Electrical Connector Pre-Molded Over-Molded Strain Relief
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Solution Overview
Problem
Current electrical connector assemblies are bulky, heavy, prone to rust and scratching, have costly machined components, allow cable movement, and have metal housings that can cause safety issues due to extreme temperature exposure, with loosely associated attachment means that allow angular and side-to-side movement.
Innovation Solution
The improved electrical connector assembly incorporates a pre-mold material to cover the connector rear and termination, an over-mold material to cover the cable and pre-mold, and a spin ring with a wiggle ring to secure the connector, providing better strain protection and a more secure connection, while the spin ring and over-mold material combination enhances the tactile feel and reduces cable movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal housing and machined components are used in electrical connector assemblies, then structural strength and durability are improved, but manufacturing cost increases and the assembly becomes bulky and heavy
Solution Approach 1:
The patent changes the material parameters from metal to molded materials (thermoplastic elastomer and thermoplastic polymer), fundamentally altering the physical and chemical properties of the connector housing and attachment means. This substitution maintains structural integrity while eliminating the need for costly machined components and reducing overall assembly weight and size.
Solution Approach 2:
The patent employs composite construction by combining two different molded materials: a thermoplastic elastomer for the connector housing and attachment means, and a thermoplastic polymer for the insulation housing. This composite approach allows each material to contribute its optimal properties (flexibility, strength, insulation) while avoiding the drawbacks of metal construction.
2Strength
If metal housing is used in electrical connector assemblies, then structural strength is improved, but safety deteriorates due to extreme temperature exposure causing burning or freezing of user skin
Solution Approach 1:
The patent changes the thermal parameters of the housing material from metal (high thermal conductivity) to thermoplastic elastomer (low thermal conductivity). This parameter change ensures that even when exposed to extreme temperatures, the housing does not rapidly conduct heat to the user's skin, eliminating burning or freezing hazards while maintaining structural strength.
3Ease of manufacture
If clamping device is used to secure cables and metal sleeve, then connection is achieved, but cable movement is allowed causing increased strain and decreased lifespan
Solution Approach 1:
The patent merges the cable clamping function with the molded connector housing by integrating a clamping cavity directly into the housing structure. This integration eliminates the need for separate clamping devices and metal sleeves, while providing complete encasement of the cable that prevents movement and reduces strain on terminations.
Solution Approach 2:
The patent uses the flexible thermoplastic elastomer material to create a molded clamping cavity that can adapt to the cable shape while providing secure retention. The flexible nature of the material allows it to grip the cable firmly without damage, preventing cable movement and reducing strain on electrical terminations.
4Device complexity
If attachment means are loosely associated with connector assembly, then assembly simplicity is maintained, but angular and side-to-side movement is allowed decreasing reliability
Solution Approach 1:
The patent merges the attachment means with the connector housing by molding the attachment means as an integral part of the housing structure. This integration eliminates loose associations and ensures that the attachment means moves only with the housing itself, preventing angular and side-to-side movement that would compromise connection stability.
Solution Approach 2:
The patent uses the composite material system (thermoplastic elastomer housing with integrated attachment means) to create a unified structure where the attachment means is firmly bonded to the housing. This composite construction ensures rigid connection between components while maintaining the overall simplicity of the assembly.
Data Source
AI summary
An electrical connector is provided wherein the electrical connector includes an electrical connector neck which separates an electrical connector rear from an electrical connector front and wherein the electrical connector rear includes an electrical connector termination. The electrical connector includes a pre-mold material securely associated with the electrical connector to cover the electrical connector rear and the electrical connector termination. Additionally, an over-mold material is securely associated with the electrical connector to cover a portion of the pre-mold material.