Cable Connection Unit With Integrated Sealing and IDC Termination
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Solution Overview
Problem
Existing junction boxes in building installations, particularly those with electronic controls for ventilation systems, face issues of unsealed conductor connections that can be damaged by moisture and require costly, time-consuming pre-assembly with connectors.
Innovation Solution
A cable connection unit with a cable seal and cable manager, featuring insulation displacement connectors (IDCs) for tool-free installation, ensuring sealed and strain-relieved connections, and a test device for verifying electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connector sockets are used to seal conductor connections, then protection against moisture is improved, but cost and installation time increase due to expensive components and pre-assembly requirements
Solution Approach 1:
The patent extracts the sealing function from separate connector sockets and integrates it directly into the junction box housing through molded-in sealing elements. This eliminates the need for expensive pre-assembled connector sockets while maintaining moisture protection, thereby reducing both cost and installation time.
Solution Approach 2:
The patent merges the sealing function with the junction box housing structure itself. The housing includes integrated sealing elements that directly seal the conductor connections without requiring separate connector sockets, combining multiple functions into a single component to simplify installation.
2Reliability
If connector sockets with pre-assembled connectors are used, then sealed connections are achieved, but installation complexity and time consumption increase
Solution Approach 1:
The patent removes the pre-assembly requirement by integrating the sealing function directly into the junction box housing. Conductors can be inserted directly into the housing where sealing elements automatically seal the connections, eliminating the need for separate pre-assembled connector sockets.
Solution Approach 2:
The sealing elements in the housing automatically seal the conductor connections as the conductors are inserted, without requiring pre-assembly of separate connectors. The system performs the sealing function automatically during the insertion process itself.
3Productivity
If individual conductor connections are made without sealing, then installation is simple and fast, but moisture can penetrate and damage electronics
Solution Approach 1:
The patent combines the conductor connection function with the sealing function in a single integrated structure. The housing includes molded-in sealing elements that automatically seal around conductors as they are inserted, providing both connection and protection simultaneously without requiring separate sealing components.
Solution Approach 2:
The patent uses flexible sealing elements (such as elastomeric seals or gaskets) molded into the housing that can deform to accommodate conductor insertion while maintaining the seal. These flexible sealing structures provide moisture protection without interfering with the simplicity of conductor insertion.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a cable connection unit (1) for a connection box (10), consisting of: a cable (4), which has at least four electrical conductors (5) surrounded by a cable sheath; a cable seal (3), which radially surrounds the cable sheath; and a cable organizer (2, 2', 2'', 2'''), in which the at least four electrical conductors (5) are held in a fanned-out arrangement. A matching connection box (10) has at least one receiving region (11) for the cable connection unit (1), in which the cable seal (3) and the cable organizer (2, 2', 2'', 2''') can each be placed. Subsequently, the cover (15) of the connection box (10) is folded down, whereby the electrical conductors of the cable (5) are pressed into respective insulation displacement contacts (14) of the connection region (11) and thereby electrically contacted.