Cable Terminator with Piercing Contacts for RJ-45
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Solution Overview
Problem
Existing cable termination assemblies require skill and time to assemble due to the need to thread conductors through small openings and are mechanically weak, making them inefficient and prone to disassembly.
Innovation Solution
A cable termination assembly featuring a wire guide with channels for easy conductor placement and a securing cap with piercing contacts that interconnect with conductors, combined with a coupler connector with an RJ-45 socket and tines, allowing for secure and efficient cable termination without the need for threading through small openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are threaded through small openings to connect to insulation displacement connectors, then electrical contact is established, but the assembly requires skill and time, reducing productivity
Solution Approach 1:
The patent removes the small opening threading step entirely by extracting this complex operation and replacing it with a simple insertion motion through a large opening. The conductor connection is achieved through piercing contacts that engage with conductors already positioned in the wire guide, eliminating the need to thread conductors through tight spaces.
Solution Approach 2:
The device is divided into distinct functional components: the wire guide for conductor positioning, the securing cap with piercing contacts for electrical connection, and the coupler connector for final assembly. This segmentation allows each component to perform its function independently, simplifying the overall assembly process.
2Reliability
If conductors are threaded through small openings and connected with insulation displacement connectors, then electrical contact is achieved, but the mechanical strength is limited and assembly is prone to disassembly
Solution Approach 1:
The patent combines conductor positioning and electrical connection into a single integrated structure. The wire guide holds conductors in place while the securing cap with piercing contacts simultaneously establishes electrical connection, creating a unified assembly that resists disassembly.
Solution Approach 2:
The wire guide pre-positions the conductors in the correct location and orientation before the securing cap is installed. This preliminary action ensures that when the piercing contacts engage the conductors, the connection is both electrically functional and mechanically strong, preventing future disassembly.
3Reliability
If individual conductors are manually positioned and connected, then electrical contact is established, but the process requires skill and is cumbersome
Solution Approach 1:
The wire guide automatically positions and aligns the conductors as they are inserted, eliminating the need for manual positioning skills. The structure itself performs the alignment function, making the assembly process accessible to operators without specialized training.
Solution Approach 2:
The wire guide acts as an intermediary device that simplifies the interaction between the operator and the conductors. Instead of requiring direct manual manipulation of individual conductors, the operator simply inserts them into the wire guide, which handles the complex positioning and alignment tasks.
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 simplifies cable termination by eliminating the need for threading conductors, enhances mechanical strength, and reduces the risk of accidental disassembly, making the process more efficient and reliable.
Implementation Method 1
piercing an insulation of each of the conductors with a piercing first end of an aligned one of the piercing contacts
Data Source
AI summary
An assembly comprising a cable terminator comprising an elongate wire guide comprising a top end and four conductor pair receiving channels, and a securing cap configured for installation over the top end and comprising four pairs of piercing contacts exposed on an upper surface is disclosed. Each pair of the piercing contacts are interconnected with a respective conductor pair, and a coupler connector comprising a forward surface comprising an RJ-45 compatible socket, wherein tines are exposed within the socket and a rearward surface comprising a cable terminator receiving socket. Pairs of contacts are exposed on an end wall of the socket. Each of the tines is interconnected with a respective one of the contacts. When the cable terminator is inserted into the cable terminator receiving socket, the upper surface of the securing cap is positioned against the end wall and each of the piercing contacts comes into contact with a respective one of the contacts, thereby interconnecting each of the tines with one of the conductors.