Cable Clamp Strain Relief for Universal Plug Connections
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Solution Overview
Problem
Existing cable tension relief devices are typically integrated into plugs during production or designed to accommodate specific relief devices, limiting flexibility and ease of use in securing cables to various types of plugs or connectors.
Innovation Solution
A clamp designed to encompass the housing and cable of an electric plug or connector, forming a pressed fit connection that deflects axial forces into the housing, while radial forces are deflected into the clamp, thereby securing the cable and preventing transfer of forces to the contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cable tension relief devices are integrated into plugs during production or designed to accommodate specific relief devices, then the connection between cable and plug is secure, but the flexibility and ease of use in securing cables to various types of plugs or connectors is limited
Solution Approach 1:
The clamp is divided into two separate jaws (first jaw and second jaw) that can be independently positioned and closed around the cable. This segmentation allows the clamp to adapt to different cable diameters and plug types while maintaining a simple manufacturing process for each individual jaw component.
Solution Approach 2:
The clamp is designed as a universal device that can be applied to various types of plugs or connectors and different cable sizes. The adjustable jaw mechanism and form-fit connection capability enable the same clamp design to serve multiple applications without requiring custom integration for each plug type.
2Reliability
If a clamp encompasses the cable and housing to deflect forces, then the cable is securely protected from tension, but the device complexity increases
Solution Approach 1:
The clamp combines multiple functions into a single integrated component: the two jaws provide cable clamping, the hinge enables adjustable closure, and the form-fit connection interfaces with the plug housing. This merging of functions into one clamp unit provides reliable cable protection without requiring multiple separate components or complex assembly mechanisms.
Solution Approach 2:
The clamp acts as an intermediary element between the cable and the plug housing. It deflects axial forces from the cable into the housing through its form-fit connection, while the hinge mechanism provides controlled flexibility. This intermediary role protects the cable and contact elements from direct force transmission while maintaining a relatively simple structural design.
3Force
If a pressed fit connection is formed between cable and clamp, then axial forces are deflected into the housing, but the manufacturing precision requirements increase
Solution Approach 1:
The pressed fit connection is created locally at specific contact points between the clamp jaws and the cable, rather than requiring precision across the entire assembly. The hinge mechanism provides local flexibility that compensates for minor dimensional variations, allowing effective force deflection while reducing overall manufacturing precision requirements.
Solution Approach 2:
The hinge mechanism introduces a variable parameter (angular rotation) that allows the clamp to adapt to slight variations in cable diameter and positioning. This parameter change capability enables the pressed fit connection to maintain effective force deflection across a range of dimensional tolerances, reducing the stringency of manufacturing precision requirements.
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 clamp effectively relieves tension in cables by decoupling the cable end in the housing from the rest of the cable, preventing force transfer to the contacts and enhancing durability against vibrations and corrosion.
Implementation Method 1
The hinge is a living hinge. This type of hinge is formed by a flexible, thin groove between the two jaws, without additional mechanical parts. The function of the hinge is assumed by this groove, where the clamp is substantially thinner.
Data Source
AI summary
A clamp relieves tension to at least one cable on an electric plug or connector. The end of the cable is in a housing for the plug or connector. At least one electric wire in the cable is connected to at least one contact on or in the plug or connector. The clamp encompasses the housing and the cable. A pressed fit connection is obtained between the cable and a clamping part of the clamp such that forces acting on the cable are deflected into the housing by the clamp.