Cable capable of eliminating internal stress of cable

Abstract

Various aspects of wire internal stress relief in a cable assembly are described herein. In one example, a cable assembly includes a cable and a modular plug at one end of the cable. The cable includes a jacket and a plurality of wires extending within the jacket. The modular plug includes a modular housing and an interlock structure for wire internal stress relief between the wire and the modular plug. Because the plurality of wires within the cable are mechanically held within the modular plug using the features of the wire internal stress relief interlock structure, the cable assembly can resist significantly opposite tensile forces between the cable and the modular plug, and separation, damage or loss in signal coupling integrity can be avoided.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 445,004, filed February 13, 2023, entitled “Cable with In-Line Strain Relief,” which is incorporated herein by reference in its entirety. Background Art

[0003] Cables and cable assemblies are used for data communication in various computing and data interconnect systems. A typical cable assembly includes: multiple signal wires or conductors; a cable sheath surrounding the wires; and a modular plug or connector attached to the ends of the wires. The cable can be cut to a specified length, and the modular connector can be crimped or otherwise secured to the end of the cable. Cable assemblies provide data and power interconnects between computers, servers, network switches, sensors, motors, and other devices. Summary of the Invention

[0004] Several examples of in-line strain relief for cable assemblies are described. An example cable assembly includes a cable and a modular plug at one end of the cable. The cable includes a jacket and a plurality of conductors extending within the jacket. The modular plug includes a modular housing and an interlocking structure for in-line strain relief between the conductors and the modular plug. Because the plurality of conductors within the cable are mechanically retained within the modular plug by the in-line strain relief interlocking structure, the cable assembly can withstand significant opposing tensile forces between the cable and the modular plug without separation, damage, or loss of signal coupling integrity. The cable assembly can also include a molded part formed between the cable and the modular plug. In contrast to other cables, the jacket is cut away and terminates within the molded part. The jacket does not extend into the modular plug and is not retained within the modular plug.

[0005] In other aspects of the embodiments, the modular plug includes a wire insert. The wire insert includes a wire insert channel, and the wire insert channel includes a straight extension region and an angled extension region. The straight extension region extends parallel to a bottom surface of the wire insert, and the angled extension region extends at an angle relative to the bottom surface of the wire insert. In various examples, the angle can vary. For example, the angle can vary between 5 degrees and 20 degrees, although in some cases, larger or smaller angles can be used.

[0006] In other aspects, the wire insert includes a strain relief groove extending from a top surface of the wire insert into the wire insert. The strain relief groove intersects and communicates with the wire insert channel in the angled extension region. The interlocking structure of the modular plug extends into the strain relief groove of the wire insert, and mechanical interference between the wire insert and the interlocking structure locks the wire insert within the modular plug.

[0007] In other aspects, a conductor of the cable extends through the conductor insert channel of the conductor insert. An area of ​​the conductor is exposed above the strain relief slot of the conductor insert. The interlock structure of the modular plug extends into the strain relief slot of the conductor insert, and the conductor is retained within the modular plug through mechanical interference between the conductor and the interlock structure. In other aspects of the embodiments, the cable includes a drain wire extending within the jacket, and the modular plug further includes a shield and a crimp ring to which the drain wire is crimped and electrically connected to the shield. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Many aspects of the present disclosure may be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, but emphasis is placed on clearly illustrating the principles of the present disclosure. Additionally, in the drawings, similar reference numerals throughout the several views indicate corresponding parts.

[0009] Figure 1 A perspective view of an example cable assembly according to various embodiments of the present disclosure is shown.

[0010] Figure 2A Showing various embodiments according to the present disclosure Figure 1 A front perspective view of a cable assembly is shown with the molded parts omitted from view.

[0011] Figure 2B Showing various embodiments according to the present disclosure Figure 1 A rear perspective view of the cable assembly is shown with the molded parts omitted from view.

[0012] Figure 3 Showing various embodiments according to the present disclosure Figure 1 The modular plug of the cable assembly is shown before assembly and crimping.

[0013] Figure 4 Showing various embodiments according to the present disclosure Figure 1 Cable assembly shown with modular plug, wire inserts, and cables prior to assembly and crimping.

[0014] Figure 5Showing various embodiments according to the present disclosure Figure 1 A perspective view of a wire insert of a cable assembly is shown.

