Elastic Bending Guard for Electric Plug Connectors
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Solution Overview
Problem
Existing plug connectors for field assembly lack a cost-effective and user-friendly solution for providing a visually attractive, secure, and adaptable cable connection that can accommodate different cable cross-sections while preventing damage from bending and tensile stresses.
Innovation Solution
An electric plug connector with a bending protection made from elastic material, featuring a connecting element that changes state irreversibly upon temperature activation, forming a permanent mechanical and adhesive bond between the housing, cable, and bending protection, ensuring secure sealing and protection against foreign bodies and stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bending protection is molded onto the cable outlet by overmolding process, then bending protection is provided, but the manufacturing cost and complexity increase
Solution Approach 1:
The bending protection is separated from the housing as an independent component that can be assembled separately. This allows the housing to be manufactured without complex overmolding processes, reducing manufacturing cost and complexity while still providing effective bending protection when the separate bending protection component is attached to the cable outlet.
2Adaptability or versatility
If cable glands with cut-out nuts are used for field assembly, then different cable cross-sections can be accommodated, but the cable or cores can be damaged by improper use
Solution Approach 1:
The traditional mechanical screw connection system is replaced with a compression-based sealing system. The bending protection component compresses against the cable outlet to create a seal and secure connection, eliminating the need for screw connections that can damage cables or cores during assembly or disassembly.
3Shape
If a professional looking connection is achieved for predetermined cable cross-sections, then visual appeal is improved, but adaptability to different cable sizes is reduced
Solution Approach 1:
The bending protection component is designed with a universal interface that can accommodate different cable cross-sections while maintaining a consistent, professional appearance. The component's structure allows it to adapt to various cable sizes through compression and deformation, providing both visual appeal and versatility without requiring different components for different cable types.
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 a reliable, visually appealing, and adaptable cable connection that securely seals different cable cross-sections, preventing damage from bending and tensile stresses, and can be easily assembled in the field using a hot air gun for temperature activation.
Implementation Method 1
upon temperature activation
Implementation Method 2
forming a permanent mechanical and adhesive bond
Implementation Method 3
The bending protection is manufactured from an elastic material
Implementation Method 4
Strain reliefs provide relief for the connectors, the lines in the cable and the connected contact elements during a tensile stress
Data Source
AI summary
An electric plug connector has a locking element configured for releasably connecting to a mating plug connector, a housing for receiving at least one cable and at least one contact element, and a bending guard which is made of an elastic material and prevents excessive bending of the connected cable, wherein the bending guard can be used for different cable cross-sections for field assembly.