Conductive Housing Cable Connector Eliminates Soldering
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Solution Overview
Problem
Existing cable connection devices require time-consuming and costly soldering and assembly processes, necessitating specialized tools to connect data cables effectively without impairing signal quality.
Innovation Solution
A cable connection device with electrically conductive connection elements, insulation displacement contacts, and a conductive housing that allows direct electrical contact between data cables' wires and shielding, eliminating the need for soldering and specialized tools by using standard tools for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional soldering and assembly processes are used to connect data cables, then reliable electrical connection is achieved, but the process becomes time-consuming and requires specialized tools
Solution Approach 1:
The patent replaces the traditional soldering process (thermal/chemical system) with a mechanical insertion system. The connection elements are simply inserted into the housing and pressed against the wire ends, eliminating the need for soldering irons, flux, and heating equipment. This mechanical substitution dramatically reduces assembly time while maintaining reliable electrical contact through the conductive housing and connection elements.
2Reliability
If traditional soldering processes are used, then reliable electrical connection is achieved, but specialized tools and equipment are required
Solution Approach 1:
The invention replaces complex soldering equipment with simple manual insertion and pressing actions. The connection elements are designed to be hand-inserted into the housing, and standard pliers or similar common tools can be used to press them against the wire ends. This eliminates the need for specialized soldering equipment, making the process accessible to anyone with basic tool knowledge.
Solution Approach 2:
The connection elements are designed with self-aligning and self-retaining features. When inserted into the housing, they automatically position themselves and maintain electrical contact through their elastic deformation. The housing structure itself provides the connection path, eliminating the need for additional assembly steps or specialized tooling.
3Reliability
If conventional cable connection devices are used, then electrical connection is achieved, but production costs increase due to complex assembly processes
Solution Approach 1:
By replacing soldering with mechanical insertion, the patent eliminates costs associated with soldering equipment, consumable materials (flux, solder wire), and the extended labor time required for soldering operations. The simple insertion and pressing process can be performed faster and with fewer resources, directly reducing production costs while maintaining signal transmission quality through the conductive connection path.
Solution Approach 2:
The invention changes the fundamental parameter of connection establishment from thermal/chemical bonding (soldering) to mechanical contact. This parameter change simplifies the manufacturing process, reduces equipment requirements, and lowers overall production costs while maintaining the essential function of electrical connection for signal transmission.
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
Enables quick, cost-effective connection of data cables' cores and shields without signal interference, providing reliable electrical and mechanical connections using standard tools, thus simplifying the handling and reducing production costs.
Implementation Method 1
Each connecting element has a first contact area, which is designed for making electrical contact with a wire of the first data cable, and a second contact area, which is designed for making electrical contact with a wire of the second data cable
Implementation Method 2
The data cables each have a shield that surrounds the cores to prevent the signal transmission from being affected by external influences
Data Source
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AI summary
The connecting device has conductive housing (12) for receiving conductor fixing portions (62,92) for fixing conductors of data cables (58,60), and electrical connector (24) for electrically connecting each conductor and/or shield of data cables. The electrical connector has several electrically conductive connecting elements (25-32) having contact areas (34,36) for contacting conductors respectively. The conductor fixing portions have several contact areas (67-74) to which an end portion of conductor is applied and which engage with contact areas of connecting elements respectively.