Insulation-Piercing Battery Connector for Industrial Cables
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Solution Overview
Problem
Connecting electrical accessories to industrial batteries is challenging due to the need for tools and the corrosive environment, which can damage cables and compromise connections.
Innovation Solution
A flexible connector with a housing, conductive pin, and fuse, made from materials like thermoplastic elastomer, that pierces through the cable insulation to create a sealed and sturdy connection, suitable for various cable sizes and profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional bolted connectors are used to connect electrical accessories to industrial batteries, then the connection can be secure and reliable, but the connection process requires tools and is time-consuming
Solution Approach 1:
The invention extracts the connection function from traditional bolted connectors by using a piercing pin that directly penetrates the cable insulation to contact the conductor, eliminating the need for tool-based fastening and significantly reducing connection time while maintaining electrical reliability
Solution Approach 2:
The connector is segmented into distinct functional components: a piercing pin for cable penetration, a housing for protection, and a sealing mechanism. This segmentation allows each component to perform its specific function efficiently, with the piercing pin enabling quick connection without requiring full connector assembly tools
2Reliability
If accessories are connected to industrial batteries, then monitoring or control functions are enabled, but the corrosive environment can damage the cable and compromise the connection
Solution Approach 1:
The housing incorporates a flexible membrane or thin film sealing structure that conforms to the cable surface, creating a protective barrier against corrosive chemicals while allowing the piercing pin to maintain electrical contact. This sealing layer prevents corrosive agents from reaching the cable and connection points
Solution Approach 2:
The piercing pin acts as an intermediary element that creates a sealed pathway through the cable insulation, allowing electrical contact while the housing and sealing structures serve as intermediary protective layers between the connection point and the corrosive external environment
3Ease of operation
If the cable insulation is pierced to create a connection, then quick connection is achieved, but the cable may be damaged and the connection compromised
Solution Approach 1:
The housing and sealing structures are designed beforehand to cushion and protect the cable around the piercing point, distributing mechanical stress and preventing further damage to the cable insulation and conductor while maintaining the electrical 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 connector provides a reliable, sealed, and durable connection to industrial battery cables, protecting against corrosive environments and ensuring stable electrical conductivity without damaging the cables.
Implementation Method 1
at least the cable mating surface of the housing is suitably flexible to conform to the contours of an electrical cable insulation surface when the pin pierces through the insulation surface of the electrical cable
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3
AI summary
The present invention relates to a flexible connector for attaching electrical accessories to an industrial battery electrical cable. The connector includes a housing and an electrically conductive pin that is positioned within the housing and protrudes through a cable mating surface of the housing. The connector also includes a fuse positioned within the housing and electrically connected to the portion of the pin within the housing, and a conductive wire, wherein at least a portion of the wire is positioned within the housing and electrically connected to the fuse. At least the cable mating surface of the housing is suitably flexible to conform to the contours of an electrical cable insulation surface when the pin pierces through the insulation surface of the electrical cable to which the connector is attached.