Cable Assembly Enlarged Insulation Strain Relief
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable assemblies with strain-relief devices are costly and inconvenient due to complex manufacturing and assembly processes, necessitating a cable end with improved mechanical properties.
Innovation Solution
A cable assembly featuring a cable with a main body and an enlarged portion of varying diameters, where the enlarged portion acts as a strain-relief device by gradually transitioning to an electrical connector, providing mechanical protection and integration with a metal shell for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a strain-relief device is used to protect the cable end, then the mechanical property and reliability are improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The cable insulation layer is integrated with the connector housing to form a unified structure. The insulation layer extends into the connector and merges with the housing, eliminating the need for separate strain-relief devices while providing mechanical protection and strain relief functionality through the integrated design.
Solution Approach 2:
The insulation layer serves multiple functions simultaneously: it provides electrical insulation, mechanical protection for the cable end, strain relief through its enlarged portion, and structural integration with the connector housing. This multi-functionality replaces the need for dedicated strain-relief components.
2Reliability
If a strain-relief device is used to protect the cable end, then the mechanical property is improved, but the manufacturing cost increases
Solution Approach 1:
The insulation layer and connector housing are merged into a single integrated component that can be manufactured as one piece or pre-assembled unit. This integration reduces the number of separate parts requiring manufacturing and assembly, thereby lowering production costs while maintaining cable end protection.
Solution Approach 2:
The insulation layer is designed to perform multiple functions including strain relief, mechanical protection, and electrical insulation. By making the insulation layer multi-functional, the patent eliminates the need for additional specialized components, reducing overall manufacturing complexity and cost.
3Device complexity
If the cable end is directly connected to the connector, then the device complexity is reduced, but the mechanical property and protection against breakage deteriorate
Solution Approach 1:
The insulation layer is designed with varying cross-sectional dimensions: a larger enlarged portion at the connector interface providing strain relief and mechanical strength, and a smaller portion extending along the cable. This local variation in geometry provides enhanced protection at the critical connection point while maintaining simplicity in the cable portion.
Solution Approach 2:
The insulation layer is pre-formed with an enlarged portion that protrudes into the connector housing before assembly. This preliminary shaping creates a built-in strain relief feature that protects the cable end from breakage during bending and connection, eliminating the need for additional protective components.
Data Source
AI summary
A cable assembly includes an electrical connector and a cable. The electrical connector defines a mating port and comprising contacts with contacting portions exposing to the mating port and connecting portion. The cable includes conductive wires connecting with the connecting portion of the contact. The cable comprises a main body and an enlarged portion connecting with the contacts. The main body is configured with a same diameter and the enlarged portion is configured with an enlarged diameter than the main portion.