Reversible Splice Connector for Reusing Crimped Cable Terminals
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Solution Overview
Problem
Existing cable connectors in medium and high voltage electrical systems require cutting and discarding specialized terminals for splicing, leading to waste and inefficiency, especially when cable length adjustments are needed.
Innovation Solution
A reversible splice connector that allows cables to be lengthened or shortened without cutting the existing terminals, maintaining a reliable electrical and mechanical bond, and enabling the reuse of existing connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If cables are spliced using traditional methods, then cable length can be extended, but the specialized crimped-on terminals must be cut and discarded, resulting in waste and loss of time
Solution Approach 1:
The invention divides the cable system into separable components: the original cable with its terminal, the splice connector, and the additional cable segment. This allows the terminal to remain on the original cable while the splice connector provides the connection interface, eliminating the need to cut the terminal.
Solution Approach 2:
The splice connector acts as an intermediary component between the original cable-terminal assembly and the additional cable. It provides a mounting interface that accepts the existing terminal without requiring it to be cut, thereby preserving the terminal for future use.
2Ease of manufacture
If cables are spliced by cutting terminals, then splicing can be performed, but installation time is increased due to the need to prepare new terminals
Solution Approach 1:
The splice connector is pre-configured with mounting features that accept existing terminals. This preliminary design allows installers to directly mount the connector onto the existing terminal without time-consuming preparation steps such as cutting or modifying the terminal.
Solution Approach 2:
The existing terminal serves itself by providing the mounting interface for the splice connector. The terminal's existing structure is utilized directly, eliminating the need for additional preparation work and reducing installation time.
3Adaptability or versatility
If cables are repeatedly spliced and unspliced, then cable configuration can be modified, but the cable length decreases with each cutting operation
Solution Approach 1:
The splice connector provides a dynamic, reversible connection mechanism that allows cables to be connected and disconnected multiple times without permanent modification. This enables flexible reconfiguration while preserving the original cable length, as the connector can be removed and reinstalled without cutting the cable.
4Ease of manufacture
If traditional splicing methods are used, then cables can be connected, but scrap material is generated and environmental sustainability is reduced
Solution Approach 1:
The invention enables recovery and reuse of the specialized crimped-on terminal by providing a splice connector that mounts to the existing terminal without requiring it to be cut. The terminal can be retained and reused when the splice is removed, preventing waste and improving environmental sustainability.
Data Source
AI summary
A reversible splice connector mechanically and electrically couples a pair of electrical cables, where at least one of the electrical cables has a crimped-on electrical cable terminal with a threaded opening at the distal end of the terminal. The reversible splice connector comprises a metallic tube with at least one fastener opening that aligns with the threaded opening of the terminal and at least one threaded fastener. The splice is installable and reversible without removing the crimped-on electrical cable terminal.