Conductive Over-Molded Strain Relief for Cable Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable connectors with strain relief mechanisms are costly and lack standardization, as additional plastic or rubber members are typically required for each connector, leading to increased stress on the cable and connector interface, which can result in conductor breakage and separation.
Innovation Solution
A cable connector system with an integrated latching mechanism and over-molded strain relief member made from electrically conductive material, which interlocks with the housing and cover to provide a grounding path and secure retention, while using a standardized housing and cover design that can accommodate various cable sizes and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional plastic or rubber members (boots) are added to the cable connector interface for strain relief, then stress transfer and conductor protection are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The strain relief member is integrated directly into the connector housing as a unified structure, eliminating the need for separate boot components. The housing itself is designed with features that provide strain relief functionality, combining structural support and stress absorption into a single element that reduces assembly steps and part count.
Solution Approach 2:
The connector housing serves multiple functions simultaneously: it provides structural support, electrical grounding through the conductive material, and strain relief through its integrated design features. This multi-functionality eliminates the need for dedicated separate components for each function, reducing overall device complexity.
2Reliability
If additional plastic or rubber members are added to the cable connector interface for strain relief, then stress transfer and conductor protection are improved, but manufacturing cost increases
Solution Approach 1:
The strain relief functionality is combined with the existing housing manufacturing process, eliminating the need for separate production and assembly of boot components. This integration reduces manufacturing steps, labor costs, and inventory management requirements.
Solution Approach 2:
The housing design provides multiple functions (structural support, grounding, strain relief) through a single component, reducing the total number of parts that need to be manufactured, inventoried, and assembled, thereby lowering overall manufacturing costs.
3Adaptability or versatility
If non-standardized strain relief solutions are used for each cable connector, then specific cable configurations can be accommodated, but manufacturing efficiency and cost-effectiveness decrease
Solution Approach 1:
The connector housing is designed with universal features that can accommodate various cable types, sizes, and configurations through standardized strain relief geometries. The conductive material and integrated design provide consistent performance across different applications without requiring custom components for each cable variant.
Solution Approach 2:
The strain relief member incorporates modular or scalable design features that can be adjusted for different cable configurations while maintaining the same basic manufacturing process. This allows standardization at the component level with flexibility in application.
4Object-affected harmful factors
If the strain relief member is made from non-conductive material, then insulation is provided, but grounding path capability is lost
Solution Approach 1:
The strain relief member is made from electrically conductive material that provides both mechanical strain relief and electrical grounding functionality. The conductive material allows the formation of a continuous grounding path from the cable shield through the strain relief member to the connector housing and ultimately to the circuit board ground plane.
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 effectively transfers stress away from the cable conductors to the housing and cover, reducing the risk of breakage and separation, while offering a cost-effective and standardized solution for strain relief, maintaining electrical contact and grounding.
Implementation Method 1
The over-molded strain relief member formed from an electrically conductive material effectively transfers stress away from the cable conductors to the housing and cover
Implementation Method 2
The over-molded strain relief is formed from an electrically conductive material and is configured to interlock with the housing and cover to secure it therein and provide a grounding path between the cable and the housing and cover
Data Source
AI summary
The present disclosure provides a cable connector assembly that includes a cable having conductors secured to contact pads formed on a printed circuit board. A housing and cover are configured to be secured together and combine to form a cavity for receiving the printed circuit board and the cable. A slug is formed around a portion of the cable. Upon assembly of the cover to the housing, the slug is disposed in a pocket formed in the cavity and helps secure the cable to the housing and cover.