Integrated High-Voltage Cable Terminal for Lighter End Connections
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Solution Overview
Problem
Conventional high voltage high current electrical cable connector systems require large and heavy terminal plates, leading to increased size and weight of connection arrangements, complex manufacturing processes, and potential assembly defects.
Innovation Solution
An integrated cable connection system where the terminal plate is eliminated, with the strands fused together to form a compact, plate-like structure that includes a slot for a fastener, and a cover plate is used to secure the connection, eliminating the need for a separate terminal plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metal plate connector terminals are used, then reliable electrical connection is achieved, but the size and weight of the connection arrangement increases
Solution Approach 1:
The patent merges the cable strands directly with the connection terminal by fusing the strands to form an integrated terminal structure, eliminating the need for separate metal plate connector terminals. This integration maintains reliable electrical connection while significantly reducing the overall weight of the connection arrangement.
Solution Approach 2:
The patent extracts and eliminates the heavy metal plate connector terminal component from the connection system, replacing it with a lighter integrated terminal formed directly from the cable strands through fusion, thereby achieving weight reduction while maintaining connection reliability.
2Reliability
If conventional metal plate connector terminals are used, then secure connection is achieved, but the device size increases
Solution Approach 1:
The patent combines the cable strands and terminal into a single integrated structure through fusion, eliminating the need for separate large metal plate terminals and their associated mounting hardware, thereby reducing the overall area occupied by the connection arrangement while maintaining secure connection.
Solution Approach 2:
The patent removes the bulky metal plate terminal component from the connection system, replacing it with a compact integrated terminal formed from the cable strands themselves, thus reducing the device size while preserving connection security.
3Reliability
If separate terminal plates are used, then reliable connection is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the terminal formation process with the cable manufacturing process by fusing the strands during cable assembly, eliminating separate terminal manufacturing and assembly steps, thereby reducing manufacturing complexity while maintaining connection reliability.
Solution Approach 2:
The patent extracts the terminal manufacturing process from the overall manufacturing system by integrating terminal formation directly into the cable manufacturing process through strand fusion, eliminating the need for separate terminal production and assembly operations.
4Reliability
If conventional terminal systems are used, then connection function is achieved, but assembly defects may occur
Solution Approach 1:
The patent merges the terminal formation with the cable manufacturing process through strand fusion, creating an integrated structure that eliminates separate assembly steps where defects could occur, thereby improving manufacturing precision while maintaining connection function.
Solution Approach 2:
The patent removes the separate terminal assembly process from the manufacturing system, replacing it with integrated terminal formation during cable manufacturing through fusion, thus eliminating potential assembly defects while preserving connection function.
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 lighter, more compact connection arrangement that reduces manufacturing complexity, weight, and space requirements, while minimizing assembly defects.
Implementation Method 1
the plurality of strands are fused together via ultrasonic welding
Data Source
AI summary
A high voltage cable includes a plurality of strands forming the cable, which has a first end and a second opposite end, the first end including a first portion and a second portion that forms a distal end of the cable. The first portion is encapsulated in insulation and the second portion is free of the insulation. The strands in the second portion are sized and shaped and fused together into a lower integrated connection terminal having a slot at the distal end, an upper face and an opposed lower face. An upper cover plate may be positioned over the integrated connection terminal in contact with the upper face, and includes an upper surface for receiving a fastener. The connection terminal consists of the fused together strands such that the first end is free from a separate lower connection terminal being welded to an end of the first portion.