Differential Pair Connector Housing to Prevent Wire Separation
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Solution Overview
Problem
In differential signal transmission using twisted pair cables, improper insertion of terminal portions into connectors can lead to widened wire intervals, degrading transmission characteristics.
Innovation Solution
A connector design with a terminal module and housing that includes a stopper to restrict the tip surface of the sheath from approaching the wire draw-out openings, preventing the signal wires from buckling and maintaining a controlled distance, thus suppressing the degradation of transmission characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the wires are untwisted to insert terminal portions separately, then the terminal portions can be properly inserted, but the interval between the wires is widened and transmission characteristics are degraded
Solution Approach 1:
The terminal portions are pre-positioned on the wires before insertion into the connector body. The housing includes pre-formed guide grooves that direct the terminal portions along the correct insertion path, ensuring proper positioning before the wires are fully inserted. This preliminary guidance prevents improper insertion while maintaining wire integrity.
Solution Approach 2:
A guide structure consisting of guide grooves and positioning protrusions acts as an intermediary between the terminal portions and the connector body. This intermediary mechanism ensures that terminal portions are inserted in the correct sequence and orientation, preventing both simultaneous improper insertion and wire interval widening.
2Ease of operation
If the wires are untwisted over the entire length of terminal portions, then separate insertion is enabled, but the wire interval is easily widened
Solution Approach 1:
The housing provides localized guidance structures (guide grooves and positioning protrusions) only at critical insertion zones where terminal portions enter the connector body. The wires are untwisted only to the extent necessary for terminal attachment, not along their entire length. This localized control maintains wire interval precision while enabling separate insertion.
Solution Approach 2:
Terminal portions are prepared and positioned on the wires before insertion into the connector body. The guide grooves are pre-formed in the housing to receive and guide the terminal portions along the correct path. This preliminary preparation ensures that when insertion occurs, the wires maintain their proper interval without requiring extensive untwisting.
3Productivity
If terminal portions are simultaneously inserted into the connector body, then insertion speed is improved, but improper insertion occurs
Solution Approach 1:
A guide structure with sequential guide grooves and positioning protrusions acts as an intermediary mechanism that forces terminal portions through a controlled insertion sequence. Even when both terminal portions are inserted simultaneously, the guide structure ensures they follow the correct path and engage at the proper positions, preventing improper insertion while maintaining high insertion speed.
Solution Approach 2:
The insertion process is segmented into distinct stages through the guide structure: first stage guide grooves receive terminal portions, positioning protrusions verify correct orientation, and second stage grooves guide final seating. This segmentation allows simultaneous insertion of multiple terminal portions while ensuring each follows the correct insertion sequence for proper positioning.
Data Source
AI summary
A connector A is provided with a terminal module 30 including a communication cable 37 having a pair of signal wires 39 embedded in an insulating sheath 38, tip regions of the pair of signal wires 39 extending as wire exposed portions 39E from a tip surface 38S of the sheath 38, and a dielectric 31 for accommodating a pair of signal terminal fittings 35 individually fixed to a pair of the wire exposed portions 39E, the wire exposed portions 39E being drawn out from signal wire draw-out openings 33 of the dielectric 31, and a housing 10 for accommodating a tip region of the communication cable 37 and the dielectric 31. The housing 10 is formed with a stopper 25 for restricting the tip surface 38T of the sheath 38 from approaching the signal wire draw-out openings 33.