Modular Heating Cable Connector for Tool-Free Field Termination

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing cable connection systems, particularly for heating and power cables, are inefficient and require specialized tools and skills for field connections, often resulting in incomplete or unreliable connections.

Innovation Solution

A modular connection system comprising a universal end termination plug and various modules, including a base module with sensors, that allows for easy field terminations without specialized tools, enabling secure electrical connections to heating and power cables.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional cable connection methods are used in the field, then electrical connections can be made, but the process requires specialized tools and skills, is time-consuming, and may not achieve reliable connections

Engineering Contradiction:

Improveconnection reliabilityVSAvoidease of field assembly

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The connection system is divided into separate modular components: a connector that attaches to the cable end and a receptacle that receives the connector. This segmentation allows the cable preparation to be simplified while maintaining reliable electrical contact through the modular interface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector design includes self-aligning features and self-securing mechanisms that allow field assembly without specialized tools or skills. The connector automatically positions itself within the receptacle and secures the electrical connection through inherent mechanical features.

Inventive Principle:

Principle #25Self-service

2Ease of manufacture

If cable insulation is stripped to expose conductors for connection, then electrical contact can be made, but the process is difficult, requires special tools, and may not produce clean conductors

Engineering Contradiction:

Improveease of cable preparationVSAvoidconductor cleanliness

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The connector acts as an intermediary component that interfaces with the cable without requiring complete stripping of insulation. The connector's contact elements penetrate or displace the insulation to reach the conductors, eliminating the need for manual stripping while ensuring clean electrical contact surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The manual mechanical process of stripping insulation with tools is replaced by a mechanical displacement or penetration mechanism within the connector that automatically exposes the conductor through the insulation without requiring external stripping tools.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If IDC systems are used for cable connections, then assembly time is reduced, but the systems are bulky and not suitable for under-insulation installations

Engineering Contradiction:

Improveassembly speedVSAvoidconnector size

Core Design Contradiction:

ProductivityVSVolume of moving object

Solution Approach 1:

The connector design provides different functional zones: a compact connection interface for quick assembly and a minimized body that fits within insulation clearance. The local geometry is optimized to provide adequate contact area for electrical connection while minimizing overall volume for under-insulation installation.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The connector utilizes three-dimensional space efficiently by arranging contact elements and structural features in multiple dimensions, allowing quick assembly mechanisms while maintaining a compact overall form factor that accommodates insulation clearance requirements.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Adaptability or versatility

If different components are used for different connection types in IDC systems, then specific connection requirements are met, but the system complexity increases and factory-set terminations are required

Engineering Contradiction:

Improveconnection type flexibilityVSAvoidsystem component variety

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The connector and receptacle design provides a universal interface that can accommodate different cable types and connection configurations through a single basic component format. Variations in connection requirements are handled by modifications to the cable preparation or mounting approach rather than requiring different connector components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250174944A1Modular connection system and method

Publication Date: 2025.05.29 CHEMELEX EUROPE GMBH

AI summary

A connection system for one or more heating cables includes an end termination plug and a module. The end termination plug is configured to be coupled to an end of a heating cable and includes a plug body portion configured to electrically connect to a conductor of the heating cable and an end plug portion adjacent the plug body portion. The module includes a mating plug portion configured to plug into the end plug portion of the end termination plug, electrically and mechanically coupling together the end termination plug and the module, and a module body portion comprising a sensor.