[0015] Figure 6A Showing various embodiments according to the present disclosure Figure 1 A front view of the wire insert of the cable assembly is shown.

[0016] Figure 6B The various embodiments of the present disclosure are shown Figure 1 A rear view of the wire insert of the cable assembly is shown.

[0017] Figure 6C Showing various embodiments according to the present disclosure Figure 1 A bottom view of the wire insert of the cable assembly is shown.

[0018] Figure 6D Showing various embodiments according to the present disclosure Figure 1 A top view of a wire insert of a cable assembly is shown.

[0019] Figure 7A Showing various embodiments according to the present disclosure Figure 6D A perspective cutaway view of a wire insert made with selected AA.

[0020] Figure 7B Showing various embodiments according to the present disclosure Figure 6D Cross-section view of the wire insert with AA selected.

[0021] Figure 8 Showing various embodiments according to the present disclosure Figure 1 A cutaway view of the cable assembly is shown. DETAILED DESCRIPTION

[0022] Cables and cable assemblies are used for data communications in various computing and data interconnect systems and other applications. A typical cable assembly can include: multiple signal wires or conductors; a cable sheath surrounding the multiple wires; and a modular plug or connector connected to the ends of the multiple wires. The cable can be cut to a specified length, and the modular connector can be crimped or otherwise secured to the end of the cable. Cable assemblies can provide data and power interconnections between computers, servers, network switches, sensors, motors, and other devices.

[0023] In some cable assemblies, the jacket of the cable is crimped or otherwise mechanically retained within the modular plug of the cable assembly using a crimping tool. For example, in some cases, an interlocking feature of a modular plug can be crimped or otherwise pressed against and retained against the jacket of the cable to mechanically secure the jacket to the modular plug. The jacket can thereby be retained to prevent the cable from being pulled out and out of the modular plug, which could interfere with the electrical connection or termination between the signal conductors of the cable and the contact blades of the modular plug. However, the jacket of some cables may be too large in diameter to fit within an industry-standard sized modular plug, particularly when the cable includes multiple conductors of a relatively large gauge.

[0024] In the context set forth above, various aspects of in-line stress relief in a cable assembly are described herein. An example cable assembly includes a cable and a modular plug at one end of the cable. The cable includes a jacket and a plurality of conductors extending within the jacket. The modular plug includes a modular housing and an interlocking structure for in-line stress relief between the conductors and the modular plug. Because the plurality of conductors within the cable are mechanically retained within the modular plug by utilizing features of the in-line stress relief interlocking structure, the cable assembly is able to withstand significant opposing pull forces between the cable and the modular plug without separation, damage, or loss of signal coupling integrity. Turning to the accompanying drawings, Figure 1 A perspective view of an example cable assembly 10 according to various embodiments of the present disclosure is shown. Figure 1 is representative, not drawn to any particular scale, and is shown to provide context for the in-line strain relief cable concepts described herein. The cable assembly 10 can be designed for data communications and include a plurality of twisted pairs of signal wires or conductors. The cable assembly 10 can be a Category 5, Category 6, Category 7, Category 8, or related cable, but the concepts described herein are not limited to use with any particular type or style of cable. In various examples, the cable assembly 10 can be shielded or unshielded using a foil shield, braided shield, drain wire, or other shielding, and in one example, the cable assembly 10 includes four twisted pairs of signal wires or conductors. Overall, the in-line strain relief concepts are not limited to use with any particular type or style of cable or cable assembly, as the concepts can be extended to use with related cables and cable assemblies other than the examples described herein.

[0025] like Figure 1As shown, the cable assembly 10 includes a modular plug 12, a cable 60 having a plurality of conductors terminated at the modular plug 12, and a modular molding 50. The modular plug 12 includes, among other features, a modular plug housing 20, a plurality of contact channels 21 formed in the top and front of the modular plug housing 20, a plug interlock arm 22, and a shield 40 extending around the sides of the modular plug housing 20. The cable 60 includes a plurality of conductors or wires extending within a jacket 61. As is understood in the art and will be described in further detail below, the signal conductors of the cable 60 are electrically connected to and terminated by contact blades inserted into and positioned within the contact channels 21. As will also be described below, a drain wire of the cable 60 is electrically connected to and terminated by the shield 40 of the cable assembly 10. The shield 40 helps the modular plug 12 resist external electromagnetic interference.

