping zones that form an integral part of the body. This extraction of the fastening function simplifies the device by removing multiple mechanical parts (screws, nuts, washers, adjustment mechanisms) while maintaining secure cable connection through the crimping action.
Solution Approach 2:
The patent merges the cable securing function with the insulating body structure itself. The crimping zones are formed as integral portions of the coupling sleeve, combining the structural, insulating, and fastening functions into a single unified component. This merging eliminates the need for separate screw systems and reduces the number of parts, thereby simplifying assembly and improving ergonomics while maintaining strong mechanical connection through the crimping action.
3Reliability
If heating system is used to shrink pre-insulated sleeves, then the insulation is applied, but the application process becomes complicated and creates burn risks for operators
Solution Approach 1:
The patent replaces the thermal shrinking mechanism with a mechanical crimping system. Instead of using heat to shrink the insulating material onto the cables, the invention uses a crimping tool to mechanically compress and deform the coupling sleeve material, creating a secure mechanical and electrical connection. This substitution eliminates the need for heating equipment, removes burn risks for operators, and simplifies the installation process while maintaining reliable insulation through the crimped connection.
4Reliability
If multiple mechanical parts are used in the coupling sleeve assembly, then the connection can be adjusted and secured, but the manufacturing cost increases and assembly becomes more difficult
Solution Approach 1:
The patent designs the coupling sleeve as a multi-functional universal component that simultaneously provides electrical insulation, mechanical protection, cable securing through crimping zones, and sealing functions. This single integrated component performs multiple functions that would traditionally require separate parts (insulating body, fastening mechanism, sealing elements), thereby reducing the number of components, simplifying assembly, and lowering manufacturing costs while maintaining connection security through its multifunctional design.
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 sleeve offers improved mechanical and electrical protection, simplified assembly, and reduced manufacturing costs while ensuring reliable electrical contact and insulation, with enhanced safety and efficiency in connecting cables.
Implementation Method 1
applying a crimping force to the sleeve (1), radially with respect to the axis (X1), so as to plastically deform a section (33) of the external insulating envelope (30)
Implementation Method 2
The sleeve (1) comprises a conductive body (10), an internal insulating envelope (20) and an external insulating envelope (30)
Implementation Method 3
applying a crimping force to the sleeve (1), radially with respect to the axis (X1), so as to plastically deform a section (33) of the external insulating envelope (30)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a connecting sleeve (1), comprising a conductive body (10) designed to receive at least one end (5) of a conductive cable (2), characterized in that the sleeve (1) also comprises at least two separate insulating sheaths (20, 30), including an inner sheath (20) and an outer sheath (30), arranged around the conductive body (10), and in that the conductive body (10) and the insulating sheaths (20, 30) comprise sections (13, 23, 33) designed to be plastically deformed during a crimping operation of the end (5) of the conductive cable (2) into the sleeve (1). The invention also relates to a method for manufacturing and a method for implementing such a sleeve (1).