Modular Plug Clamping Elastic Sheet Durability
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Solution Overview
Problem
Existing modular plugs with clamping elastic sheets made from hard plastic materials are prone to breaking upon repeated use, leading to unreliable network connections due to the inability to maintain a stable grip within the cable interface.
Innovation Solution
A modular plug design featuring a clamping elastic sheet made from nylon or polyoxymethylene (POM) materials, integrated with a recess and projection mechanism, allowing for repetitive pressing and bending without breakage, and manufactured through a dual injection molding process using polycarbonate resin for the terminal and POM for the elastic sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hard plastic material is used for the clamping elastic sheet, then the manufacturing process is simple, but the clamping elastic sheet breaks easily during repeated use
Solution Approach 1:
The patent changes the material parameter of the clamping elastic sheet from hard plastic to soft elastic material (such as TPE, TPR, or silicone rubber). This material parameter change enables the clamping elastic sheet to be repeatedly pressed and bent without breaking, solving the durability problem while maintaining manufacturing simplicity through injection molding processes.
Solution Approach 2:
The patent uses composite material structure where the clamping elastic sheet is made of soft elastic material and the terminal is made of hard plastic material. This combination allows the clamping elastic sheet to provide reliable clamping force through elastic deformation while the hard plastic terminal maintains structural integrity, resolving the contradiction between ease of manufacture and reliability.
2Reliability
If the clamping elastic sheet is made from soft elastic material, then the clamping elastic sheet can be repeatedly pressed and bent without breaking, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the clamping elastic sheet and the terminal into a single integrated component through injection molding. The soft elastic material for the clamping elastic sheet and hard plastic material for the terminal are molded together in one process, eliminating the need for separate manufacturing and assembly steps. This merging approach maintains manufacturing simplicity while achieving reliable, break-resistant clamping elastic sheet.
3Ease of manufacture
If the clamping elastic sheet is made from hard plastic material, then the manufacturing process is simple, but the connection reliability becomes unstable after repeated use
Solution Approach 1:
The patent introduces dynamic elasticity to the clamping elastic sheet by using soft elastic material. The clamping elastic sheet can dynamically adapt to the cable interface through elastic deformation during repeated insertions and withdrawals. This dynamic property ensures stable connection by allowing the clamping projection to repeatedly engage with the cable interface without breaking, maintaining connection stability while keeping the manufacturing process simple through injection molding.
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
Ensures reliable network connections by providing a stable and durable clamping mechanism that prevents the elastic sheet from breaking, maintaining a secure grip during repeated insertions and withdrawals.
Implementation Method 1
a material of the clamping elastic sheet is nylon or polyoxymethylene (POM)... providing a stable and durable clamping mechanism that prevents the elastic sheet from breaking, maintaining a secure grip during repeated insertions and withdrawals
Implementation Method 2
an upper side of the terminal is connected with a clamping elastic sheet through injection moulding, a front end of the clamping elastic sheet is provided with a projection that matches the recess in shape and size, the projection is tightly inlaid within the recess
Data Source
Figure 1~2
Figure 3~4
AI summary
The present application is directed to a modular plug, including a terminal containing a metal contact, an upper surface of a front end of the terminal is provided with a recess, an upper side of the terminal is connected with a clamping elastic sheet through injection moulding, a front end of the clamping elastic sheet is provided with a projection that matches the recess in shape and size, the projection is tightly inlaid within the recess, a top end of the clamping elastic sheet extends downwardly and overlays on a front surface of the terminal, a material of the clamping elastic sheet is nylon or POM, and a material of the terminal is polycarbonate resin. The present application also discloses a method of processing such modular plug. The present application possesses a beneficial characteristic in that the clamping elastic sheet can be repetitiously pressed and bent without breaking easily and the elastic piece can securely connect onto the terminal.