[0026] The cable assembly 10 can be embodied as a cable similar to a Category 5, 6, 7, 8, or related cable used in data communications applications. In that context, in one example, the modular plug 12 can be designed as an RJ45 modular plug. As is understood in the art, the modular plug 12 can be inserted into a modular port, such as an RJ45 port, to establish an electrical connection between the signal conductors of the cable 60 and the pins or terminals within the port. The cable assembly 10 can be formed from a variety of suitable materials. For example, the modular plug housing 20 can be formed from a plastic or other polymer material, and the shield 40 can be formed from a conductive metal sheet (e.g., cut, bent, or otherwise formed). The cable 60 can include: a plurality of wires or conductors, such as sheathed copper wire of 22, 24, 26, or 28 American wire gauge (AWG); a foil or braided shield or an unshielded drain wire of 22, 24, 26, or 28 AWG; and a jacket formed from polyvinyl chloride or other suitable material. The molded member 50 can be formed of polyvinyl chloride or other polymer-based materials suitable for molding around the modular plug 12 and the end of the cable 60. The molded member 50 includes a circumferential grip ring 52 that helps grasp and position the cable assembly 10 when the modular plug 12 is inserted into or removed from a modular port.

[0027] In cable assemblies similar to cable assembly 10, the jacket 61 of the cable 60 is typically crimped or otherwise mechanically retained within the modular plug housing 20 using a crimping tool. For example, one or more strain relief interlocking features of the modular plug housing 20 can be crimped or otherwise pressed against and retained against the jacket 61 within the modular plug housing 20 to mechanically secure the jacket 61 to the modular plug housing 20. The jacket 61 is thereby retained within the modular plug housing 20 to prevent the cable 60 from being pulled out and removed from the modular plug housing 20, which could interfere with electrical connection or termination between the signal conductors of the cable 60 and the contact blades located within the contact channels 21.

[0028] However, in some cases, the jacket 61 of the cable 60 may be too large in diameter or other characteristics to fit within the modular plug housing 20, particularly when the cable 60 includes relatively large, standard-sized signal conductors. Additionally, the molded part 50 is not necessarily designed to securely hold the jacket 61 of the cable 60 or to retain the jacket 61 of the cable 60 to the modular plug housing 20. Without a measure to retain the jacket 61 of the cable 60 to the modular plug housing 20, the cable 60 may be easily pulled out of the modular plug 12, causing damage to the cable assembly 10.

[0029] According to various aspects of various embodiments described herein, the cable assembly 10 is designed to facilitate strain relief not between the jacket 61 and the modular plug 12, but rather directly between the wires within the cable 60 and the modular plug 12. As described below, the jacket 61 of the cable 60 is cut back and does not extend into the modular plug housing 20 of the modular plug 12. Thus, the jacket 61 extends only to a point within the molded part 50. However, because the wires or conductors within the cable 60 are mechanically retained within the modular plug housing 20 using a one-wire strain relief design, the cable assembly 10 can withstand significant opposing tensile forces between the cable 60 and the modular plug housing 20 without separation, damage, or loss of signal coupling integrity.

[0030] Figure 2A Show Figure 1 A front perspective view of the cable assembly 10 is shown with the molded member 50 omitted from view. Figure 2B A rear perspective view of the cable assembly 10 is shown with the molded part 50 omitted from view. Other features of the modular plug 12 and the cable assembly are shown in FIG. Figure 2A and Figure 2BThe modular plug 12 includes a plug cavity 29 within the modular plug housing 20. A plurality of wires 62 of a cable 60 extend into the plug cavity 29, wherein the plurality of wires 60 are arranged inline for connection to contact blades within the contact channels 21 of the modular plug 12. The plurality of wires 62 of the cable 60 are arranged in a straight line side-by-side pattern within the plug cavity 29 using a wire insert. The wire insert is described later with reference to FIG. Figure 4 、 Figure 5 as well as 6A to 6D Further details are given.

