Modular Cable Connector With Integrated Grounding and Size Adaptation
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Solution Overview
Problem
Existing connectors for shielded or armored cables lack adaptability to various cable dimensions and are not area-efficient, with exposed grounding wires posing safety risks and potential for secondary damage, while existing solutions that protect the grounding position within the connector are not adjustable and inefficient in terms of space usage.
Innovation Solution
A modular connector with a compressible body and axial groove that securely fits around the cable, featuring a braided wire conductor arrangement sandwiched between the compressible body and the cable, allowing for optimal contact and corrosion resistance, and peelable sheets for diameter adjustment to accommodate different cable sizes, providing a secure and efficient grounding solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a grounding wire is connected to the cable outside the connector, then the grounding location is exposed and accessible for verification, but the risk of intentional or unintentional damages increases and exposed grounding cables may pose safety risks
Solution Approach 1:
The grounding function is extracted from the external grounding wire configuration and integrated into the connector body itself. The connector includes a grounding element (conductive component) that directly contacts the cable screen or armor, eliminating the need for separate external grounding wires and their associated safety risks while maintaining grounding verification capability through the connector's designated grounding terminal.
Solution Approach 2:
The grounding element is nested within the connector structure, specifically positioned between the compressible body and the cable screen/armor. This nested configuration protects the grounding function within the connector housing while still providing external access to the grounding terminal for verification purposes, thus resolving the contradiction between protection and accessibility.
2Object-affected harmful factors
If a grounding element is forced towards the cable screen using gland nuts, then the grounding position is protected inside the connector, but the connectors are not readily adjustable to cables of various dimensions and are not area efficient
Solution Approach 1:
The connector employs a compressible body that can dynamically adjust its compression force and internal geometry to accommodate cables of various dimensions. The compressible body deforms elastically under compression to apply consistent grounding force on the cable screen/armor while adapting to different cable sizes, eliminating the need for fixed gland nut configurations.
Solution Approach 2:
The connector utilizes parameter changes in the compressible body's physical state (compression ratio, density) to achieve adaptability. By varying the compression force applied to the compressible body, the connector can accommodate different cable dimensions while maintaining effective grounding contact, thus providing both protection and versatility.
3Ease of operation
If regular cable connectors are used with external grounding wires, then the performance is readily verifiable, but both the grounding wire and grounding location are exposed increasing risk of damage
Solution Approach 1:
The vulnerable external grounding wire is extracted and replaced by an integrated grounding element within the connector. The grounding function remains verifiable through the connector's external terminal, but the critical grounding contact point is protected inside the connector body, eliminating the exposure and damage risk associated with external grounding wires.
Solution Approach 2:
The connector employs a compressible body that acts as a protective flexible shell enclosing the grounding element. This compressible body protects the grounding contact area from damage while still allowing for effective electrical contact with the cable screen/armor, thus resolving the contradiction between protection and functionality.
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 modular connector ensures reliable and adaptable grounding with reduced risk of damage, enhanced safety, and efficient current transport, while maintaining a compact and area-efficient design, capable of handling high currents and preventing electromagnetic interference.
Implementation Method 1
a connector in accordance with e.g. US 5 059 747 or US-RE-38 294 E, where a grounding element is forced towards the cable screen as a pair of gland nuts are forced towards each other
Implementation Method 2
The use of a compressible body (which is resilient too) as a pushing means for forcing a conductor arrangement towards the cable
Data Source
Figure 1
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Figure 5~7
AI summary
A modular connector for cables and pipes has a compressible body (208) with an axial groove provided therein for arrangement of a shielded cable extending from a first end to a second end, and the groove is dimensioned or dimensionable to sealingly fit around a circumference of the shielded or armored cable or the pipe. The connector (200) further comprises a conductor arrangement arranged between the first end and die second end, the conductor arrangement may be sandwiched between the compressible body (208) and a cable screen or armor of the cable or the pipe. The the conductor arrangement (210) further extends to an outside of the modular connector (200).