Insulation Piercing Connector with Telescoping Body
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Solution Overview
Problem
Existing electrical connectors for high and medium voltage cables face challenges in providing reliable and efficient connections due to differences in cable sizes and insulation layers, leading to issues with electrical resistance and durability.
Innovation Solution
The development of a multi-tap insulation piercing connector with a telescoping mechanism and secondary blade members that adjust to accommodate various cable sizes, featuring a compression mechanism and insulation piercing features to ensure low resistance current paths and environmental sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional IP connectors are used with fixed blade configurations, then the connector structure is simple, but the connector cannot accommodate different cable sizes effectively, leading to poor electrical contact and high resistance
Solution Approach 1:
The connector employs telescoping body members that can slide relative to each other along a slide axis, transforming the fixed structure into a dynamic one. This allows the connector to adapt to different cable sizes by adjusting the spacing between jaw portions, while maintaining a relatively simple overall structure through controlled movement rather than multiple fixed configurations
Solution Approach 2:
The connector body is divided into multiple telescoping body members (first body member, second body member) that can move independently relative to each other. This segmentation allows each member to be optimized for specific functions while collectively providing size adaptability, resolving the contradiction between versatility and structural simplicity
2Reliability
If compression force is increased to ensure reliable electrical contact, then electrical connection reliability improves, but torque requirements and mechanical stress increase
Solution Approach 1:
The connector applies compression force progressively during the telescoping action, changing the compression parameter from zero to optimal value gradually. This controlled parameter change ensures reliable electrical contact through adequate compression while minimizing peak torque requirements and mechanical stress on the system
3Adaptability or versatility
If connector components are made larger to accommodate bigger cables, then cable size adaptability improves, but material usage and heat generation increase
Solution Approach 1:
Rather than creating a single oversized connector to accommodate all cable sizes, the invention uses dynamic telescoping body members that adjust their spacing to match the actual cable size. This allows the connector to maintain compact dimensions for smaller cables while extending only when needed for larger cables, minimizing material usage across the full range of applications
Solution Approach 2:
The telescoping mechanism provides universal adaptability within a single connector design, eliminating the need for multiple fixed-size connectors. This multi-functionality allows one connector to serve various cable sizes without requiring proportionally larger components, reducing overall material consumption
4Adaptability or versatility
If jaw portions are fixed in position, then the connector structure is simpler, but the connector cannot adjust to different cable combinations, reducing versatility
Solution Approach 1:
The jaw portions are made movable through the telescoping body members, allowing them to adjust their positions dynamically based on the cable combination. This dynamic positioning capability provides versatility for different cable sizes and configurations without requiring a complex multi-component adjustment mechanism, as the telescoping action itself provides the necessary degrees of freedom
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 connector provides reliable, low-resistance electrical connections with reduced torque requirements and enhanced durability by accommodating different cable sizes and maintaining contact despite thermal cycling, while minimizing material usage and heat generation.
Implementation Method 1
The compression mechanism is configured and operable to apply a clamping load along a clamping axis extending through both of the first and second electrical conductors to force the first insulation piercing feature into electrical engagement with the first electrical conductor and to force the second insulation piercing feature into electrical engagement with the second electrical conductor
Implementation Method 2
The first insulation piercing feature is configured to pierce through the first insulation layer and electrically engage the first electrical conductor. The second insulation piercing feature is configured to pierce through the second insulation layer and electrically engage the second electrical conductor
Data Source
AI summary
An electrical connector for mechanically and electrically connecting first and second cables, each including an elongate electrical conductor covered by an insulation layer, includes a connector body, an electrically conductive first insulation piercing feature on the connector body, an electrically conductive second insulation piercing feature on the connector body and electrically connected to the first insulation piercing feature, and a compression mechanism. The first insulation piercing feature is configured to pierce through the first insulation layer and electrically engage the first electrical conductor. The second insulation piercing feature is configured to pierce through the second insulation layer and electrically engage the second electrical conductor. The compression mechanism is configured and operable to apply a clamping load along a clamping axis extending through both of the first and second electrical conductors to force the first and second insulation piercing features into electrical engagement with the first and second electrical conductors, respectively.