Insulation Piercing Connector End Cap for Pull-Out Resistance
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Solution Overview
Problem
Conventional insulation piercing (IP) connectors are susceptible to pull-out and impact forces due to insecure end caps, which can lead to disconnection of electrical cables.
Innovation Solution
An electrical connector assembly with a protective end cap featuring pivotally connected portions and locking features, combined with an elastomeric seal and conductive piercing members, ensures secure enclosure and protection of the connection, preventing disconnection under mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional end caps are used with IP connectors, then the device complexity is reduced, but the reliability deteriorates due to susceptibility to pull-out and impact forces
Solution Approach 1:
The end cap is divided into first and second portions that can be separately positioned and secured, allowing each portion to perform specific functions (cable enclosure and connector protection) while collectively providing enhanced security against pull-out and impact forces
Solution Approach 2:
The end cap portions are configured to enclose and protect internal components (cable end and connector means) within a nested structure, where the first portion encloses the cable end and the second portion secures the connector means, creating a protective hierarchy
2Reliability
If a secure enclosed end cap design is implemented, then the reliability improves against mechanical stress, but the ease of operation deteriorates due to restricted cable access
Solution Approach 1:
The end cap portions are configured to be movable relative to each other, allowing the end cap to transition between an open state during installation (easy cable access) and a secured closed state during operation (impact resistance), providing dynamic adaptability to different operational phases
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 enhanced end cap design provides a stronger, impact-resistant connection that remains secure against pull-out and impact forces, ensuring reliable electrical continuity between cables.
Implementation Method 1
an elastomeric seal inserted over a terminal end of the cable
Implementation Method 2
The clamping mechanism is configured and operable to force the at least one piercing member through the insulation layers of the first and second cables and into electrical engagement with the conductors
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An electrical connector assembly (10) including an insulation piercing connector (100) having a pair of clamping jaws (120, 130). At least one of the jaws (120, 130) includes at least one electrically conductive piercing member (116T, 118T), and a male connector member (150) extending outwardly from one of the clamping jaws (120). A clamping mechanism (140) is configured to force the at least one piercing member (116T, 118T) through the insulation layers (12B, 14B) of the first and second cables (12, 14) and into electrical engagement with the conductors (12A, 14A) of the first and second cables (12, 14) to form an electrical connection between the first and second cables (12, 14). An elastomeric seal (300) is inserted over the terminal end of the first cable (12), and a protective end cap (400) is secured to the male connector member (150) and encloses the terminal end of the first cable (12).