Field-terminable Single Pair Ethernet Connector with Integrated Wire Cap
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Solution Overview
Problem
There is a need for a simple, inexpensive, and field-terminable single pair Ethernet connector that can establish electrical continuity and provide strain relief, accommodating both screened and unscreened cables in various gauges, while being adaptable to small form factors and compatible with low bandwidth applications like security cameras and smart building devices.
Innovation Solution
A communication connector with an outer housing, shielding wrap, and contact carrier assembly that includes insulation displacement contacts (IDCs) and an integrated wire cap with a hinge feature for easy termination, along with strain relief ribs to secure the cable, and grounding tabs to reduce alien crosstalk and ensure electrical grounding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a compact connector design is used to achieve higher density of data channels, then space utilization is improved, but manufacturing complexity and termination difficulty increase
Solution Approach 1:
The connector is divided into modular components: an outer housing, a contact carrier assembly with insulation displacement contacts, and an integrated wire cap. This segmentation allows each component to be manufactured independently using standard processes, then assembled together, maintaining ease of manufacture while achieving a compact overall form factor that accommodates multiple contact pairs.
Solution Approach 2:
The contact carrier assembly is nested within the outer housing, and the wire cap is integrated into the contact carrier assembly. This nested structure maximizes space utilization by arranging components in concentric layers, achieving high density without increasing the overall connector footprint or complicating the manufacturing process.
2Adaptability or versatility
If a field-terminable design is used to allow custom cabling structures, then adaptability is improved, but termination tool complexity increases
Solution Approach 1:
The connector incorporates self-terminating features including an integrated wire cap that automatically crimps conductors to the IDCs when the contact carrier assembly is inserted into the outer housing, and built-in strain relief ribs that automatically grip the cable jacket. These self-service mechanisms eliminate the need for external crimping tools and complex termination equipment, allowing field technicians to complete custom cabling installations with simple hand-operated tools while maintaining high adaptability.
3Reliability
If shielding features are added to improve electrical performance, then signal quality is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The shielding features are merged with the existing connector components rather than added as separate elements. The outer housing incorporates shielding elements, and the contact carrier assembly includes integrated shielding structures. This merging approach improves electrical performance and reduces alien crosstalk without significantly increasing device complexity or manufacturing cost, as the shielding is integrated into the primary structural components.
4Ease of operation
If insulation displacement contacts are used to simplify conductor connection, then ease of operation is improved, but contact reliability may worsen
Solution Approach 1:
The insulation displacement contacts are pre-configured in the contact carrier assembly with precise positioning features and alignment channels. The integrated wire cap is pre-formed with crimping surfaces that engage the IDCs at optimal locations. This preliminary preparation ensures that when the conductor is inserted and the wire cap is actuated, the IDCs reliably pierce the insulation and establish solid electrical contact, maintaining both ease of operation and contact reliability.
Data Source
AI summary
A communication connector has an outer housing with an opening, a shielding wrap at least partially enclosing the outer housing, and a contact carrier assembly configured to be interested into the opening of the outer housing. The contact carrier assembly at least partially encloses at least two contacts each with an insulation displacement contact (IDC). The contact carrier assembly also has an integrated wire cap that utilizes a hinge feature to press cable conductors of a cable into their respective IDCs.