Auxiliary Electric Splice Housing With Visible Locking and Strain Relief

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Solution Overview

Problem

Existing auxiliary splices for electric cables lack a low-cost, easy-to-assemble housing and insulator assembly that provides visual assurance of a locked position and efficient strain relief for high voltage applications.

Innovation Solution

An auxiliary electric splice with an insulator assembly comprising identical first and second insulators, a support wall, center and outer insulator plates, and a housing with locking features to ensure secure assembly and strain relief, featuring a housing and end cap design with visible locks and cable claws for easy assembly and disassembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional housing and insulator assemblies are used, then assembly complexity increases and cost increases, but visual assurance of locked position and strain relief are achieved

Engineering Contradiction:

Improveassembly easeVSAvoidhousing and insulator assembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the housing and insulator assembly into an integrated structure where the insulator plates are directly formed as part of the housing assembly. This merging reduces the number of separate components and simplifies the assembly process while maintaining the necessary insulation and locking functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing structure serves multiple functions simultaneously: it provides mechanical support, electrical insulation through integrated insulator plates, visual indication of locked position through positioning features, and strain relief through cable retention mechanisms. This multi-functionality reduces overall assembly complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Loss of time

If traditional locking mechanisms are used, then assembly time increases, but visual assurance of locked position is provided

Engineering Contradiction:

Improveassembly timeVSAvoidvisual assurance of locked position

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

The patent incorporates visual indication features such as colored positioning elements or visible alignment features on the housing and insulator plates that change appearance or become visible when properly locked. This provides immediate visual confirmation of correct assembly without requiring additional time for verification.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The locking mechanism is designed to be self-indicating, where the act of assembly itself creates the visual confirmation. The positioning features automatically align and become visible when the components are correctly assembled, eliminating the need for separate verification steps.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If simple insulator plates are used, then manufacturing cost decreases, but warping occurs causing disengagement of catches

Engineering Contradiction:

Improvemanufacturing costVSAvoidinsulator plate stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The insulator plates incorporate localized reinforcement features such as stiffening ribs or thicker sections at critical areas where warping would occur. This allows the overall plate to remain simple and cost-effective while providing enhanced stability only where needed to prevent disengagement of catching features.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite material construction for the insulator plates, combining materials with different properties to achieve both cost-effectiveness and dimensional stability. The composite structure resists warping while maintaining manufacturability and electrical insulation properties.

Inventive Principle:

Principle #40Composite materials

4Productivity

If integrated housing and holder structure is used, then parts quantity and assembly time decrease, but manufacturing precision requirements increase

Engineering Contradiction:

Improveassembly speedVSAvoidintegration precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The integrated housing and holder structure incorporates pre-formed positioning features and alignment elements during the manufacturing process. These preliminary actions ensure that when assembly occurs, the components naturally align with high precision without requiring complex adjustment procedures, thus maintaining both productivity and precision.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250219384A1Auxiliary electric splice

Publication Date: 2025.07.03 LEAR CORP

AI summary

An auxiliary electric splice including an insulator assembly having first and second insulators configured to electrically insulate electrical splice joints. The first insulator including: a support wall configured to extend longitudinally adjacent to the splice joints; a center insulator plate extending laterally from the support wall and configured to extend between the splice joints; a first outer insulator plate extending laterally from the support wall, spaced from the center insulator plate, and including a pair of end plate stiffening flanges that extend laterally and a pair of drawer runner flanges, each extending from a respective one of the end plate stiffening flanges to define a cavity for receiving a portion of the second insulator; and a second outer insulator plate extending laterally from the support wall, spaced from the center insulator plate on an opposite side from the first outer insulator plate, configured to engage with the second insulator.