Cable Connection Unit With Seal and Organizer for Fast Moisture-Tight Wiring
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Solution Overview
Problem
Existing cable connection solutions for connection boxes, especially those with electronic control systems in ventilation systems, face issues with moisture penetration due to unsealed conductor connections and are either costly or time-consuming to install, particularly when using prefabricated cables with plug connectors.
Innovation Solution
A cost-effective cable connection unit with a cylindrical cable seal and cable manager that allows tool-free installation, using insulation displacement terminals for electrical contacting, and a two-part cable manager design for error reduction and simplified fabrication, along with a hinged cover for protection and easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection boxes are equipped with plug connector sockets for sealed connections, then moisture protection is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs a cable seal made of elastomeric material that radially encloses the cable sheath and integrates with the housing to form a moisture-tight seal. This flexible sealing approach protects against moisture penetration without requiring complex plug connector sockets, thereby maintaining reliability while reducing device complexity.
2Reliability
If prefabricated cables with plug connectors are used, then connection reliability is improved, but installation time increases
Solution Approach 1:
The patent implements self-service features including self-aligning contact openings in the cable manager that guide conductors into proper positions, and insulation displacement contacts that automatically establish electrical connections when the cable is inserted. These features enable reliable connections without requiring prefabricated cables with plug connectors, reducing installation time while maintaining connection reliability.
3Ease of operation
If insulation displacement terminals are used for tool-free installation, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-configuring the cable manager with contact openings positioned and dimensioned to receive insulation displacement contacts. The cable seal and cable manager are designed as integrated components with predetermined geometries that ensure proper alignment and contact pressure. This preliminary preparation enables tool-free installation by operators while maintaining the manufacturing precision needed for reliable electrical contacts through controlled molding processes.
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 reliable, time-saving, and cost-effective method for connecting cables to connection boxes without tools, ensuring sealed connections and reducing installation time, while maintaining protection from dust and water ingress.
Implementation Method 1
The cable connection unit has a cable seal which radially encloses the cable sheath... The cable seal has a sealing function but at the same time represents a strain relief for the connected cable.
Implementation Method 2
The cable connection unit has a cable manager which is provided for holding and fixing the four electrical conductors of the cable. The four electrical conductors lie next to one another in a plane in the cable manager.
Implementation Method 3
In the case of insulation displacement contacting, the electrical conductors are pushed between two metal blades, as a result of which the insulation of the conductors is penetrated and an electrical contact between the conductor and the insulation displacement terminal is produced.
Implementation Method 4
The cable seal is advantageously a one-piece injection-molded part which is fastened to the cable sheath by an injection-molding process. The cable manager may be a one-piece injection-molded part which is fastened to the electrical conductors or molded thereto by an injection-molding process.
Data Source
AI summary
A cable connection unit for a connection box is provided including a cable, which has at least two electrical conductors surrounded by a cable sheath; a cable seal, which radially surrounds the cable sheath; and a cable organizer, in which the at least two electrical conductors are held in a fanned-out arrangement. A matching connection box has at least one receiving region for the cable connection unit, in which the cable seal and the cable organizer can each be placed. A cover of the connection box may then be folded down, whereby the electrical conductors of the cable are pressed into respective insulation displacement contacts of the connection region and thereby electrically contacted.