Insulation-Penetrating Connection Module for Branching Continuous Conductors
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Solution Overview
Problem
Existing connection systems for continuous electrical conductors are not suitable for creating branches on installed cables without cutting the conductors, and they often require complex assembly or lateral insertion, making them unsuitable for retrofitting or handling continuous cables.
Innovation Solution
A connection system using IDC contacts with fork contacts and a pre-assembled module frame that absorbs wiring forces, allowing for easy insertion and connection of continuous and branching conductors without screws, and featuring eccentric actuating devices for defined contact guidance, enabling quick retrofitting of branches on installed cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection systems with insulation-penetrating conductors are used, then secure contacting is achieved, but the device complexity increases and ease of operation deteriorates due to requiring closed openings and lateral insertion
Solution Approach 1:
The connection system is divided into modular components: a base plate with receptacles for continuous conductors, and separate connection disks that can be independently inserted and removed. Each connection disk contains insulation-penetrating contacts that can be individually operated, allowing secure contacting while simplifying the overall operation through modular design
Solution Approach 2:
Instead of requiring conductors to be inserted laterally through closed openings, the invention inverts the approach by providing open receptacles on the base plate where conductors are first placed, and then connection disks are inserted from above to make contact. This reverses the traditional insertion direction and greatly simplifies operation
2Adaptability or versatility
If connection disks are rotatably arranged on a shaft, then structural flexibility is improved, but the device complexity increases and ease of operation deteriorates due to requiring lateral insertion
Solution Approach 1:
The invention inverts the traditional rotational arrangement by keeping connection disks on a shaft but allowing them to be inserted and removed from above in a linear direction rather than requiring lateral insertion. This maintains the structural flexibility of the shaft arrangement while dramatically simplifying the operation to vertical insertion/removal
3Productivity
If a pre-assembled connection module is used, then productivity is improved through quick installation, but the device complexity increases due to module assembly requirements
Solution Approach 1:
The base plate is pre-assembled with receptacles and positioning features for continuous conductors before the connection disks are inserted. This preliminary preparation allows for rapid installation of multiple connection points without requiring complex module assembly, as each connection disk can be independently and quickly inserted into its designated receptacle
Solution Approach 2:
The connection system is segmented into a permanently mounted base plate and removable connection disks. This segmentation allows the base plate to be pre-installed with conductors, and then connection disks can be quickly added or removed as needed, improving productivity without requiring complex modular assembly of the entire system
4Ease of operation
If IDC contacts are used without screws, then ease of operation is improved, but the force absorption capability deteriorates
Solution Approach 1:
The invention merges the advantages of screw connections (force absorption) with IDC contacts (ease of operation) by using IDC fork contacts that are spring-loaded to provide strong contact force and secure mechanical retention, while eliminating the need for screws. The spring mechanism provides continuous pressure to maintain reliable electrical and mechanical connection
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 system provides a compact, easy-to-handle solution for creating branches on continuous conductors, allowing for secure and efficient connection of both continuous and branching conductors, with the ability to absorb high wiring forces and facilitate defined contact perpendicular to the conductor extension, thus enhancing the structural design and usability.
Implementation Method 1
two tension spring terminals for connecting branching conductors
Implementation Method 2
each of which is provided with an insulation-penetrating screw
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
Connection system for realizing branches on a plurality of continuous electrical conductors (21), in particular a sectionally stripped cable (22), comprising a base plate (2) with several adjacent receptacles (20) for receiving the conductors (21) of the sectionally stripped cable (22), a preferably attachable and lockable connection module arranged on the base plate (2) with a module frame (4) with several receiving slots (6) for receiving connection discs (4) with base bodies (7) made of insulating material, the connection discs (4) having at least one insulation-penetrating contact (8) actuated by an eccentric (16), which is directed towards the base plate and serves to contact one of the conductors (21), and at least one branch connection (9) for branching conductors.