Conductive Cage Electrical Connector Tool-Free Cable Insertion
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Solution Overview
Problem
Existing electrical connectors are bulky, require additional tools for cable decoupling, and are not suitable for reliable use with both solid and stranded cables, leading to potential deformations and reduced flexibility in miniaturization and reuse.
Innovation Solution
A compact electrical connector design featuring a conductive containment cage with an elastic pressure element and a sliding casing that allows cable insertion and removal without tools, using engagement couplings for structural integrity and a modular design for flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If additional tools like screwdrivers are used to open metallic contacts for cable coupling, then cable connection is achieved, but device complexity increases and manufacturing precision is compromised due to uncontrolled deformations
Solution Approach 1:
The connector enables cable insertion and removal through its own structural mechanisms (elastic pressure element and sliding casing) without requiring external tools. The user interacts directly with the connector's built-in features rather than needing separate tools, making the system self-sufficient for its primary function.
Solution Approach 2:
The patent removes the need for external tools (screwdrivers, nails) from the connection process. By integrating the opening mechanism directly into the connector structure through the sliding casing and elastic pressure element, the harmful external tools are extracted from the system, eliminating their negative effects.
2Adaptability or versatility
If additional functional components are added to enable cable decoupling, then cable removal capability is provided, but manufacturing precision deteriorates due to uncontrolled deformation of metallic parts
Solution Approach 1:
The connector's built-in sliding casing and elastic pressure element work together to provide controlled cable release. The system uses its own structural components rather than external tools, ensuring that metallic parts are manipulated in a controlled manner that preserves manufacturing precision.
Solution Approach 2:
The sliding casing acts as an intermediary mechanism that mediates between the user's action and the metallic contacts. Instead of directly manipulating the metallic parts with uncontrolled tools, the sliding casing provides a controlled interface that protects the integrity of the metallic contacts while enabling cable decoupling.
3Ease of operation
If a plastic element with lever function is used for cable insertion/removal, then tool-free operation is achieved, but reliability decreases due to deformation during reflow soldering
Solution Approach 1:
The elastic pressure element provides dynamic, flexible pressure rather than rigid mechanical leverage. This elastic mechanism can accommodate thermal expansion and contraction during soldering without permanent deformation, while still providing the necessary force for cable insertion and removal.
Solution Approach 2:
The patent changes the material property parameter from rigid plastic to elastic material. This parameter change allows the element to withstand thermal stress during reflow soldering through elastic deformation rather than permanent plastic deformation, maintaining reliability while enabling tool-free operation.
4Adaptability or versatility
If multiple distinct components are assembled to create the connector, then functional capabilities are achieved, but volume increases contrary to miniaturization trends
Solution Approach 1:
The patent merges multiple functions into a unified structure. The containment cage, elastic pressure element, and sliding casing work as an integrated system rather than separate assemblies. This merging reduces the overall volume while maintaining all necessary functional capabilities for cable connection and decoupling.
Solution Approach 2:
The sliding casing nests within the containment cage structure, and the elastic pressure element is integrated within the casing. This nested arrangement allows multiple functional components to occupy overlapping spatial volumes, minimizing the overall connector size while preserving full functionality.
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 reduces the number of components, eliminates the need for external tools, ensures reliable cable connection and disconnection, and allows for modular and cost-effective assembly, enhancing the logistical and productive aspects of electrical connectors.
Implementation Method 1
an elastic pressure element (24) extending from said upper wall towards the inner compartment of said containment cage and configured to hold the electric cable in contact with said lower wall
Data Source
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AI summary
The invention describes an electrical connector consisting of a substantially parallelepiped-shaped containment cage with structural function, provided with a pair of lateral walls, a lower wall and an upper wall that develop according to a substantially longitudinal direction and define a substantially closed inner compartment for housing at least one electrical wire or cable. The containment cage is provided, at a front end thereof, with an opening for the insertion of the electrical wire or cable to be removably connected to the electrical connector. An elastic pressure element extends from the upper wall towards the inner compartment of the containment cage, so as to hold - by friction - the electrical wire or cable in electrical contact with the lower wall. One or more connection elements with electrical circuits for the transmission of the signals transferred by the electrical wire or cable extend from the lower wall towards the outer part of the containment cage. The lateral walls, the lower wall, the upper wall, the elastic pressure element and the one or more connection elements with electrical circuits are made from a single block of electrically conductive material, folded upon itself to form the containment cage. The structural and box-shaped strength of the block that constitutes the containment cage is guaranteed by a fit-coupling obtained through one or more engagement couplings obtained on one of the longitudinal sides of the containment cage, so that the engagement couplings are capable of irreversibly connecting the lower wall to one of the lateral walls of the containment cage.