Flexible Electrical Cord Connector with Protective Cap
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Solution Overview
Problem
Existing methods for producing flexible electrical cords struggle to maintain protective coatings during cutting to length, which can compromise IP protection classes and lead to cumbersome connectors that risk damaging light sources like LEDs.
Innovation Solution
A method and connector system that allows flexible electrical cords to be cut to length while retaining protective coatings, enabling simple and economical cutting and connection, with integrated conductive lines and tubular conductors for secure power supply, and reducing the connection system's dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If connectors are removed and cords are cut to length, then the cords can be customized for different applications, but the protective coating is compromised and IP protection classes are lost
Solution Approach 1:
The protective cap is pre-installed on the connector before the cord is cut to length. This preliminary action ensures that the protective coating is not compromised during the cutting process, maintaining IP protection classes while allowing cord customization.
Solution Approach 2:
The protective cap acts as an intermediary element between the connector and the environment. It protects the connector's electrical contacts and the cord's protective coating during cutting and handling, preventing damage and maintaining protection standards.
2Ease of operation
If traditional connectors are used, then electrical connection can be established, but the connectors are cumbersome and may damage light sources like LEDs
Solution Approach 1:
The connector is designed with a flexible, thin protective cap that covers the electrical contacts. This flexible structure provides protection without being cumbersome, reducing the risk of damage to light sources while maintaining connection capability.
Solution Approach 2:
The protective cap is designed as a simple, easily replaceable component that can be discarded or replaced if damaged, rather than using complex, durable traditional connectors that pose a damage risk.
3Ease of manufacture
If protective coating is removed during connector fitting, then connectors can be installed, but protection against ingress of solid bodies, dust, water, and accidental contact is compromised
Solution Approach 1:
The protective cap is installed on the connector before the cord is cut and before connector fitting. This preliminary installation ensures that the protective coating remains intact throughout the manufacturing process, while connector installation is still facilitated by the pre-prepared connector.
Data Source
AI summary
A method of producing cut-to-length flexible electrical cords includes providing a flexible strip having a plurality of electrically conductive lines extending along the strip, arranging along said strip a plurality of electrical connectors including a plurality of tubular electrical conductors extending in a bridge-like manner between two subsequent portions of one of the conductive lines of said plurality, separating a portion of a given length from said flexible strip by cutting at least one said connector in a transverse plane, thus cutting the plurality of tubular electrical conductors in the cut connector, whereby said portion separated from said flexible strip forms a flexible electrical cord having, at one end at least, a plurality of electrical connection holes or sockets exposed as a result of the cutting of said tubular conductors.