Cable Connector Protective Sheath With Rigid Magnetic Half-Shells
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Solution Overview
Problem
Existing protective covers for plug-in connections are inadequate in providing mechanical and moisture protection, especially in harsh environments like construction sites, and are not effective against accidental damage or exposure to liquids.
Innovation Solution
A protective cover comprising two non-deformable, non-absorbent half-shells made of electrically insulating material, with a tapered shape and magnetic closure, designed to securely enclose the plug-in element and prevent displacement, while allowing limited moisture ingress without risking short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a cardboard protective cover is used, then the device is simple and inexpensive, but it provides inadequate mechanical protection and cannot reliably protect against moisture or liquids
Solution Approach 1:
The protective cover is divided into two separate half-shells that can be assembled around the plug connector. This segmentation allows each half-shell to be manufactured simply while the combined structure provides comprehensive protection. The two halves can be produced using simple injection molding and then joined together, maintaining manufacturing ease while achieving reliable mechanical and moisture protection.
Solution Approach 2:
The protective cover uses a composite structure combining two non-deformable, non-absorbent plastic materials. This composite approach provides both mechanical strength to prevent crushing and moisture resistance to block liquid ingress, resolving the contradiction between simple manufacturing and reliable protection.
2Strength
If a rigid non-deformable material is used, then mechanical protection is improved, but the protective cover becomes more difficult to manufacture and assemble
Solution Approach 1:
Dividing the rigid protective cover into two separate half-shells makes assembly feasible. Each half-shell can be manufactured with the required rigidity and strength, then joined together to form the complete protective enclosure. This segmentation resolves the contradiction by making the rigid structure manufacturable and assembleable.
Solution Approach 2:
A joining mechanism (such as clips, screws, or interlocking features) acts as an intermediary to connect the two rigid half-shells. This intermediary element enables assembly of the rigid structure without compromising the mechanical strength provided by the non-deformable material.
3Manufacturing precision
If the cavity is tightly fitted to the plug connector, then protection precision is improved, but the protective cover design becomes more complex
Solution Approach 1:
The cavity interior is designed with local quality variations - specifically an undercut region - to achieve precise fitting of the plug connector. This localized geometric feature provides accurate positioning and secure retention without requiring the entire protective cover design to be complex. The undercut allows the cavity to be precisely tailored to the connector shape while maintaining overall design simplicity.
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 provides reliable mechanical protection against accidental damage and moisture, ensuring the plug-in connection remains secure and undamaged during assembly and disassembly, with a stable and easy-to-use design that maintains its shape under external forces.
Implementation Method 1
cooperating magnetic elements on both half-shells
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to a protective cover for a plug connector on a cable, in particular a plug and/or a socket, with a cavity for receiving the plug connector, and with at least one through-hole for the cable, wherein the cavity is dimensioned such that only the plug connector itself fits into it without the corresponding plug connector counterpart, characterized in that the protective cover comprises two half-shells which together enclose the cavity and each consist of a non-deformable and non-absorbent material.