Conductive Rubber Plug Connector for High-Data-Rate Cable Assembly
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Solution Overview
Problem
Existing connectors are unsuitable for high data rate applications, as they are not reliable for transmitting both data signals and currents, and they often require complex tools, are not easily assembled, and have limited design flexibility due to insulation displacement, crimping, or screw connection technologies.
Innovation Solution
A connector system using conductive rubber with alternating conductive and non-conductive layers, allowing for easy assembly and reversible connection of solid or stranded conductors without additional tools, suitable for a wide range of conductor cross-sections and capable of transmitting high data rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation displacement terminals are used to contact conductors, then electrical contact can be achieved, but the connector size increases and design flexibility is reduced
Solution Approach 1:
The patent uses a conductive rubber element with alternating conductive and non-conductive layers. The conductive layers contact the conductors while the non-conductive layers provide insulation. This flexible layered structure achieves reliable electrical contact without requiring large insulation displacement terminals, thus reducing connector size while maintaining contact reliability.
Solution Approach 2:
The conductive rubber element combines conductive and non-conductive materials in alternating layers within a single component. This composite structure integrates both electrical contact and insulation functions into one element, eliminating the need for separate terminals and insulation structures, thereby reducing overall connector volume.
2Reliability
If screw connection technology is used for connecting conductors, then reliable electrical contact is achieved, but the connector requires larger size and limited area of application
Solution Approach 1:
The patent merges the contact and insulation functions into a single conductive rubber element with alternating layers. This eliminates the need for separate screw terminals and insulation structures, significantly reducing the connector footprint while maintaining reliable electrical contact through the layered structure.
Solution Approach 2:
The flexible conductive rubber element can be compressed to establish contact with conductors without requiring screw fastening mechanisms. This thin-film approach reduces the connector area while achieving reliable contact through elastic deformation and layer compression.
3Reliability
If crimping technology is used to connect contact elements to conductors, then electrical contact is achieved, but the connection cannot be detached and reconnected
Solution Approach 1:
The conductive rubber element is elastic and can be dynamically compressed and released. This allows the connector to be repeatedly assembled and disassembled while maintaining reliable electrical contact. The elastic property enables the contact pressure to be restored after each connection cycle, providing unlimited reconnectability.
Solution Approach 2:
The elastic conductive rubber element automatically maintains contact pressure through its inherent elastic recovery. No additional fastening or tightening mechanisms are required - the material itself provides the necessary contact force through elastic deformation, enabling easy assembly and disassembly while maintaining reliable contact.
4Reliability
If cage tension spring is used to connect conductors, then electrical contact can be achieved, but a tool is required and a lot of space is needed
Solution Approach 1:
The conductive rubber element is designed to be self-assembling through elastic compression. No tools or additional actuators are required - the elastic recovery of the rubber provides the necessary contact force automatically. This eliminates the complexity of cage tension springs and associated assembly tools.
Solution Approach 2:
The flexible conductive rubber element replaces rigid cage tension springs with a compliant material that can be easily compressed and secured. This thin-film approach reduces both the space required and the assembly complexity, as the elastic material can be简单地 compressed to establish contact without requiring spring mechanisms or tools.
5Reliability
If insulation displacement terminals are used, then electrical contact is achieved, but conductor cross-sections are restricted
Solution Approach 1:
The conductive rubber element can be manufactured with varying layer thicknesses, conductive particle concentrations, and material compositions to optimize contact pressure and electrical conductivity for different conductor types. This parameter adjustability allows the same basic structure to accommodate various conductor cross-sections while maintaining reliable contact.
Solution Approach 2:
The composite structure of alternating conductive and non-conductive layers can be tailored to accommodate different conductor types. The conductive layers can be designed with appropriate hardness and conductivity for solid or stranded conductors, while the non-conductive layers provide insulation. This material versatility enables the connector to handle various conductor cross-sections reliably.
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 connector system provides reliable transmission of data signals and currents with a compact design, allowing for easy assembly and use with various conductor types, including solid and stranded conductors, without the need for additional tools, and maintains performance under harsh conditions.
Implementation Method 1
a conductive rubber with at least one conductive layer, in particular with at least two conductive layers, wherein the at least one conductor is connectable to at least one conductive layer in an electrically conductive manner
Implementation Method 2
A conductive rubber essentially consists of an elastically deformable material with alternating conductive and non-conductive layers
Data Source
Figure 1~3
Figure 4a~4b
Figure 5
AI summary
The invention relates to a plug connector (1, 1', 1'', 1''') to which a cable (6) having at least one insulated conductor (7) can be connected, wherein the plug connector (1) has a conductive rubber element (4) with at least one conductive layer (5), but preferably with at least two conductive layers (5, 5'). The electrical connection of the conductors is realized by means of the conductive rubber element. The conductive rubber element can also form the plug face of the plug connector. As an alternative, the conductors can be connected to contact elements by means of the conductive rubber element.