Flexible Spacer for Cable Splicing Sleeve Adaptation
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Solution Overview
Problem
Existing spacers for multi-core electrical cables are cumbersome to handle and require adaptation for different cable cross-sections and sleeve sizes, making them difficult to assemble and secure, especially when filled with insulating compounds.
Innovation Solution
A spacer comprising a central part with radially extending arms of equal length, featuring thickened sections for flexibility and made of thermally stable plastic, such as polyoxymethylene, which can bend to adapt to sleeve diameters and maintain spacing between cable cores through elastic properties, with a recess and projection system for adjustable length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If spacers are made from multiple individual parts to be assembled, then the number of receiving areas for wires can be adjusted, but handling becomes cumbersome and assembly becomes difficult
Solution Approach 1:
The patent merges multiple separate spacer parts into a single integrated injection-molded component. The spacer body contains multiple receiving areas formed directly in the molded structure, eliminating the need to assemble multiple individual parts. This maintains adaptability for different wire configurations while dramatically improving ease of handling and assembly.
Solution Approach 2:
The spacer is designed as a universal component that can accommodate different numbers and configurations of wires through its multiple receiving areas. The single-piece design serves multiple functions: providing structural support, isolating wire ends, and accommodating variable wire counts without requiring different spacer models or assembly steps.
2Volume of moving object
If spacers are made with small dimensions to fit small diameter sleeves, then they can be used in compact spaces, but the individual parts become correspondingly small and difficult to assemble
Solution Approach 1:
By combining all spacer components into a single injection-molded piece, the patent eliminates the assembly step entirely. Even when the spacer is small enough to fit in compact sleeves, the integrated design means there are no small individual parts to handle and assemble, solving the manufacturing difficulty while maintaining the compact volume needed for small diameter applications.
3Manufacturing precision
If spacers are made rigid to maintain precise spacing, then spacing precision is improved, but they cannot adapt to different sleeve diameters
Solution Approach 1:
The patent incorporates flexible elements into the spacer structure, allowing the spacer to elastically deform and adapt to different sleeve diameters. The flexible portions enable the rigid spacing elements to maintain precise wire separation while the overall spacer structure can expand or contract to fit various sleeve sizes, combining spacing precision with adaptability.
4Stability of the object's composition
If spacers are designed for specific sleeve diameters to ensure secure placement, then placement stability is improved, but different spacer types are needed for different cable cross sections
Solution Approach 1:
The patent designs a universal spacer that can be used across different cable cross sections and sleeve diameters. The spacer incorporates flexible elements and multiple receiving areas that allow it to adapt its configuration while maintaining stable placement. This single multi-functional design replaces the need for multiple specialized spacer types, reducing device complexity while preserving placement stability.
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 spacer is easy to handle, adaptable to various cable sizes, and maintains effective insulation and spacing between cores during assembly and under mechanical stress, ensuring secure placement and preventing short circuits.
Implementation Method 1
The thinner sections of the arms are more flexible and therefore act as flex points. With a corresponding external load, the arms preferably bend at or in these thin sections. Due to the elastic properties of the plastic from which the elements are made, the bent sections will spring back under no load.
Data Source
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Figure 3
AI summary
The invention relates to a spacer for spacing apart connected cable cores in a cable splicing sleeve. The spacer comprises at least one element which has a middle part and a plurality of arms. The arms are attached to the middle part and extend radially outwards. The spacers according to the invention are used in particular in cable splicing sleeves which can be filled with insulating compounds.