[0031] The jacket 61 does not extend to a location within the modular plug 12. Instead, the jacket 61 is shortened before entering the modular plug 12. However, the wires 62 of the cable 60 extend into the plug cavity 29 of the modular plug 12 and are terminated there. The plurality of wires 62 include a plurality of twisted pairs of signal wires or conductors, such as four twisted pairs in the example shown, and a drain wire 63. The signal conductors of the plurality of wires 62 are terminated and electrically connected to contact blades located within the contact channel 21 of the modular plug 12. The drain wire 63 is crimped to the crimp ring 42 of the shield 40 at the rear of the modular plug 12.

[0032] The modular plug housing 20 also includes a molded part release tab 26 that includes a molded part through-hole 27. Figure 2A and Figure 2B As shown, after the cable 60 is assembled with the modular plug 12, the molded part 50 can be formed around the modular plug 12 and the cable 60 in a separate assembly step. The material of the molded part 50 can extend or flow through the molded part perforations 27 into the rear of the modular plug 12 and over the top of the modular plug 12 to form the top 54 of the molded part 50 (see FIG. Figure 1 ).

[0033] As described above, the cable assembly 10 is designed to facilitate strain relief not between the jacket 61 and the modular plug housing 20, but rather directly between the conductors 62 of the cable 60 and the modular plug housing 20. The jacket 61 of the cable 60 is shortened and does not extend into the modular plug housing 20. Because the conductors 62 of the cable 60 are mechanically retained within the plug cavity 29 of the modular plug housing 20 using an in-line strain relief design, the cable assembly 10 can withstand significant opposing tensile forces between the cable 60 and the modular plug 12 without separation, damage, or loss of signal coupling integrity.

[0034] Figure 3 Showing various embodiments according to the present disclosure Figure 1The modular plug 12 of the cable assembly 10 is shown prior to assembly and crimping. The modular plug 12 includes a plurality of contact blades, such as contact blade 70A, positioned within the contact channels 21. When the modular plug 12 is crimped to the cable 60 using a crimping tool, the plurality of contact blades are depressed and respectively enter the plurality of conductors 62 of the cable 60. When the modular plug 12 is crimped to the cable 60, the contact blades electrically connect and contact the conductors 62.

[0035] The modular plug housing 20 also includes a wire release interlock 28 ("interlock 28"). Figure 3 When the modular plug 12 is crimped onto the cable 60 , the interlock structure 28 can rotate and press down into the plug cavity 29 of the modular plug housing 20 to mechanically press against and hold the wires 62 of the cable 60 within the modular plug 12 .

[0036] Figure 4 Showing various embodiments according to the present disclosure Figure 1 The modular plug 12, the wire insert 100, and the cable 60 of the cable assembly 10 are shown before assembly and crimping. A cutaway view of the modular plug 12 is shown in FIG. Figure 4 2 so that the plug cavity 29 within the modular plug 12 is visible. Prior to the wire insert 100 being inserted into the plug cavity 29 of the modular plug 12, the plurality of wires 62 of the cable 60 are arranged in an in-line, side-by-side pattern within the wire insert 100. More particularly, the wires 62A-62D, etc., are shown inserted into and extending through the wire insert channels within the wire insert 100. The wires 62A-62D extend from the rear end 121 of the wire insert 100 to the front end 120 of the wire insert 100.

[0037] After being arranged as shown, the wire insert 100 and the wire 62 can be connected together in Figure 4 The wire insert 100 is inserted into the plug cavity 29 of the modular plug 12 in the direction "Da" shown. In addition, the drain wire 63 can be located and assembled in the crimp ring 42 of the shield 40 at the rear of the modular plug 12. To facilitate alignment, the wire insert 100 includes a plug interlock track 111 on one side of the wire insert 100 and a plug interlock track 112 on the opposite side of the wire insert 100 (see FIG. Figure 6A and Figure 6B). Interlocking tracks 111, 112 extend along the bottom of the wire insert 100 from the rear end 121 of the wire insert 100 to the front end 120 of the wire insert 100. When the wire insert 100 is inserted into the modular plug 12, the interlocking track 112 can extend and slide into the interlocking channel 29A of the modular plug housing 20 to help position and align the wire insert 100 within the plug cavity 29. The interlocking track 111 can also extend and slide into a similar interlocking channel (not shown) on an opposite side of the modular plug housing 20.

