Insulation-Piercing Contact Terminal for Grounding Insulated Cables
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing contact terminals fail to efficiently connect insulated electrical cables to conductive support structures for grounding purposes, leading to increased theft of uninsulated ground conductors in railway systems.
Innovation Solution
A contact terminal with a base body, clamping contact elements, insulation piercing members, and a clamping device that allows for secure electrical connection of insulated cables to conductive support structures by piercing through the insulation to contact underlying conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uninsulated ground conductors are used in railway installations, then the electrical connection to support structures is simple and direct, but the conductors are vulnerable to theft and dismantling
Solution Approach 1:
The patent applies insulation piercing technology that penetrates through the cable insulation layer to establish electrical contact with the conductor inside, while the insulation layer itself remains intact and protective. This allows the use of insulated cables without requiring removal of the protective insulation, thus preventing theft while maintaining electrical connection capability
Solution Approach 2:
The contact terminal acts as an intermediary device that bridges the insulated cable and the conductive support structure. It pierces through the insulation layer to create an electrical pathway without requiring the insulation to be removed, thus protecting the cable from theft while establishing reliable electrical connection
2Reliability
If insulated cables are used as ground conductors, then theft prevention is improved, but the assembly effort increases due to the need to penetrate insulation
Solution Approach 1:
The contact terminal integrates multiple functions into a single component: the insulation piercing element, the clamping contact element, and the connection to support structure are combined into one device. This merging allows simultaneous penetration of insulation, establishment of electrical contact, and mechanical fixation in a single assembly operation, thus reducing overall assembly effort while maintaining theft resistance
Solution Approach 2:
The contact terminal is pre-configured with insulation piercing elements and clamping contact elements in specific positions and orientations. This preliminary arrangement allows the installer to simply insert and secure the terminal without performing separate steps for insulation removal, contact establishment, and mechanical fixation, thus reducing assembly effort
3Strength
If conventional clamps are used to fasten cables to support structures, then mechanical fastening is achieved, but electrical connection through insulation is not established
Solution Approach 1:
The contact terminal merges the mechanical fastening function of conventional clamps with the electrical connection function of insulation piercing elements. The same device that mechanically secures the cable to the support structure also pierces through the insulation to establish electrical contact, thus achieving both mechanical strength and electrical reliability simultaneously
Solution Approach 2:
The contact terminal is designed as a multi-functional device that performs both mechanical fastening and electrical connection tasks. It can fasten various types of cables (insulated or uninsulated) to conductive support structures while simultaneously establishing electrical contact, thus providing universal applicability without compromising either mechanical strength or electrical reliability
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
Facilitates secure and efficient electrical connection of insulated cables to support structures, preventing theft by allowing the use of insulated cables as ground conductors without additional assembly effort.
Implementation Method 1
at least one insulation piercing member (12, 13) used to contact an electrical conductor located beneath the insulation of a cable
Implementation Method 2
a clamping device (7) used to clamp the at least one clamping contact element (6) against the supporting structure
Implementation Method 3
to contact the shielding located beneath the outer insulation of shielded electrical cables and to electrically connect it to a supporting structure that represents the earth
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Described is a contact terminal 1 for fastening and electrically connecting a cable 23 having electrical insulation 22 to an electrically conductive support structure 21, which contact terminal 1 comprises - a base body 2 with a cable receptacle 5 through which a cable 23 to be fastened can be passed, and with at least one clamping contact element 6 which can be placed under pretension against the support structure 21, - at least one insulation penetration member 12 which is in electrical connection with the at least one clamping contact element, comprises at least one penetration body and is adjustable relative to the base body 2,13 for contacting an electrical conductor 24 located beneath the insulation 22 of the cable 23 and - a tensioning device 7 for applying a prestress to the at least one tensioning contact element 6 relative to the supporting structure 21 and for establishing an electrical contact between the at least one insulation penetrating part 12, 13 and the at least one electrical conductor 24 of a cable 23 guided through the cable receptacle 5 by pushing the at least one penetrating body of the insulation penetrating member 12, 13 through the insulation 22 of the cable 23 located on the outside of the electrical conductor 24 to be contacted.