Insulation-Piercing Busbar Connector for Fast Cable Taps
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Solution Overview
Problem
Existing methods for connecting multiple cables to a larger cable in solar arrays are complex and require significant training and specialized tools, making them inefficient and time-consuming.
Innovation Solution
An insulation piercing electrical connector system that uses a central busbar with sharp connection ends to penetrate the insulation of a larger cable, allowing for quick and easy electrical connections between multiple cables and the larger cable via a central busbar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional cable connection methods are used, then reliable electrical connection is achieved, but the process becomes complex and time-consuming
Solution Approach 1:
The connection system is divided into distinct functional components: the central busbar with piercing elements, individual cable connectors, and insulation pieces. Each component performs a specific function, allowing for simplified assembly and faster connection without compromising reliability.
Solution Approach 2:
The sharp piercing elements on the busbar automatically penetrate the cable insulation during insertion, creating electrical contact without requiring manual stripping or specialized tools. The system performs the insulation penetration function itself, eliminating complex preparation steps.
2Ease of operation
If traditional cable connection methods are used, then secure electrical connection is achieved, but extensive training and specialized tools are required
Solution Approach 1:
The piercing elements automatically penetrate the cable insulation upon insertion, and the compression mechanism self-adjusts to create reliable electrical contact. This self-service functionality eliminates the need for specialized tools and extensive training, making the connection process accessible to users with minimal skill.
Solution Approach 2:
The piercing element, electrical contact, and compression function are merged into a single integrated busbar component. This consolidation eliminates the need for separate tools for insulation removal, contact creation, and securing, simplifying the overall operation.
3Productivity
If insulation piercing connection is implemented, then quick connection is achieved, but proper insulation penetration must be ensured
Solution Approach 1:
The sharp piercing elements are pre-configured with precise geometry and hardness to ensure they penetrate the insulation to the correct depth automatically during insertion. This preliminary design ensures consistent penetration precision without requiring operator skill or adjustment.
Solution Approach 2:
The piercing elements are designed with specific material properties (sharpness, hardness) and geometric parameters (angle, length) that enable reliable insulation penetration. By optimizing these parameters, the system achieves both quick connection and precise penetration control.
Data Source
AI summary
In one or more embodiments, an insulation piercing electrical connector device, a system for connecting one or more cables to a larger sized cable via central busbar and a method for providing an insulation piercing electrical connector or a system for connecting one or more cables to a larger sized cable via central busbar are disclosed. The system for connecting one or more cables to a larger cable via central busbar includes a central busbar provided with at least one connection end, wherein the central busbar is also connected to one or more cables, and wherein at least one connection end is sharp such that it is capable of penetrating the insulation of the larger cable and makes an electrical connection between the one or more cables to the larger cable via central busbar when penetrated in the insulation of the larger cable.