[0038] The wire insert 100 includes a blade penetration area 130 including a plurality of contact blade penetrations 130-134 (see also FIG. Figure 5 ), etc. The contact blade perforations 130-134 are perforations or openings through the wire insert 100. When the wire insert 100 and the wires 62 are fully inserted into the plug cavity 29 of the modular plug 12, the blade perforation area 130 can be positioned below the contact blades 70A-70D of the modular plug 12. After insertion, the modular plug 12 can be crimped to the wire insert 100 and the wires 62 of the cable 60.

[0039] During the crimping step, the contact blades 70A-70D of the modular plug 12 are Figure 4 Wire insert 100 is pressed downward in the direction "Db" shown. During this step, contact blades 70A-70D are pressed downward and partially extend through contact blade through-holes 130-134 of wire insert 100 to electrically connect with wires 62A-62D, etc., of cable 60. For example, tapered contact point 71D of contact blade 70D will extend downward through contact blade through-hole 134 of wire insert 100 and partially into wire 62D. During this crimping step, contact blade 70D will be electrically connected to wire 62D. Other contact blades will also be electrically connected to other wires 62 of cable 60 in a similar manner.

[0040] During crimping, the interlocking structure 28 of the modular plug housing 20 is also depressed and locked in place. Figure 4 The wire insert 100 includes a strain relief slot 110. Portions of the wires 62A-62D or the insulating sleeves of the wires 62A-62D are exposed above the strain relief slot 110. During crimping, the interlocking structure 28 is depressed and rotated downward in the direction "Dc" into the area of ​​the strain relief slot 110. More specifically, the interlocking structure 28 is rotated downward until the interlocking edge 28A is engaged and seated beneath the locking edge 26A of the molded part release tab 26, also as shown. Figure 8 The interlocking structure 28 is then retained and locked in place based on a mechanical interference between the interlocking edge 28A and the locking edge 26A.

[0041] In this locked position, the interlocking structure 28 also presses against the wires 62A-62D exposed on the strain relief slot 110 of the wire insert 100. The interlocking structure 28 thus provides direct in-line strain relief because, in this arrangement, the interlocking structure 28 presses against the wires 62 of the cable 60. For example, rather than pressing against the jacket 61 of the cable 60, the interlocking structure 28 directly contacts the wires 62 or the jackets of the wires 62 to hold the wires 62 and the wire insert 100 in place.

[0042] Figure 5 Showing various embodiments according to the present disclosure Figure 1 A perspective view of the wire insert 100 of the cable assembly 10 is shown. Figure 6A Showing a front view, Figure 6B Showing a rear view, Figure 6C shows a bottom view, and Figure 6D A top view of the wire insert 100 is shown. The wire insert 100 is shown in a representative example. Figure 5 as well as 6A to 6D The wire insert 100 is not drawn to any particular scale or size, but in some cases, the wire insert 100 can vary in size, shape, and style. The wire insert 100 can be formed from a plastic, polymer, or other suitable material.

[0043] Refer to 6A to Figure 6D The wire insert 100 includes a front end 120, a rear end 121, a top surface 122 and a bottom surface 123. Figure 6A and Figure 6B As best shown, the wire insert 100 also includes a plurality of wire insert channels, including wire insert channels 140-143, extending from the front end 120 of the wire insert 100 to the rear end 121 of the wire insert 100. Eight wire insert channels are shown, but in other examples, the wire insert 100 can include more or fewer insert channels. The wire insert channels partially intersect with each other to form a single continuous insert channel within the wire insert 100. The insert channel is formed to include a plurality of cylindrical gaps or openings, each of which is sized to provide a nominal gap for the extension of a signal conductor of the cable 60. For example, each of the wire insert channels 140-143 provides a cylindrical gap or opening for the extension of one of the conductors 62A-62D of the cable 60.

[0044] like Figure 4As shown, the wires 62A-62D of the cable 60 can be inserted into the wire insert passages 140-143, respectively. The wire insert 100 includes a stress relief slot 110. The stress relief slot 110 is formed in the form of a void or cutout extending from the top surface 122 into the wire insert 100. The stress relief slot 110 intersects (and exposes or opens) the wire insert passage in the wire insert 100 at a position along an inclined passage area of ​​the wire insert passage. Thus, as also shown in FIG. Figure 4 As shown, a portion of the wires 62A- 62D or the insulation jackets of the wires 62A- 62D are exposed above the strain relief slot 110 .

