Cable Connector Insulator Embedding Terminals and Cables
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Solution Overview
Problem
Conventional cable connectors are prone to short circuits due to inadequate electrical insulation and water infiltration, which existing technologies have not effectively addressed.
Innovation Solution
A cable connector design featuring an insulating body with embedded electrical terminals and cables, filled with an insulator, a mounting plate with circular holes, and a capacitor for electromagnetic shielding, made from moulded plastic with a hollow frame and covers to prevent short circuits and water ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cable connectors are used with basic insulation structure, then the device complexity is low, but the reliability is poor due to short circuits and water infiltration
Solution Approach 1:
The connector is divided into distinct functional components: a hollow frame structure, a separate insulator filling the internal cavity, mounting plates for cable positioning, and capacitor elements for electromagnetic shielding. This segmentation allows each component to optimize its specific function while collectively achieving high reliability.
Solution Approach 2:
The insulator is nested within the hollow frame structure, with cables and electrical terminals embedded within the insulator material. The capacitor elements are integrated within the same internal cavity. This nested arrangement maximizes space utilization and ensures comprehensive protection of electrical components.
2Reliability
If adequate electrical insulation and water protection are implemented, then the reliability improves, but the manufacturing complexity increases
Solution Approach 1:
The insulator serves multiple functions simultaneously: it provides electrical insulation between conductive elements, acts as a barrier against water infiltration, and serves as the matrix for embedding cables and terminals. This merging of functions into a single component simplifies the manufacturing process while maintaining high reliability.
Solution Approach 2:
The connector employs composite construction combining the hollow frame structure with the insulator material filling, creating a composite assembly that leverages the advantages of different materials to achieve both protection and manufacturability.
3Reliability
If electromagnetic shielding elements are added to prevent interference, then the reliability improves, but the device complexity increases
Solution Approach 1:
The capacitor elements serve dual purposes: they provide electromagnetic shielding to protect against interference, and simultaneously act as electrical connection elements within the circuit. This self-service approach eliminates the need for separate shielding components, reducing overall device complexity while maintaining reliability.
Data Source
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AI summary
A cable connector is provided which includes an insulating body (11) comprising a frame (13) which defines a region (131) therein; a plurality of electrical terminals (14, 15) fixed to the insulating body (11) and extending into the region (131); and a plurality of cables (1, 2) electrically connected to the electrical terminals (14, 15) respectively in the region (131). The region (131) is filled with an insulator (18) to embed the electrical terminals (14, 15) and the cables (1, 2). The cable connector has a relatively high reliability.