Piercing Junction Housing for Flexible High-Current Cable Routing
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Solution Overview
Problem
Existing cable connection systems for charging stations, particularly for electric vehicles, face challenges with high current requirements, necessitating large cable cross-sections that are inflexible and difficult to route, leading to installation complexities and potential short circuits.
Innovation Solution
A cable connection system using separate round cables routed parallel to each other, with junction boxes that allow strip-free connections via piercing contact elements, providing flexibility and ease of installation, while ensuring electromagnetic and environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large cable cross-sections (25 mm² or more) are used to supply high currents to charging stations, then the current carrying capacity is sufficient, but the cables become inflexible and difficult to route
Solution Approach 1:
The patent divides the through-line into separate round cables instead of using a single flat cable. Each round cable can be independently routed, allowing flexible installation while maintaining the required current carrying capacity through appropriate cable selection for each individual cable
2Ease of operation
If separate round cables are used instead of flat cables, then routing flexibility and ease of installation improve, but the complexity of managing multiple separate cables increases
Solution Approach 1:
Junction boxes are inserted into a junction housing, creating a nested structure that organizes multiple separate round cables and their connections in a compact, manageable manner, reducing the overall complexity of cable management
3Ease of manufacture
If traditional cable connection methods are used, then connections can be established, but stripping insulation and potential short circuits during installation occur
Solution Approach 1:
The patent replaces traditional mechanical stripping and twisting connections with piercing contact elements that penetrate the insulation and directly contact the conductor. This substitution eliminates the need for insulation removal and reduces the risk of short circuits during installation
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 system enables flexible routing of high-current cables, reduces installation complexity, prevents short circuits, and ensures quick, secure connections suitable for charging stations and other applications, with enhanced protection against water and dust.
Implementation Method 1
Piercing contact elements are provided for strip-free contacting, which are suitable for piercing the insulation of the respective round cable and establishing contact with its conductor
Implementation Method 2
Each junction box contacts a round cable of the through-line without stripping. Piercing contact elements are provided for strip-free contacting, which are suitable for piercing the insulation of the respective round cable and establishing contact with its conductor
Implementation Method 3
The round cables of the through-line are routed parallel to one another. The parallel routing of the individual round cables effectively prevents short circuits
Implementation Method 4
a junction housing, wherein the junction housing comprises a plurality of inputs for each round cable of the through-line, as well as a plurality of outputs for each round cable of the through-line. The junction housing comprises a plurality of outlets for branch lines
Data Source
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AI summary
A cable connection system for connecting a through-line to a charging station is provided, wherein the cable connection system comprises a plurality of cores of a through-line, which are designed as separate round cables, wherein the round cables of the through-line are routed parallel to one another, a junction housing, wherein the junction housing comprises a plurality of inputs for each round cable of the through-line, as well as a plurality of outputs for each round cable of the through-line. The junction housing comprises a plurality of outlets for branch lines, which can be connected to the charging station via the outlets, as well as a plurality of junction boxes inserted into the junction housing, which can be connected to the charging station via the outlets. Each junction box contacts a round cable of the through-line without stripping via piercing contact elements which are suitable for piercing the insulation of the respective round cable and making contact with its conductor.A junction box connects each branch line to the corresponding round cable of the through line, whereby each branch line within the junction box is connected to an associated outlet for the branch line.