Modular Cable Connector Assembly with Sonic Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multi-pin cable connectors are inefficient and inflexible due to overmolding, which limits customization and requires cutting cables for custom installations, introducing inefficiency and calculated loss.
Innovation Solution
The solution involves a cable connector assembly using first and second shell elements with strain relief features and a compression collar, allowing assembly without overmolding or adhesives, and sonic welding for secure connection, enabling customizable pin arrangements and easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If overmolding is used to create cable connectors, then mass production is achieved, but customization is limited and pin/wire positions cannot be changed
Solution Approach 1:
The cable connector is divided into separate modular components: individual cable positions are defined by separate guide elements rather than a monolithic overmolded structure. This segmentation allows each cable position to be independently configured and customized while maintaining mass production capabilities through standardized modular assembly.
2Adaptability or versatility
If one end of the cable is cut off to expose individual wires for custom installation, then customization is enabled, but inefficiency and calculated loss are introduced
Solution Approach 1:
The connector is pre-configured with guide elements and positioning features that define exact cable positions before installation. This preliminary preparation eliminates the need for post-installation customization or cable cutting, allowing direct installation of complete cable assemblies while maintaining full customization capability through pre-configured guide element arrangements.
3Reliability
If traditional cable connector assembly methods are used, then secure connection is achieved, but complex assembly processes and adhesives are required
Solution Approach 1:
The assembly process replaces chemical bonding (adhesives) and complex mechanical fastening systems with a simplified mechanical insertion system. Guide elements provide precise positioning and alignment through geometric constraints alone, allowing components to be assembled through straightforward insertion without requiring adhesives, fasteners, or complex assembly procedures while maintaining secure connections.
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
This approach provides a customizable, efficient, and reliable cable connector assembly that simplifies installation, reduces waste, and enhances holding ability under force, while avoiding electrical interference and crossover.
Implementation Method 1
the first and second shell elements are sonically welded together
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A cable connector for receiving a cable and a connector block. The cable connector including a first shell element with a first strain relief holding feature, a first connector block receiving feature, and a recess; a second shell element with a second strain relief holding feature, a second connector block receiving feature, and a projection; and a strain relief element defining a cable aperture sized to receive the cable, a compression collar, and a wing portion. The projection is received within the recess. The first and second strain relief holding features cooperate to support and maintain the strain relief element. The first and second connector block receiving features cooperate to support and maintain the connector block. The wing portion of the strain relief element is arranged to increase a holding ability of the strain relief element when a twisting or axial force is applied to the cable,