Connector Pull Tab Leverage for Narrow Channel Removal
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Solution Overview
Problem
Existing connector designs for consumer-facing edge devices, such as those with USB-C ports, are difficult to remove from narrow channels due to their design, leading to strain on cables and potential breakage.
Innovation Solution
A connector head assembly featuring an elongate overmold with a pivotally attached pull tab, which provides leverage for easy removal and acts as a strain relief to prevent cable damage, incorporating a living hinge or separate pivot mechanism for enhanced usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector head assembly is designed without a pull tab, then the structure remains simple and compact, but the connector becomes difficult to remove from narrow channels and the cable is subjected to strain and potential breakage
Solution Approach 1:
The connector head assembly is segmented into distinct functional components: the elongate overmold that encases the cable terminal, the pull tab that provides leverage for removal, and the living hinge that connects them. This segmentation allows each component to perform its specific function optimally while maintaining overall simplicity
Solution Approach 2:
The pull tab acts as an intermediary element between the user and the connector body. It provides a leverage point that mediates the force application, allowing easy removal without directly manipulating the connector body or putting strain on the cable
2Ease of operation
If the connector head assembly includes a pull tab with living hinge, then easy removal from narrow channels is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The pull tab and elongate overmold are merged into a single integrally formed component through the living hinge. This combining eliminates the need for separate parts and complex assembly processes, while the living hinge itself is formed as an integrated feature during the molding process
Solution Approach 2:
The living hinge utilizes parameter changes in the material properties, specifically the transition between rigid and flexible states. The hinge region is designed with modified material parameters (thickness, composition) that allow it to pivot during removal while maintaining structural integrity during normal use
3Force
If the elongate overmold is made longer to provide better leverage, then removal force is reduced, but the overall cable assembly length increases
Solution Approach 1:
Instead of extending the overmold length in one dimension to provide leverage, the design utilizes the width dimension by creating a pull tab that extends perpendicular to the main body. This dimensional change provides effective leverage while keeping the overall cable assembly compact
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
Facilitates easy removal of connectors from narrow channels while preventing cable strain and breakage, ensuring durability and user convenience.
Implementation Method 1
The elongate overmold and the pull tab may be integrally formed such that the pivotal attachment of the pull tab is formed as a living hinge integrated into an outer surface of the elongate overmold
Implementation Method 2
A pulling force applied to the pull tab may be configured to separate the receptacle connector from a receptacle in which the receptacle connector is configured to be held
Data Source
AI summary
Various embodiments include a connector head assembly for an electrical cable attached to one or more receptacle connectors. The connector head assembly may include an elongate overmold having a longitudinal extent that is longer than a height or width thereof. The elongate overmold may be configured to encase a terminal end of the electrical cable coupled to the one or more receptacle connectors inside the elongate overmold. The connector head assembly may also include a pull tab pivotally attached to the elongate overmold on an upper surface thereof. A pulling force applied to the pull tab may be configured to separate the receptacle connector from a receptacle in which the receptacle connector is configured to be held.