Sealed Insulation Piercing Connector for Moisture Protection
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Solution Overview
Problem
Existing connector systems for electrical conductors lack a reliable and efficient method to form sealed connections that protect against environmental factors, particularly moisture, while ensuring secure electrical continuity and accommodating various conductor sizes and configurations.
Innovation Solution
A sealed connector system comprising an insulation piercing connector with a compression mechanism and a sealant-filled enclosure assembly, where the connector system includes a pair of blade members and a sealant-filled housing with pivotally connected cover members, ensuring electrical continuity and environmental protection by encapsulating the connection within a gel-based sealant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation piercing connector is used to form mechanical and electrical connections between insulated cables, then electrical continuity is achieved, but protection against environmental factors such as moisture is insufficient
Solution Approach 1:
The connector is nested within a housing that contains a sealant-filled cavity. The sealant acts as an inner protective layer surrounding the connector, while the housing provides an outer protective shell, creating a nested protective structure that prevents moisture ingress while maintaining electrical continuity.
Solution Approach 2:
A sealant is introduced as an intermediary substance between the connector and the external environment. The sealant fills the cavity within the housing and provides a protective barrier that prevents moisture from reaching the electrical connector, while allowing the connector to maintain its electrical function.
2Object-affected harmful factors
If a sealed enclosure is added to protect the connector, then environmental protection is improved, but device complexity increases
Solution Approach 1:
The housing serves multiple functions simultaneously: it provides structural support for the connector, contains the sealant to prevent moisture ingress, and offers mechanical protection. This multi-functionality reduces the need for separate protective components, thereby limiting the increase in device complexity while improving environmental protection.
Solution Approach 2:
The housing is designed as a relatively simple enclosing structure that contains the sealant and protects the connector. By using a straightforward housing design rather than complex multi-layer protection systems, the solution improves environmental protection while minimizing the increase in device complexity.
3Reliability
If the connector is enclosed within a sealed housing, then protection against corrosion is enhanced, but ease of manufacture decreases
Solution Approach 1:
The sealant is pre-filled into the housing cavity before the connector is installed. This preliminary action simplifies the manufacturing process by eliminating the need for complex sealing operations after assembly, while still providing effective corrosion protection through the sealant barrier.
Solution Approach 2:
The nested structure allows the connector to be inserted into the pre-prepared housing containing the sealant. This modular nested design simplifies manufacturing compared to integrated sealed structures, as the connector and housing can be prepared separately and then assembled together with the sealant already in place.
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 seal that prevents moisture ingress, ensures long-lasting electrical connectivity, and accommodates a range of conductor sizes, offering enhanced protection against corrosion and mechanical impacts, while being suitable for various electrical power systems including solar power generation.
Implementation Method 1
encapsulating the connection within a gel-based sealant
Implementation Method 2
compression mechanism... the piercing members are forced through the insulation layers
Data Source
Figure 1
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AI summary
An enclosed connection system for mechanically and electrically connecting first and second cables, the cables each including an elongate electrical conductor covered by an insulation layer, includes an insulation piercing connector and an enclosure. The insulation piercing connector includes at least one electrically conductive piercing member and a clamping mechanism. The clamping mechanism is configured and operable to force the at least one piercing member through the insulation layers of the first and second cables and into electrical engagement with the conductors of the first and second cables such that the conductors of the first and second cables are electrically connected to one another through the at least one piercing member. The enclosure is configured to receive and cover the connection and to protect the insulation piercing connector.