Segmented Strain Relief Connector for Photovoltaic Cables

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Solution Overview

Problem

Existing connectors for photovoltaic systems are costly to produce due to the need for separate strain relief and sealing components for each cable diameter, and they often require expensive manufacturing processes and stockkeeping, with existing solutions not effectively addressing moisture and vibration protection.

Innovation Solution

A plug design featuring a clamping ring with interconnected, radially movable segments connected via flexible film elements and a separate elastic sealing ring, allowing for cost-effective production and effective strain relief without punctual heavy loads, compatible with various cable diameters and weather conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate strain relief and sealing components are used for each cable diameter, then reliable moisture protection and strain relief are achieved, but manufacturing costs increase and stockkeeping complexity increases

Engineering Contradiction:

Improvemoisture protection and strain reliefVSAvoidmanufacturing cost and stockkeeping

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The clamping ring is divided into multiple movable segments that can radially collapse around the cable. This segmentation allows a single design to accommodate various cable diameters without requiring separate components for each size, reducing manufacturing costs and stockkeeping complexity while maintaining reliable strain relief and moisture protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connector design integrates both strain relief and sealing functions into a universal component structure that works with cables of different diameters. The movable segments and elastic sealing ring create a multi-functional system that adapts to various cable sizes, eliminating the need for diameter-specific components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If a rigid clamping structure is used for strain relief, then high pull-out force is achieved, but punctual heavy loads are applied to the cable insulation

Engineering Contradiction:

Improvepull-out forceVSAvoidpunctual heavy loads on cable insulation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The clamping ring is segmented into multiple movable sections that distribute the clamping force around the cable circumference. This prevents concentrated punctual loads on the cable insulation while maintaining high overall pull-out force through the collective action of all segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The clamping segments are designed to be movable rather than rigid, allowing them to dynamically adapt to the cable surface. This dynamic structure distributes loads more evenly across the cable insulation, preventing localized stress concentrations while maintaining strong strain relief.

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If interconnected segments are used to avoid torsion, then flexible and torsion-free movement is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveflexible movement without torsionVSAvoidsegment connection structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The segments are interconnected by thin film elements that provide flexibility for radial movement while preventing torsional deformation. These thin film connections achieve the desired flexible, torsion-free movement with minimal manufacturing complexity compared to more rigid connection mechanisms.

Inventive Principle:

Principle #30Flexible shells and thin films

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 cost-effective, durable connector that ensures reliable moisture protection and strain relief across different cable diameters, reducing manufacturing costs and enhancing compatibility with existing systems while maintaining high pull-out forces and effective sealing.

Implementation Method 1

the sealant is formed as an elastic ring which can be pressed against the cable

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

the strain relief can be formed by the cable-enclosing molding compound

Methodology Applied

Scientific EffectMechanical deformation: Deformation

Data Source

PatentEP2249439B8Connector for photovoltaic systems

Publication Date: 2012.11.14 FLACH ROSMARIE

AI summary

The invention relates to a connector, particularly for photovoltaic systems, with a segmented strain relief element and a sealing element implemented as a separate component, which is forced into the sealing position by the strain relief element in the assembled connector. The strain relief element is provided with several interconnected and mutually movable segments for engaging the cable. The segments are connected to each other via film elements and form a clamping ring that cuts into the cable. The strain relief element is designed with an end face of the clamping ring to advance the sealing element.