[0045] Figure 7A Show Figure 6D A perspective cutaway view of the wire insert 100 made with AA selected, and Figure 7B Show Figure 6D The cross-sectional view made by the selected AA. Figure 7A As shown, the stress relief slot 110 is formed in the form of a void or cutout extending from the top surface 122 into the wire insert 100. The stress relief slot 110 intersects (and exposes or opens) the wire insert passageway in the wire insert 100. As a specific example, Figure 7B The wire insertion channel 143 is shown to be open and exposed to a region R of the stress relief slot 110 .

[0046] Reference Figure 7B The wire insert channel 143 includes a straight extension area 143P and an inclined extension area 143I. The straight extension area 143P is parallel to the bottom surface 123 of the wire insert 100 and extends below the contact blade through hole 134. The inclined extension area 143I is at an angle relative to the bottom surface 123 of the wire insert 100. Extends and intersects the stress relief groove 110. In various embodiments, the angle Can be changed. For example, the angle Can vary between 5 and 20 degrees, but in some cases larger or smaller angles can be used. As a specific example, the angle Can be about 5 degrees, 6 degrees, 7 degrees, 8 degrees, 9 degrees, 10 degrees, 11 degrees, 12 degrees, 13 degrees, 14 degrees or 15 degrees. In the example shown, the angle It is about 10 degrees, but other angles can be used.

[0047] Figure 8 Showing various embodiments according to the present disclosure Figure 1 A cross-sectional view of the cable assembly 10 is shown. Figure 8 The cross-section shown is along Figure 6DThe wire insert 100 and the wires 62 of the cable 60 are located within the plug cavity 29 of the modular plug 12, which is also filled with the material of the molded part 50. The molded part 50 also extends through the perforation 27 of the molded part release sheet 26 (see also Figure 4 The drain wire 63 is positioned within and crimped into the crimp ring 42 of the shield 40 to provide an electrical connection between the drain wire 63 and the shield 40. The shield 40 helps the modular plug 12 resist external electromagnetic interference. The crimp ring 42 and the drain wire 63 are also surrounded by the material of the molded part 50.

[0048] In the illustrated view, wire 62D extends within wire insert 100. Contact blade 70D of modular plug 12 is depressed and partially extends into wire 62D. In the illustrated arrangement, contact blade 70D is electrically coupled to wire 62D. Other contact blades of modular plug 12 are also electrically coupled to other wires 62 of cable 60 in a similar manner.

[0049] The interlocking structure 28 of the modular plug housing 20 is also locked in place to provide a mechanical interference within the strain relief slot 110 of the wire insert 100. For example, a portion of the wire 62D is exposed within the strain relief slot 110. As part of the crimping step described above, the interlocking structure 28 is pressed into and locked into the area positioned within the strain relief slot 110. In particular, the interlocking edge 28A of the interlocking structure 28 is caught and seated beneath the locking edge 26A of the molded part release tab 26. Based on the mechanical interference between the interlocking edge 28A and the locking edge 26A, the interlocking structure 28 is thereby retained and locked in place.

[0050] In this locked position, interlocking structure 28 presses against wire 62D, etc., exposed above strain relief slot 110 of wire insert 100. In particular, interlocking corner 28B of interlocking structure 28 presses into or against wire 62D. Interlocking structure 28 thus provides direct in-line strain relief because, in this arrangement, interlocking structure 28 presses against wire 62 of cable 60. For example, rather than interlocking structure 28 pressing against outer jacket 61 of cable 60, interlocking structure 28 directly contacts wire 62 or the jacket of wire 62 to hold wire 62 and wire insert 100 in place.

[0051] Because the conductors 62 within the cable 60 are mechanically retained within the modular plug 12 using an in-line strain relief design, the cable assembly 10 can withstand significant opposing pulling forces between the cable 60 and the modular plug 12 without separation, damage, or loss of signal coupling integrity. For example, if the modular plug 12 is inserted and locked into a port or receptacle, and the cable 60 is to be pulled or disengaged from the plug 12, a mechanical interference between the interlocking structure 28 and the conductors 62 will prevent the conductors 62 from being pulled out of the modular plug 12. Due to the interlocking surface 28C of the interlocking structure 28 and the surface 110A of the release slot 110 (see FIG. 1 ), the cable assembly 10 can withstand significant opposing pulling forces between the cable 60 and the modular plug 12 without separation, damage, or loss of signal coupling integrity. Figure 7A ) therebetween, the wire insert 100 will not be removed from the modular plug 12.

