Enclosed Cable Connector Assembly for Sealed Insulation-Piercing Joints
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Solution Overview
Problem
Existing connection systems for elongate electrical conductors, such as those used in high voltage electrical distribution and transmission lines, face challenges in forming secure and protected connections, particularly in environments where insulation piercing connectors are used, as they may not adequately prevent unintended intrusion or ensure long-term sealing and protection against environmental factors.
Innovation Solution
A connection system comprising an insulation piercing connector and an enclosure assembly with a protective end cap, which secures the connection between elongate electrical conductors by using blade members with serrations to pierce through insulation and provide electrical continuity, while the enclosure assembly and gel sealants ensure protection and sealing, preventing unintended intrusion and maintaining a reliable seal over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation piercing connectors are used to form connections between insulated cables, then electrical continuity and mechanical connection are achieved, but protection against unintended intrusion and environmental factors is insufficient
Solution Approach 1:
The connection system is divided into distinct functional components: the insulation piercing connector for electrical connection, the enclosure assembly for protection, and the gel sealant for sealing. This segmentation allows each component to specialize in its function while working together to solve the overall problem of reliable and protected connections.
Solution Approach 2:
The insulation piercing connector is nested within the enclosure assembly, which is then sealed with gel sealant. This nested structure provides layered protection where the connector performs its electrical function while being physically protected and sealed by the surrounding structures, addressing both connection reliability and protection needs.
2Reliability
If blade members with serrations are used to pierce insulation, then electrical continuity is established, but mechanical complexity increases
Solution Approach 1:
The blade members feature serrations only at their tips where they contact the insulation, rather than being serrated along their entire length. This localized feature provides the necessary piercing capability while keeping the rest of the blade structure simple and easy to manufacture.
Solution Approach 2:
The serrated blade members are designed to self-pierce the insulation layer when clamping force is applied, without requiring additional piercing tools or complex mechanisms. The mechanical pressure from the clamping action combined with the serrated edges automatically accomplishes the insulation penetration and conductor contact.
3Object-affected harmful factors
If enclosure assembly with gel sealant is added for protection, then sealing and protection are improved, but device complexity increases
Solution Approach 1:
The gel sealant acts as a flexible sealing medium that conforms to the contours of the connector and enclosure interior. This flexible sealing approach provides effective environmental protection without requiring complex rigid sealing structures or multiple gaskets.
Solution Approach 2:
The enclosure assembly combines rigid housing material for structural protection with soft gel sealant for environmental sealing. This composite approach uses materials with complementary properties to achieve both mechanical strength and sealing effectiveness in a relatively simple overall structure.
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 effectively secures and protects electrical connections by ensuring mechanical and electrical integrity, preventing unintended intrusion, and maintaining a durable seal against environmental factors, thus enhancing safety and reliability in various installation scenarios.
Implementation Method 1
an enclosure configured to be installed about the connection after the connection has been formed, such that the enclosure covers the connection and protects the electrical connector
Data Source
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AI summary
An enclosed connection system (20) for mechanically and electrically connecting first and second cables (12, 14) each including an elongate electrical conductor (12A, 14A) covered by an insulation layer (12B, 14B), includes an electrical connector (200), an enclosure (100), and a protective end cap (300). The electrical connector (200) is configured to form a connection (22) with the first and second cables (12, 14) wherein the conductors (12A, 14A) of the first and second cables (12, 14) are electrically connected by the electrical connector (200). The enclosure (100) is configured to receive and cover the connection (22) and to protect the electrical connector (200). The enclosure (100) includes a plurality of enclosure ports (EP1-EP4) each configured to receive a cable (12, 14). The protective end cap (300) is configured to selectively cover at least a selected one of the enclosure ports (EP1-EP4).