Integrated Cable Terminal for Compact High-Voltage Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional high voltage electrical cable terminal connection systems are bulky, heavy, and complex, requiring additional manufacturing steps and prone to loose strands during assembly, which can lead to defects.
Innovation Solution
An electrical cable with integrated strands forming a fused connection terminal at one end, eliminating the need for a separate terminal plate, thereby reducing weight, size, and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical cable terminal connection systems are used, then reliable electrical connection is achieved, but the system becomes bulky, heavy, and complex
Solution Approach 1:
The patent merges the cable conductor and terminal into a single integrated structure. The terminal is formed by fusing the cable strands themselves, eliminating the need for a separate terminal component. This combining of functions reduces system complexity while maintaining reliable electrical connection through the fused strand structure.
Solution Approach 2:
The patent extracts and eliminates the separate terminal plate from the conventional connection system. By forming the terminal directly from the cable strands through fusion, the design removes the additional terminal component, thereby simplifying the overall system structure while preserving connection functionality.
2Reliability
If conventional electrical cable terminal connection systems are used, then reliable electrical connection is achieved, but the size and weight of the cable connection arrangement increase
Solution Approach 1:
The cable and terminal are merged into a single integrated component where the terminal is formed by fusing the cable strands. This eliminates the need for additional terminal material, directly reducing the weight of the cable connection arrangement while maintaining reliable electrical connection.
3Reliability
If conventional electrical cable terminal connection systems are used, then electrical connection is achieved, but additional manufacturing steps and assembly complexity are required
Solution Approach 1:
The manufacturing process merges the terminal formation step with the cable manufacturing process. By fusing the strands during cable production, the terminal is created as an integral part of the cable, eliminating subsequent terminal attachment steps and simplifying the overall manufacturing process.
Solution Approach 2:
The terminal is formed preliminarily during the cable manufacturing process itself, rather than as a separate post-processing step. The strands are fused to create the terminal structure before the cable is completed, which simplifies subsequent assembly operations and reduces manufacturing complexity.
4Reliability
If conventional electrical cable terminal connection systems are used, then electrical connection is achieved, but loose strands during assembly can occur leading to defects
Solution Approach 1:
The cable strands are merged into a unified fused structure at the terminal end, eliminating loose individual strands. This fusion process binds all strands together securely, preventing them from becoming loose during assembly operations and thereby improving manufacturing precision and reducing defects.
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 integrated connection terminal results in a lighter, more compact, and efficient cable connection system that requires less space and reduces manufacturing complexity while minimizing the risk of loose strands.
Implementation Method 1
the plurality of strands are fused together via ultrasonic welding
Data Source
AI summary
A high voltage high current electrical cable includes a plurality of strands forming the electrical cable, where the electrical cable includes a first end and a second opposite end, with the first end having a first portion and a second portion. The second portion forming a distal end of the first end of the cable, with the first portion of the cable being encapsulated in an insulation material and the second portion being free of the insulation material. The plurality of strands in the second portion are sized and shaped and fused together into an integrated connection terminal, with the integrated connection terminal consisting of the fused together plurality of strands such that the first end of the electrical cable is free from a separate terminal component being coupled thereto.