[0052] Terms such as "top," "bottom," "side," "front," "back," "right," and "left" are not intended to provide an absolute frame of reference. Rather, these terms are relative and are intended to identify certain features in relationship to one another, as the posture of the structures described herein can vary. The terms "comprising," "including," "having," and the like are synonymous and are used in an open-ended manner and do not exclude additional elements, features, actions, operations, and the like. Furthermore, the term "or" is used in its inclusive sense, not its exclusive sense, and thus, when used to connect a list of elements, the term "or" means one, some, or all of the elements in the list.

[0053] Unless otherwise specified, combination language, such as "at least one of X, Y, and Z" or "at least one of X, Y, or Z," is generally used to identify combinations of one, any two, or all three (or more if a larger group is identified), such as X and only X, Y and only Y, Z and only Z, a combination of X and Y, X and Z and Y and Z, and all of X, Y, and Z. Unless otherwise specified, such combination language generally does not intend and does not identify or require the inclusion of at least one of X, at least one of Y, and at least one of Z.

[0054] Unless otherwise defined herein, the terms "about" and "substantially" in connection with a particular range, percentage, or related measure of deviation illustrate at least some manufacturing tolerance between a theoretical design and a manufactured product or component, such as the American Society of Mechanical Engineers (ASME). Y14.5 and related ISO As one skilled in the art will recognize, even without explicit reference to "approximately," "substantially," or related terms, or even with respect to theoretical terms such as "perpendicular," "orthogonal," "highest point," "collinear," "coplanar," etc., such manufacturing tolerances are still considered.

[0055] The above-described embodiments of the present disclosure are merely examples of embodiments to provide a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-described embodiments without departing substantially from the spirit and principles of the present disclosure. In addition, components and features described for one embodiment may be included in another embodiment. All such modifications and variations are intended to be included within the scope of the present disclosure.

Claims

1. A cable assembly, comprising: a cable comprising a jacket and a plurality of twisted pairs extending within the jacket; as well as A modular plug is provided at one end of the cable, the modular plug comprising a modular housing and an interlocking structure for in-line strain relief between the twisted pair wires and the modular plug.

2. The cable assembly according to claim 1, wherein: The cable also includes a drain wire extending within the outer jacket; The modular plug further includes a shield; and The drain wire is crimped and electrically connected to a crimp ring of the shield.

3. The cable assembly of claim 1 , wherein: The modular plug also includes a wire insert; The wire insert includes a wire insert channel; and The wire insertion channel includes a straight extension area and an inclined extension area.

4. The cable assembly of claim 3, wherein: The straight extension area of ​​the wire plug extends parallel to a bottom surface of the wire plug; as well as The angled extension region of the wire insert extends at an angle relative to a bottom surface of the wire insert.

5. The cable assembly according to claim 3, wherein: The wire insert also includes a strain relief slot extending from a top surface of the wire insert into the wire insert.

6. The cable assembly of claim 3, wherein: The wire insert further includes a stress relief slot extending from a top surface of the wire insert into the wire insert; as well as The stress relief groove intersects and communicates with the wire insertion channel in the inclined extension area.

7. The cable assembly according to claim 3, wherein: The interlocking structure of the modular plug extends into a strain relief slot of the wire insert, and the wire insert is locked in the modular plug through mechanical interference between the wire insert and the interlocking structure.

8. The cable assembly of claim 3, wherein: A conductor of the cable extends through the conductor insert channel of the conductor insert; An area of ​​the wire is exposed above a stress relief slot of the wire insert; as well as The interlocking structure of the modular plug extends into the strain relief slot of the wire insert, and the wire is retained in the modular plug by mechanical interference between the wire and the interlocking structure.

9. The cable assembly of claim 1, further comprising a molded member formed between the cable and the modular plug, wherein The jacket is cut away prior to the modular plug and terminates within the molded part.

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