Data Cable Plug Connector Axial Rotational Fixation
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Solution Overview
Problem
Existing data cable plug connectors face challenges in ensuring axial and rotational fixation, as well as unambiguous angular alignment, particularly in high-speed bus systems, due to the need for precise alignment of electrical contacts with the housing and line leads.
Innovation Solution
A data cable with a plug connector featuring a rotationally symmetrical bush and a molded piece with form-locking elements, including a bead with stamped or cut perforations, provides axial and rotational fixation through form-locking connections between the bead, the molded piece, and the housing, ensuring unambiguous alignment and preventing relative rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rotationally symmetrical bush with deep-drawn tube is used for the plug connector, then manufacturing cost is reduced and ease of manufacture is improved, but axial and rotational fixation of the housing becomes difficult to ensure
Solution Approach 1:
The patent introduces asymmetric form-locking elements (protrusions and recesses) on the bead of the deep-drawn tube that break the rotational symmetry. These asymmetric features engage with corresponding features on the molded piece to prevent relative rotation while maintaining the cost-effective deep-drawn tube construction. This resolves the contradiction by adding minimal asymmetric features to an otherwise symmetric, easy-to-manufacture bush structure.
Solution Approach 2:
The form-locking elements are pre-formed on the bead of the deep-drawn tube before final assembly. The bead is compressed and shaped during or after the deep-drawing process to create the protrusions and recesses that will later engage with the molded piece. This preliminary formation of locking features simplifies the overall assembly process while ensuring reliable fixation.
2Manufacturing precision
If precise alignment of electrical contacts with housing and line leads is required, then unambiguous angular position is achieved, but assembly complexity and difficulty increase
Solution Approach 1:
Asymmetric form-locking elements are formed on the bead of the deep-drawn tube, creating a mechanical key-and-lock system with the molded piece. This asymmetric engagement automatically establishes the correct angular position of the housing relative to the line leads during assembly, eliminating the need for complex alignment procedures or additional alignment features.
Solution Approach 2:
The patent combines multiple functions into the single molded piece: it provides electrical insulation, structural support, and rotational positioning. The form-locking elements are integrated into the molded piece's geometry, merging the alignment function with the structural connection function. This integration reduces assembly complexity by eliminating separate alignment mechanisms.
3Stability of the object's composition
If axial fixation of the housing is ensured, then positional stability is improved, but rotational fixation against relative rotation becomes difficult
Solution Approach 1:
The bead on the deep-drawn tube is compressed to form asymmetric protrusions and recesses that extend in the axial direction. These asymmetric features engage with corresponding features on the molded piece to prevent both axial displacement and rotational movement simultaneously. The single bead structure thus provides dual fixation functionality without requiring separate axial and rotational locking mechanisms.
Solution Approach 2:
The form-locking connection merges axial and rotational fixation functions into a single mechanical engagement system. The protrusions and recesses on the bead create interlocking geometry that resists both axial separation and rotational movement, eliminating the need for separate fixation mechanisms for each degree of freedom.
Data Source
AI summary
A data cable including an electrical line with a plurality of line leads, an electrical shield, a molded piece including first counterpart form-locking elements and a housing enclosing the molded piece, wherein the housing has a central opening. The data cable further including a plug connector disposed on an end of the data cable, wherein the plug connector is electrically connected to the shield, wherein the plug connector includes a bush that is enclosed by the molded piece. The bush includes a deep-drawn tube and a bead with second form-locking elements which with the counterpart form-locking elements form a first form-locking connection, wherein an outer contour of the molded piece and an inner contour of the central opening of the housing form a second form-locking connection.