Single Pole Cable Connector Hexagonal Sleeve
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Solution Overview
Problem
Conventional single pole connectors are prone to permanent assembly, slip and rotation issues, and expose metallic components when the insulating sleeve is damaged, posing safety risks and requiring complete replacement.
Innovation Solution
A single pole cable connector design featuring a non-circular insulating sleeve with a hexagonal cross-section and a nonmetallic locking sleeve, allowing for secure engagement and disengagement without exposing metallic components, using a nonconductive screw for locking and a release mechanism for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring finger retention mechanism is used to secure the contact, then the contact is securely locked in place, but the assembly becomes permanent and cannot be disassembled for reuse
Solution Approach 1:
The connector transitions from a static permanent assembly to a dynamic reversible system. The cam mechanism allows the connector to shift between locked and unlocked states, enabling repeated assembly and disassembly while maintaining secure contact retention during operation.
Solution Approach 2:
The connector is divided into separable components: the insulating sleeve with cam mechanism, the contact, and the cable assembly. This segmentation allows the contact to be independently removed and replaced without damaging the insulating sleeve, enabling reuse of the connector body.
2Reliability
If a metallic locking ring is used within the rubber sleeve, then the contact is securely locked, but the metal may be exposed when the rubber sleeve splits or tears creating safety hazards
Solution Approach 1:
The metallic locking ring is replaced with a non-conductive cam mechanism integrated into the insulating sleeve. This substitution eliminates the exposed metal hazard while maintaining the locking function through the cam's interaction with the contact's flat surface, and the entire assembly remains electrically insulated.
Solution Approach 2:
The connector uses composite construction combining the insulating rubber sleeve with an integrated non-conductive cam mechanism. This composite design ensures that no conductive materials are exposed, as both the sleeve and cam provide insulation while working together to secure the contact.
3Reliability
If the complete connector must be replaced when the insulating sleeve is damaged, then safety is maintained, but cost and time are increased due to inability to reuse the connector body
Solution Approach 1:
The connector is segmented into a reusable insulating sleeve assembly and a replaceable contact-cable assembly. When the cable or contact is damaged, only that portion needs replacement while the insulating sleeve with its cam mechanism can be reused, reducing time and cost compared to replacing the entire connector.
Solution Approach 2:
The design allows recovery and reuse of the insulating sleeve and cam mechanism after the contact or cable portion is discarded. The modular architecture enables the valuable insulating components to be retained and reused multiple times, while only the consumable electrical contacts are replaced.
Data Source
AI summary
A single pole cable connector includes an insulating sleeve defining a channel and a non-circular contact positioned in the channel. The insulating sleeve may further include a non-circular, nonmetallic locking sleeve defining a portion of the channel. The channel and contact may be hexagonal-shaped in some cases. The insulating sleeve may have an exterior surface having two flat surfaces disposed opposite each other.