Insulation-Piercing Cable Connector for Protected Branch Taps

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Solution Overview

Problem

Existing connectors for electrical cables often fail to provide a simple and effective method for establishing electrical continuity between main and secondary cables, particularly in applications like connecting photovoltaic panels to a bus cable.

Innovation Solution

A connector design featuring two movable jaws with channels for the main cable, clamping means to hold the jaws in place, and sub-jaws with conductive teeth and spring elements to concentrate clamping force on the main cable, allowing for easy insertion of secondary cables.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If clamping force is applied to hold secondary cables in existing connectors, then electrical connection is established, but the force damages the secondary cables and fails to effectively perforate the main cable insulation

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoiddamage to secondary cables

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The connector is divided into distinct functional zones: clamping means for securing the main cable, spring elements for contacting secondary cables, and insulated teeth for electrical connection. This segmentation allows each component to perform its specific function without interfering with others, resolving the contradiction by separating the clamping function from the electrical contact function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different parts of the connector have different properties: the clamping means applies high force to the main cable insulation, while the spring elements apply gentle contact force to secondary cables, and the teeth provide electrical conductivity with insulation. This local differentiation of properties allows the connector to simultaneously achieve reliable electrical connection while protecting secondary cables from damage.

Inventive Principle:

Principle #3Local quality

2Reliability

If conventional connector designs are used, then electrical continuity is attempted, but the architecture is complex and the connection process is not simplified

Engineering Contradiction:

Improveelectrical continuityVSAvoidconnector architecture

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The connector merges multiple functions into a single integrated structure: the insulated teeth serve both as electrical contacts and as part of the clamping mechanism, the spring elements provide both contact force and cable positioning, and the clamping means simultaneously secures the main cable and positions the teeth. This merging reduces overall complexity while maintaining electrical continuity reliability.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If clamping force is concentrated on secondary cables in existing designs, then connection is made, but the force should instead be applied to the main cable insulation for effective perforation

Engineering Contradiction:

Improveconnection processVSAvoidclamping force application

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

The connector is designed so that the clamping means first secures the main cable and positions the insulated teeth against the cable insulation before the spring elements contact the secondary cables. This preliminary action ensures that the main cable is properly positioned and the teeth are ready to perforate the insulation, allowing the connection process to proceed smoothly with force applied in the correct sequence and location.

Inventive Principle:

Principle #10Preliminary action

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 design ensures efficient electrical connection by applying clamping force directly to the main cable's insulation, preventing damage to secondary cables and simplifying the connection process.

Implementation Method 1

a spring element arranged so as to exert a force against the sub-jaw at a bearing zone of the sub-jaw

Methodology Applied

Scientific EffectElastic force: Elasticity

Implementation Method 2

the force used for implementing the clamping is fully applied to the teeth to perforate the sheath of the main electric cable

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 3

sub-jaw having teeth made from electrically conductive material, disposed at the channel and oriented towards the other sub-jaw

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20250183567A1Connector with insulation perforation

Publication Date: 2025.06.05 SI DE CONSTR DAPPAREILS & DE MATERIEL ELECTRIQUES (SICAME)

AI summary

A connector with two jaws, each including a channel receiving a main electric cable and which are able to move between a separated position and a clamped position, clamping means holding the jaws in the clamped position, at least one passage intended for inserting a secondary electric cable, for each jaw a sub-jaw with teeth disposed at the channel, and, for each sub-jaw, a spring element exerting a force against the sub-jaw at a bearing zone, wherein each passage emerges at the bearing zone and spring element so as to enable the secondary electric cable to be inserted between the bearing zone and the spring element.