Manual Electrical Connector with Segmented Clamping and Insulation
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Solution Overview
Problem
Existing electrical connectors for the photovoltaics industry require specialized tools for crimping and are not easily detachable, posing challenges in handling and ensuring reliable contact, especially under tensile loads, and are not suitable for single-pole applications.
Innovation Solution
A two-subassembly electrical connector design with a clamping device that can be manually actuated between open and closed states, allowing for easy insertion and secure sealing of the conductor end, featuring a cap nut for watertight closure and a locking mechanism for stability, along with a linear guide for precise movement and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a crimping connection is used to connect the cable to the contact element, then a reliable electrical contact is established, but a special tool is required and the connection becomes permanently fixed and non-detachable
Solution Approach 1:
The clamp is designed with a resilient clamping element that can dynamically transition between open and closed states. The spring-loaded mechanism allows the clamp to automatically adjust to the conductor and maintain reliable electrical contact while enabling easy insertion and removal without special tools.
Solution Approach 2:
The clamp incorporates a self-actuating mechanism where the resilient element automatically engages with the conductor upon insertion and maintains clamping force without requiring external tools. The design allows the connector to serve itself by using the insertion motion to trigger the clamping action.
2Reliability
If a flexible spring clamp with complex shape is used, then the conductor can be clamped, but a relatively high force is required to close the clamp and the overall size becomes large and difficult to handle
Solution Approach 1:
The connector is divided into separate functional components: a first sub-assembly containing the contact area and clamping device, and a second sub-assembly with the hollow body. This segmentation allows each component to be optimized independently, simplifying the overall structure while maintaining clamping functionality.
Solution Approach 2:
The spring constant and geometric parameters of the clamping element are optimized to reduce the closing force required. The resilient element is designed with specific elasticity characteristics that enable effective clamping with minimal actuation force, and the arm length is optimized to reduce the overall size while maintaining mechanical advantage.
3Ease of manufacture
If the connector is designed as a single integrated unit, then manufacturing is simplified, but the ability to manually actuate the clamping device and provide electrical insulation in closed state becomes more challenging
Solution Approach 1:
The connector comprises a first sub-assembly with the clamping device and a second sub-assembly with the hollow body that provides insulation. These sub-assemblies can be manufactured separately and then assembled, combining the benefits of modular design with integrated functionality. The separation allows independent optimization of manufacturing processes for each sub-assembly.
Solution Approach 2:
The hollow body serves multiple functions: it provides electrical insulation in the closed state, protects the contact area, and forms part of the sealing structure. The cap nut also serves dual purposes by closing the contact area and providing a mounting interface for the hollow body.
4Strength
If the clamp is designed for plugging onto a bus bar, then it can handle high current applications, but it is not suited for single contacting applications
Solution Approach 1:
The clamp design is made versatile to accommodate different application types. The contact area and clamping mechanism are designed to work effectively whether connecting to a bus bar or a single conductor, allowing the same connector design to serve multiple purposes in different electrical connection scenarios.
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
Enables simplified manual connection and disconnection of electrical cables without specialized tools, ensuring reliable electrical contact and protection against moisture, while maintaining mechanical stability and ease of use.
Implementation Method 1
a resilient clamping element which can be elastically deformed in a first direction towards the contact area so as to clamp the received conductor end onto the contact area
Implementation Method 2
The first and the second sub-assemblies are formed to release the clamping device in the open state for manually clamping the conductor end, and to electrically insulate the contact area including the clamping device in the closed state
Implementation Method 3
The hollow body is configured to enclose the contact area including clamping device in the closed state in a watertight manner. Moisture is particularly critical because it can result in a short or in corrosion of the conductor
Data Source
AI summary
The present invention relates to an electrical connector with a first and a second sub-assembly. The first sub-assembly comprises a contact area for receiving a conductor end and for establishing an electrical contact with the received conductor end. The first sub-assembly further comprises a clamping device for clamping the conductor in the contact area. The second sub-assembly comprises a hollow body with a hollow space for receiving the contact area. The first and the second sub-assemblies are made as one piece and are configured to release the clamping device in the open state for manually clamping the conductor end, and to electrically insulate the contact area including the clamping device in the closed state.