Insulated Contact Element for Ready-to-Use Electrical Cable
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Solution Overview
Problem
In the production of ready-made electrical cables, the stripped area of wires, including contact elements, often unintentionally comes into electrical contact with conductive elements like braided shields during assembly, leading to short circuits when the outer conductor sleeve is slid onto the cable.
Innovation Solution
Applying an insulating coating, such as a lacquer or passivation layer, to sections of the contact element not intended for electrical contact, through openings in the insulating carrier, prevents unwanted electrical contact with conductive foreign bodies, allowing these sections to remain partially exposed for assembly while maintaining insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact element is left exposed for electrical contact, then electrical connectivity is ensured, but unwanted electrical contact with conductive foreign bodies occurs
Solution Approach 1:
The patent applies insulating coating only to specific sections of the contact element where insulation is needed, while leaving other sections exposed for electrical contact. This local differentiation resolves the contradiction by providing insulation precisely where required without compromising assembly flexibility in contact areas.
Solution Approach 2:
The contact element is divided into functionally distinct sections: insulated portions for preventing unwanted contact and exposed portions for intended electrical connections. This segmentation allows each section to fulfill its specific function independently, resolving the contradiction between insulation and accessibility.
2Reliability
If the contact element is fully encased in carrier material for insulation, then electrical insulation is improved, but weight increases and assembly possibilities are reduced
Solution Approach 1:
Instead of fully encasing the contact element, the patent applies insulating coating only to specific sections where insulation is needed. This localized approach provides adequate electrical insulation while minimizing the amount of insulating material used, thereby reducing weight and preserving assembly flexibility.
Solution Approach 2:
The patent applies insulation partially rather than completely to the contact element. This partial action is sufficient to prevent unwanted electrical contact while avoiding the excess weight and reduced assembly flexibility that would result from complete encasement.
3Reliability
If insulating coating is applied to the contact element, then unwanted electrical contact is prevented, but manufacturing complexity increases
Solution Approach 1:
The insulating coating is applied to the contact element before final assembly into the carrier. This preliminary action allows the coating process to be integrated into the manufacturing flow without requiring complex post-assembly insulation mechanisms, thereby limiting the increase in manufacturing complexity.
Solution Approach 2:
The patent changes the physical state or properties of the contact element by applying an insulating coating, transforming it from a fully conductive state to a partially insulated state. This parameter change achieves the desired insulation effect through a relatively simple manufacturing step rather than complex structural design.
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
This solution effectively prevents unintended electrical contacts, saving weight and offering assembly flexibility by isolating non-contact sections of the contact element, ensuring reliable electrical insulation without fully encasing them in carrier material.
Implementation Method 1
the area of a respective wire that is accessible through at least the opening in the insulating carrier and is provided with an electrical contact element is connected in a partial section, namely in a partial section that does not serve as an electrical contact (for contacting a mating connector), with one of the insulating sleeve of the wire provided with different electrical insulation, with an insulating coating being applied to that section of the contact element as electrical insulation
Data Source
Figure 1
AI summary
The invention relates to a pre-assembled electrical cable with at least one conductor (1) surrounded by an insulating sheath (12), which extends in the longitudinal direction (L) of the cable between a first and a second free end of the cable and which is freed from the insulating sheath (12) at the first free end (E) of the cable and provided with an electrical contact element (11), and with an electrically insulating carrier (4) in which the at least one conductor (1) with its contact element (11) is received, wherein the carrier (4) is provided with at least one opening (40) through which the contact element (11) is accessible from the outside. According to the invention, the contact element (11) accessible through the opening (40) is provided in a partial section (11b) with insulation different from that of the insulating sheath (12).