Cable Strain Relief Ring for Stable Overmolded Connector Anchoring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable strain relief methods, such as overmolding, often fail to form a sufficient connection between the connector housing and the cable jacket due to differing material requirements, leading to potential disconnection of the cable.
Innovation Solution
A metallic ring element with a larger initial inner circumference is deformed to fit snugly over the cable jacket, with radially protruding sections for anchoring, allowing for a stable overmolding process using a plastic encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector housing and cable jacket are overmolded together using the same material, then the manufacturing process is simplified and cost-effective, but the bond between the connector housing and cable jacket is insufficient leading to potential cable disconnection
Solution Approach 1:
The solution segments the strain relief structure into distinct components: a connector housing, a cable jacket, and an intermediate metallic ring element. This segmentation allows each component to be optimized for its specific function while maintaining overall structural integrity and preventing cable disconnection.
Solution Approach 2:
A metallic ring element is introduced as an intermediary component between the connector housing and cable jacket. This ring element serves as a mediator that provides both mechanical anchoring and overmolding surfaces, enabling reliable bonding while maintaining manufacturing simplicity.
2Reliability
If a metallic ring element is deformed to fit tightly over the cable jacket, then the anchoring stability is improved, but the manufacturing complexity increases due to the deformation and reshaping process
Solution Approach 1:
The metallic ring element undergoes parameter changes during manufacturing - specifically, its cross-sectional dimensions are modified through deformation and reshaping processes. This allows the ring to achieve a tight fit around the cable jacket while providing outwardly projecting sections for anchoring, balancing reliability with manufacturability.
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 solution provides a secure and cost-effective cable strain relief that prevents cable disconnection by ensuring a tight fit and stable anchoring, enhancing the durability of the connector assembly.
Implementation Method 1
The ring element is deformed and reshaped from its original cross-section to an effectively smaller one, so that the 'unfolded' inner circumference is smaller than the original inner circumference, resulting in a tight fit on the cable sheath. The material that needs to be displaced is reshaped during a forming and bending process, creating a doubling of the material and radially outward-protruding sections of the ring element.
Data Source
Figure 1~1a
Figure 2
AI summary
The invention relates to a method for producing a cable grip (1) for a cable (30) that is to be attached to a plug (2), has a round cross-section and includes a cable sheath (31) having an outer circumference.