Integrally Formed Cable Connector Socket for Power Networks
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Solution Overview
Problem
Conventional cable connection devices require additional steps and components, leading to increased manufacturing costs, assembly complexity, and potential air pockets that can cause electrical stress and reliability issues.
Innovation Solution
A cable assembly with an integrally formed connector socket and conductor element, eliminating the need for separate connectors and reducing parts, which simplifies manufacturing, assembly, and reduces the risk of air pockets by allowing for pre-assembly and the use of a shrinkable jacket for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate connector socket is attached to the conductor element, then the connection device can be assembled with modular components, but the assembly process requires additional steps and time
Solution Approach 1:
The connector socket is integrally formed with the conductor element as a single piece, eliminating the need for separate attachment steps. This merging of components reduces assembly time and eliminates the interface between separate parts while maintaining modular manufacturing benefits.
2Ease of manufacture
If a separate connector socket is attached to the conductor element, then the connection device can be manufactured with standardized parts, but the interface between parts creates air pockets that generate electrical stress
Solution Approach 1:
The integral formation of the connector socket with the conductor element eliminates interfaces where air pockets could form. This single-piece construction ensures continuous electrical contact and eliminates the need for cage electrodes to shield against electrical stress from interfaces.
3Adaptability or versatility
If multiple separate components are used in the connection device, then the design can be optimized for each individual component, but the number of parts increases manufacturing cost
Solution Approach 1:
The connector socket and conductor element are combined into a single integrally formed component, reducing the total number of parts while maintaining the functional optimization of each element through integrated design.
4Ease of manufacture
If multiple separate components are used in the connection device, then each component can be independently manufactured, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The integral formation of the connector socket with the conductor element eliminates assembly steps while allowing the entire component to be manufactured using optimized processes suitable for the specific application requirements.
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 solution results in a more cost-effective, reliable, and easier-to-assemble cable connection device with improved mechanical stability and reduced electrical stress, enhancing the reliability and efficiency of power cable connections in electrical installations.
Implementation Method 1
The jacket is made of a shrinkable material. The shrinkable material is shrunk over the conductor element and the cable plug
Data Source
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AI summary
Cable connection device (2) for connecting a power cable to an electrical installation of a power network, comprising a conductor element (11) having a first end portion (21), a second end portion (31), and a middle portion (41) disposed between the first and the second end portion. The conductor element comprises a connector socket (50), arranged at the first end portion, for mating with a cable plug. The connector socket is integrally formed with the middle portion.