Connector Plug Axial Load Transfer via Reinforced Annular Element
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Solution Overview
Problem
Existing multi-conductor cables face challenges in securely anchoring the tension load transferring string within the connector plug, leading to inadequate transfer of axial loads to the connected jack, which can cause mechanical strain on the cable wires and expose the connector plug housing to heavy strains.
Innovation Solution
The solution involves an annular element with transverse pin and reinforcement mould that securely anchors the high-strength Kevlar tension load transferring string, allowing proper axial load transfer to the jack while enabling the connector plug housing to be made of low tensile materials like plastic by using an annular element with wings and a mould to lock the pin in place, ensuring rotational and axial load transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the tension load transferring string is anchored directly in the connector plug housing, then the axial load can be transferred to the jack, but the connector plug housing is exposed to heavy strains that require high-tensile materials
Solution Approach 1:
A steel reinforcement mould is introduced as an intermediary component between the Kevlar string and the plastic connector plug housing. The mould receives the axial load from the string and transfers it to the housing, allowing the housing to be made of low-tensile plastic material while maintaining reliable load transfer capability
Solution Approach 2:
The solution combines multiple materials with different properties: high-strength Kevlar for the tension load transferring string, steel for the reinforcement mould to handle heavy strains, and low-tensile plastic for the connector plug housing. This composite approach allows each component to be optimized for its specific function
2Ease of operation
If the annular element is made rotatable relative to the cable, then assembly is easier, but rotational locking relative to the cable is lost
Solution Approach 1:
The annular element is designed with rotational freedom during assembly to facilitate easy installation, but incorporates asymmetric wings that engage with corresponding features on the cable to provide rotational locking after assembly. This dynamic design allows the element to transition from a movable state during assembly to a fixed state during operation
Data Source
Figure 1~6
Figure 3B~5
AI summary
A connector plug (11) intended for a multi-conductor cable (10) with an axial load transferring non-conducting tensile string (15) and includes a casing (24) carrying a number of contact elements (26) attached to the conductors (13,14) of the cable (10) and intended to engage corresponding contact elements connected to a matching jack, and the tensile string (15) is anchored relative to the casing (24) via an annular element (18) mounted at the end of the cable (10), and a transverse pin (19) firmly attached to the tensile string (15) of the cable (10) and positively engaging the annular element (18), wherein the annular element (18) has a rim portion (20) with a bigger outer diameter than the outer cross sectional dimension of the cable (10) so as to engage an internal shoulder (25) on the casing (24) and enable transfer of axial load from the tensile string (15) of the cable (10) to the casing (24) and further to a connected matching jack via the transverse pin (19) and the annular element (18).