Modular Communications Plug With Conductor Manager

Solution Overview

Problem

Complex plug designs for cable termination increase installation times and the likelihood of faulty installations due to the multitude of components involved.

Innovation Solution

A modular communications plug with a simplified design featuring a plug housing, conductor manager, and strain-relief boot, which reduces the number of distinct components and simplifies the installation process by using preassembled insulation piercing contacts and a conductor manager with angled channels to efficiently route and pierce conductors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a complex plug design with multiple components is used, then the electrical contact and strain relief functions are achieved, but the installation time and complexity increase

Engineering Contradiction:

Improveelectrical contactVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The plug is divided into distinct modular components: a body housing containing insulation piercing contacts, a separate conductor manager with channels for each conductor, and a boot for strain relief. This segmentation allows each component to be optimized independently while simplifying the overall assembly process, as the conductor manager can be pre-assembled with the body before final insertion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conductor manager is designed with pre-formed channels and routing paths that guide conductors through the plug assembly. The insulation piercing contacts are pre-positioned within the body housing, ready to engage conductors as the conductor manager is inserted. This preliminary arrangement of components eliminates the need for complex manual positioning during installation.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a complex plug design with multiple components is used, then the electrical contact and strain relief functions are achieved, but the installation complexity increases

Engineering Contradiction:

Improveelectrical contactVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The plug is divided into distinct modular components: a body housing containing insulation piercing contacts, a separate conductor manager with channels for each conductor, and a boot for strain relief. This segmentation allows each component to be optimized independently while simplifying the overall assembly process, as the conductor manager can be pre-assembled with the body before final insertion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conductor manager features self-aligning channels and routing paths that automatically guide conductors into the correct positions. The insulation piercing contacts are designed to self-engage with conductors as the conductor manager is inserted into the body, eliminating the need for complex manual positioning or adjustment during installation.

Inventive Principle:

Principle #25Self-service

3Productivity

If a simplified plug design with fewer components is used, then the installation time and complexity are reduced, but the conductor routing and electrical contact may be compromised

Engineering Contradiction:

Improveinstallation efficiencyVSAvoidconductor contact

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The conductor manager integrates multiple functions into a single component: it provides conductor routing through angled channels, positions conductors for electrical contact, and works with the body housing to provide strain relief. This merging of functions maintains reliability while reducing the number of separate components and simplifying installation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductor manager is designed as a universal component that handles multiple conductors simultaneously through its array of channels. Each channel performs the complete function of routing, positioning, and contact engagement for its respective conductor, eliminating the need for separate components for each conductor and simplifying the overall assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11476616B2Modular communications plug

Publication Date: 2022.10.18 PANDUIT CORP

AI summary

A modular communications plug is disclosed having a simplified design that allows for more efficient termination of a cable into the plug. The plug includes modular components that are applicable to different applications.