Field Termination Plug With Adjustable Piercing Terminals
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Solution Overview
Problem
Conventional RJ-45 modular plugs are inconvenient for installers to assemble with Category 6A cables due to the larger wire diameter, requiring advanced cable assemblies from factories, which limits field termination capabilities.
Innovation Solution
A field termination plug design featuring a contact retainer, plug housing, terminal connection unit, and pivoting cover, allowing for easy attachment and termination of wires to network jacks, with adjustable piercing terminals and a strain relief device for accommodating various cable sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional RJ-45 modular plug with 8×1.10 mm holes is used, then it is suitable for Category 5e or 6 cables with wire diameter less than 1.10 mm, but it cannot accommodate Category 6A cables with wire diameter of approximately 1.50 mm
Solution Approach 1:
The plug housing features adjustable piercing terminals that can be repositioned along the housing to accommodate different wire diameters. The piercing terminals can be adjusted between different positions to match the spacing requirements of various cable types including Category 6A cables with 1.50 mm wire diameter, thereby changing the geometric parameters of the plug to achieve compatibility across different cable standards.
2Reliability
If installers use pre-assembled cable assemblies from factories, then assembly quality is ensured, but field termination capability is lost and installation flexibility is reduced
Solution Approach 1:
The plug incorporates a self-contained wire organization system with integrated wire guides and a pivoting cover that automatically organizes wires during the termination process. This self-service mechanism enables installers to perform reliable field terminations without requiring external tools or pre-assembled cables, maintaining assembly quality while restoring field termination capability.
3Ease of manufacture
If a fixed piercing terminal design is used, then manufacturing is simple, but adaptability to different cable sizes is limited
Solution Approach 1:
The piercing terminals are designed to be adjustable rather than fixed, allowing them to be repositioned along the plug housing to accommodate different cable sizes and wire diameters. This dynamic adjustment capability enables the same plug design to work with various cable types from Category 5e to Category 6A, providing versatility while maintaining relatively simple manufacturing processes.
Data Source
AI summary
A field termination plug includes a contact retainer, a plug housing, a terminal connection unit, and a cover pivotally connectable to the plug housing. The plug housing includes a front portion and an accommodation portion. The terminal connection unit has contacts and piercing terminals electrically coupled to the respective contacts. When the plug housing carries the terminal connection unit and the contact retainer is attached to the front portion, the contacts are disposed on the front portion for electrical coupling to a network jack and the piercing terminals are disposed upward on the accommodation portion. When the cover is pivoted to an open position, the piercing terminals are exposed for disposition of a wire organizer for attachment of the wires. The cover pivoted to a closed position presses the wire organizer such that the wires attached to the wire organizer are terminated to the respective piercing terminals.