In-line Power Outlet Cam-Lever Piercing Mechanism
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Solution Overview
Problem
The installation of power outlets along electrical reticulation cables is cumbersome and risky, requiring the removal of insulation sheaths and potential damage to conducting elements, especially when dealing with existing cables.
Innovation Solution
A power cable in-line power outlet assembly that allows for the connection of power conducting elements without removing the outer or inner insulation sheaths, using a cam-lever mechanism to pivot and force connector blades through the insulation for contact with the conductors, enabling secure and tool-free installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional power outlet installation methods are used (cutting cable and removing insulation), then power outlets can be installed along power cables, but the process becomes time-consuming and requires multiple tools
Solution Approach 1:
The connector element is divided into distinct functional parts: cutting edges for piercing insulation, contact elements for electrical connection, and insulating portions for isolation. This segmentation allows each part to perform its specific function efficiently without requiring separate tools or steps for each operation.
Solution Approach 2:
The invention combines multiple functions (cutting insulation, making electrical contact, and providing structural support) into a single integrated connector element. This merging eliminates the need for separate cutting tools, stripping tools, and connection terminals, thereby simplifying the installation process and reducing time requirements.
2Reliability
If conventional power outlet installation methods are used (cutting and stripping insulation), then power outlets can be installed, but there is always a danger of incorrectly connecting conductors and damaging insulation
Solution Approach 1:
The connector element acts as an intermediary between the cable and the outlet terminals. Its insulating portions ensure that only the intended conductor contacts make electrical connection, preventing incorrect connections. The controlled cutting edges pierce only the insulation without damaging the underlying conductors, eliminating the risk of conductor damage associated with conventional stripping methods.
Solution Approach 2:
The connector element performs its own insulation cutting and conductor contact functions without requiring external tools or manual insulation removal. The cutting edges automatically pierce the insulation at the correct locations when the connector is inserted, and the contact elements automatically establish electrical connections, reducing human error and improving reliability.
3Ease of operation
If the outer insulating sheath is removed to install a power outlet (as in AU200242444 B2), then the outlet can be installed without cutting the cable, but the heavy outer sheath is difficult to remove and there is risk of cutting into and damaging conducting elements
Solution Approach 1:
Instead of removing the entire outer insulating sheath, the connector element creates localized openings only at the specific positions where conductor contacts are needed. The cutting edges pierce the outer sheath and inner insulation only at the precise locations required for electrical connection, leaving the rest of the insulation intact and eliminating the risk of widespread damage to conducting elements.
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
Facilitates rapid and safe installation of power outlets along cables without damaging insulation, reducing the risk of incorrect connections and insulation degradation, and eliminating the need for tools.
Implementation Method 1
said connector elements urged into cutting contact with said outer insulating sheath and thence respective said separate insulating sheaths and thence each of said at least two power conducting elements by rotation of at least a component of the power cable in-line power outlet
Data Source
AI summary
A power cable in-line power outlet (and associated method of use); said outlet including at least two sockets or slots for receiving power conducting pins of a plug of a powercord; said sockets or slots providing access to connector elements engaging with corresponding power conducting elements of said power cable; said power cable comprising an outer insulating sheath enclosing separate insulating sheaths of each said at least two power conducting elements; said power cable urged into cutting contact with said connector elements by rotation of a cam-lever from an initial non-contacting position to a position in which each of said power conducting elements of said power cable are in contact with said connector elements.