Cable Connection Assembly Using Piercing Clamps for Stable Wiring

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Solution Overview

Problem

Conventional charging devices face instability in connections between control elements and signal sources, and between control elements and ground wires, due to complex soldering and riveting processes, which complicates maintenance and reduces connection stability.

Innovation Solution

A cable connection device with a casing and connection components that include clamping and conductive parts, where the power cables are clamped and partially pierced by the clamping parts to establish electrical connections, eliminating the need for soldering and riveting, and allowing for easy replacement and increased stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering and riveting processes are used to connect control elements with signal sources and ground wires, then electrical connections are established, but the connection stability is insufficient and the manufacturing process becomes complicated

Engineering Contradiction:

Improveconnection stabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional soldering and riveting mechanical processes with a compression connection mechanism. The compression connection component applies mechanical pressure directly to the cable conductor through contact pieces, establishing electrical connections without thermal or mechanical fastening processes. This substitution eliminates the complexity of soldering and riveting while providing stable, reliable connections that can be easily assembled and disassembled.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If soldering and riveting processes are used to establish connections, then electrical connectivity is achieved, but the manufacturing cost increases and production efficiency decreases

Engineering Contradiction:

Improveconnection stabilityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The compression connection mechanism replaces time-consuming soldering and riveting operations with a simple compression assembly action. The connection component can be quickly installed by compressing the cable assembly, significantly reducing manufacturing cycle time and increasing production efficiency while maintaining reliable electrical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The compression connection component is designed to self-establish electrical connections through its inherent compression structure. The contact pieces automatically contact the cable conductors when compression is applied, eliminating the need for additional fastening steps or specialized equipment, thereby simplifying the manufacturing process and reducing costs.

Inventive Principle:

Principle #25Self-service

3Reliability

If traditional soldering and riveting methods are used, then connections are established, but maintenance and replacement become difficult

Engineering Contradiction:

Improveconnection stabilityVSAvoidmaintenance ease

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent divides the connection system into separable components: the compression connection component and the cable assembly. This segmentation allows the cable or connection component to be independently replaced without affecting the entire charging device. The modular design enables easy maintenance and repair by simply removing and replacing the relevant component, significantly improving ease of repair compared to traditional soldered or riveted connections.

Inventive Principle:

Principle #1Segmentation

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 solution provides a stable and simple assembly process, reducing manufacturing costs and increasing production yield while maintaining connection integrity, even when exposed to external forces.

Implementation Method 1

The clamping part clamps the at least one power cable and partially pierces the insulating sleeve, so that the clamping part is electrically connected with the wire core

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS11824288B2Cable connection device

Publication Date: 2023.11.21 DELTA ELECTRONICS INC(CN)

AI summary

A cable connection device is provided. The cable connection device includes a casing, a connection component, a power cable and a circuit board. The casing includes a first accommodation space, a second accommodation space and a channel. The channel is in communication between the first accommodation space and the second accommodation space. The connection component is penetrated through the channel and includes a clamping part disposed in the first accommodation space and a first conductive part disposed in the second accommodation space. Portion of the power cable is disposed in the first accommodation space. The clamping part clamps the power cable and partially pierces the insulating sleeve, so that the clamping part is connected with the wire core. The circuit board is disposed in the second accommodation space and comprises second conductive part. The second conductive part is contacted with the first conductive part.