Insulating Element for Electrical Cable Connections
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Solution Overview
Problem
Existing methods for connecting electrical devices with tubular metal jackets to lead wires are time-consuming, error-prone, and require significant space, often resulting in short circuits and unheated lengths due to difficulties in insulating and positioning conductor ends.
Innovation Solution
A method using an insulating element with receptacles that precisely fit the conductor ends, allowing for reproducible positioning and electrical connection through openings, which can be sealed for protection, and a sleeve to enclose the connection for stability and insulation, reducing the risk of short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating sleeves are slid over the connection point to insulate conductor ends, then insulation is provided, but the process becomes difficult and incomplete when there is little space between conductor ends, leading to short circuits
Solution Approach 1:
The insulating element is prepared in advance with pre-formed recesses that match the conductor ends' geometry. The conductors are inserted into these pre-configured recesses before the insulating element is finalized, ensuring proper positioning and insulation without requiring difficult post-assembly operations in confined spaces
Solution Approach 2:
The insulating element acts as an intermediary component with specifically designed recesses that receive and position the conductor ends. These recesses serve as a mediating structure that facilitates both the mechanical connection and electrical insulation, eliminating the need to directly manipulate insulating sleeves in tight spaces
2Reliability
If connection methods use wrapping with foils or adhesive tapes, then insulation is achieved, but the process becomes very labor-intensive
Solution Approach 1:
The insulating element is segmented into multiple functional zones: recesses for receiving individual conductor ends, walls providing insulation between conductors, and integrated positioning features. This segmentation allows each conductor to be independently positioned and insulated, enabling automated assembly processes and improving manufacturing efficiency
Solution Approach 2:
The insulating element combines multiple materials with complementary properties: electrically insulating materials to prevent short circuits, mechanically stable materials to maintain positioning, and potentially thermally conductive materials to manage heat. This composite approach achieves reliable insulation while enabling efficient manufacturing
3Reliability
If potting with potting compound is used to seal the connection, then sealing is provided, but it does not always reliably reach bare parts, leading to insufficient sealing
Solution Approach 1:
The recesses in the insulating element are pre-configured to extend to or near the bare conductor parts. This preliminary design ensures that when the insulating element is assembled, the insulation and sealing are automatically applied to all necessary areas, eliminating the need for additional potting operations and ensuring reliable sealing
Solution Approach 2:
The sealing function is extracted from the potting compound and integrated directly into the insulating element's structure through the recesses' geometry. The recesses themselves provide the sealing barrier, eliminating the need for separate sealing materials and simplifying the overall connection structure
4Reliability
If conventional connection methods are used, then electrical connection is established, but considerable space is required, resulting in an undesirably large unheated length
Solution Approach 1:
The insulating element's recesses are designed to nest the conductor ends within the insulating structure itself. The conductors are positioned and insulated within the recesses, which are integrated into the insulating element that is already part of the compact connection assembly. This nesting eliminates the need for additional external insulation and positioning components, minimizing the overall unheated length
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 method enhances connection quality, reduces space requirements, improves manufacturing reliability, and ensures precise positioning, resulting in stable and reliable electrical connections with minimal unheated length.
Implementation Method 1
an insulating element made of an electrically insulating material with receptacles for the insertion of at least one contact section of an electrical conductor of the electrical device and of at least one contact section of an electrical conductor of the connecting cable
Implementation Method 2
The recesses of the insulating element ensure precise and reproducible positioning of the respective contact sections
Implementation Method 3
an electrical connection is established between the respective contact sections in the area of the opening that forms the further access to the contact area
Data Source
Figure 1a~1b
Figure 1c~1d
Figure 1e~1f
AI summary
A method is provided for connecting an electrical device (10), which has a tubular metal sheath (13) and contact sections (11, 12) of electrical conductors of the electrical device (10) projecting from the end face of the tubular metal sheath (13), to contact sections (21, 22) of electrical conductors (23, 24) of a connecting cable (20), comprising the steps of providing an insulating element (40, 140) made of an electrically insulating material with receptacles (41, 42, 43, 44, 141, 142, 143, 144) for the insertion of at least one contact section (11, 12) of an electrical conductor of the electrical device (10) and at least one contact section (21, 22) of an electrical conductor (23, 24) of the connecting cable (20), wherein the receptacles (41, 42, 43, 44, 141, 142, 143, 144) are located in a contact area (45,48, 145,148) merge into one another and with at least one opening (46,47,49,50,146,147,149,150) providing further access to the contact area (45,48, 145, 148), inserting at least one contact section (11, 12) of an electrical conductor of the electrical device (10) and at least one contact section (21, 22) of an electrical conductor (23, 24) of the connecting cable (20) into receptacles (41, 42, 43, 44, 141, 142, 143, 144) of the insulating element, such that the respective contact sections (11, 21, 12, 22) overlap or abut each other in the contact area (45, 48, 145, 148), and establishing an electrical connection (51, 52) between the respective contact sections (11, 21, 12, 22), wherein the establishment of this electrical connection (51, 52) is through the opening (46, 47, 49, 50, 146, 147, 149, 150) which provides further access to the contact area (45,48,145,148) forms, through which occurs and a corresponding electrical device (10).