Two-Part Insulating Body for Low-Voltage Screw Connector Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing screw connectors for low-voltage cables face challenges such as assembly errors due to insufficient mixing of resin components, health hazards from isocyanate content, leaks, and the need for a heat source for heat-shrink tubing, which can damage cables and joints.
Innovation Solution
A screw connector with a two-part insulating body arrangement, comprising a first and second insulating body made of electrically insulating plastic, that encases the connector body and cable ends, preventing electrical contact and providing easy assembly through complementary, force-fit connections guided by the Poka-Yoke principle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If casting resin is used to insulate and protect the connector, then electrical insulation and mechanical protection are provided, but assembly errors occur due to insufficient mixing of resin components and health hazards from isocyanate content
Solution Approach 1:
The patent extracts and removes the hazardous resin casting process entirely, replacing it with a mechanical insulating body made of plastic material. This eliminates the isocyanate health hazard while maintaining the electrical insulation function through the insulating body arrangement that encases the conductor and connector.
Solution Approach 2:
The invention changes the material parameter from chemical resin (epoxy/polyurethane) to mechanical plastic material. This parameter change eliminates the mixing process and associated assembly errors, while also removing the isocyanate content health hazard, yet maintains electrical insulation through the plastic insulating body.
2Device complexity
If a single insulating body is used, then the structure is simple, but assembly is difficult and alignment is imprecise
Solution Approach 1:
The patent divides the insulating body into multiple separate parts (first insulating body portion and second insulating body portion) that can be assembled sequentially. This segmentation makes assembly easier and enables precise alignment through complementary connection surfaces and guiding features, while the segments together form the complete insulating enclosure.
3Reliability
If the insulating body is designed to encase the entire connector, then complete insulation is achieved, but assembly becomes complex and time-consuming
Solution Approach 1:
The insulating body is segmented into multiple portions that can be assembled in a simplified sequence. The first portion is attached to one end of the conductor/connector assembly, and the second portion is attached to the other end, with complementary connection surfaces ensuring precise alignment. This segmented approach achieves complete insulation enclosure while maintaining fast assembly.
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a screw connector for cables with nominal voltages up to 1 kV (low voltage), wherein the screw connector has a connector body for receiving cable ends to be joined and clamping screws. According to the invention, it is particularly provided that the screw connector has an insulating body arrangement (1) comprising a first insulating body (2) and a second insulating body (3) separately formed therefrom, wherein the first insulating body (2) has a sleeve-shaped base body (4) made of an electrically insulating material, from which a first region of the connector body is received or can be received, and wherein the second insulating body (3) has a sleeve-shaped base body (5) made of an electrically insulating material, from which a second region of the connector body is received or can be received.