Insulation-Piercing Connector With Sealed Multi-Cable Solar Taps
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Solution Overview
Problem
Existing solar energy farm applications face challenges in securely connecting smaller gauge solar panel cables to large gauge conducting cables without stripping insulation, requiring a connection that is easy to install, watertight, and protected from outdoor elements.
Innovation Solution
An insulation piercing connector with an enclosure housing insulation piercing blades and terminal pins, allowing for toolless installation, and providing a watertight seal and electrical coupling using a T-bolt and nut system, capable of accommodating various cable sizes and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If insulation piercing blades are used to connect branch cables to main cables without stripping insulation, then installation time is reduced and ease of operation is improved, but ensuring secure electrical connection and reliability becomes more challenging
Solution Approach 1:
The patent introduces an intermediary enclosure housing system that contains the insulation piercing blades and provides a controlled environment for the piercing operation. The enclosure with cable access ports and internal mounting structures mediates between the piercing action and the external environment, ensuring secure connections while maintaining ease of installation through toolless operation.
Solution Approach 2:
The connector is segmented into distinct functional components: the enclosure housing, insulation piercing blade assembly, cable clamp, and seal elements. This segmentation allows each component to be optimized for its specific function - the blades for easy piercing, the clamp for secure cable holding, and the seal for protection - while working together to achieve both ease of installation and connection reliability.
2Adaptability or versatility
If the connector is designed to accommodate various cable sizes and materials, then adaptability is improved, but device complexity increases
Solution Approach 1:
The enclosure housing is designed as a universal platform that can accommodate multiple cable sizes and types through adjustable cable clamps and configurable blade positions. The same basic enclosure structure serves multiple functions: providing mechanical support, environmental protection, cable management, and electrical isolation, thereby reducing overall device complexity while maintaining high adaptability.
Solution Approach 2:
The connector utilizes parameter changes in the cable clamp mechanism and blade positioning system to adapt to different cable diameters and materials. By adjusting these parameters within the same device structure, the connector achieves versatility without requiring multiple specialized components, thus avoiding increased complexity.
3Object-affected harmful factors
If the enclosure provides watertight sealing and protection from outdoor elements, then protection capability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs flexible gasket seals and thin film sealing elements within the enclosure housing to achieve watertight protection. These flexible sealing components can be easily manufactured and installed, providing effective protection against moisture and environmental elements without requiring complex manufacturing processes or heavy-duty structural modifications to the enclosure.
4Ease of operation
If insulation piercing blades protrude through the enclosure for direct access, then ease of operation is improved, but protection of internal components from elements is worsened
Solution Approach 1:
The enclosure housing acts as an intermediary protective barrier that allows blade accessibility while protecting internal components. The housing includes sealed cable access ports and internal mounting structures that enable the piercing blades to extend into the cable path while maintaining environmental isolation. This intermediary structure resolves the contradiction by providing both accessibility and protection simultaneously.
Data Source
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AI summary
An insulation piercing connector for a solar system install is provided that is installed easily and provides multiple connections, using industry standard connectors, and protects the internal components from the elements such as water infiltration and UV exposure.