Modular Plug with Segmented Leadframes for High Current
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Solution Overview
Problem
Existing electrical connectors, such as RJ-45 connectors, have limited current carrying capability, which restricts the power supply to electronic devices.
Innovation Solution
A modular plug design with a plug housing and leadframe assembly that groups plug contacts into power circuits, using a stuffer cap with a strain relief member to securely engage the cable, allowing for higher current carrying capacity by distributing the current across multiple contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If standard RJ-45 connectors are used, then the connector structure is simple and compatible with existing interfaces, but the current carrying capability is limited
Solution Approach 1:
The plug contacts are divided into two separate leadframes (first leadframe with first plug contacts, second leadframe with second plug contacts), each carrying different power circuits. This segmentation allows independent optimization of each leadframe for high current carrying capability while maintaining the overall RJ-45 interface compatibility.
Solution Approach 2:
The patent utilizes the full 8-position RJ-45 interface by arranging plug contacts across two leadframes in different spatial configurations. The first leadframe carries power circuits on positions 1, 2, 3, 6 and the second leadframe carries power circuits on positions 4, 5, 7, 8, effectively using the dimensional space of the connector to increase current capacity.
2Power
If multiple plug contacts are used to increase current capacity, then the power transmission capability is improved, but the manufacturing complexity increases
Solution Approach 1:
Multiple plug contacts on each leadframe are electrically commoned together to form power circuits. The first leadframe commoned contacts form a first power circuit, and the second leadframe commoned contacts form a second power circuit. This merging approach simplifies manufacturing by reducing the number of separate wire terminations needed while maintaining high power transmission capability.
Solution Approach 2:
The leadframes are designed to provide both mechanical support for multiple plug contacts and electrical commoning functionality through integrated commoning pads. This multi-functionality reduces the number of separate components needed, simplifying the manufacturing process while enabling high current capacity through multiple parallel contact paths.
3Reliability
If the cable is securely engaged to handle higher currents, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The strain relief member is integrally formed with the leadframe, eliminating the need for separate strain relief components. The leadframe itself provides both electrical commoning and mechanical strain relief functions through its integrated structure, simplifying the overall device while improving reliability.
Solution Approach 2:
The leadframe is constructed from electrically conductive material that provides both electrical pathways for high current and mechanical strength for cable strain relief. This composite functionality within a single component reduces overall device complexity while ensuring reliable cable engagement for high power applications.
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
The modular plug design enhances the current carrying capability, enabling more efficient power transmission to electronic devices by utilizing multiple contacts within the RJ-45 interface, thereby overcoming the limitations of standard connectors.
Implementation Method 1
The strain relief member includes a base and a spring beam extending from the base such that the spring beam is cantilevered from the base, wherein the spring beam is configured to engage the cable and thereby pinch the cable between the interior side of the stuffer cap and the spring beam
Data Source
AI summary
A modular plug (14) includes a plug housing (34) having a mating end (36) and a cable end (38) and plug contacts (42) at the mating end. The plug housing (34) and the plug contacts (42) are shaped and positioned to define an RJ-45 modular plug mating interface. The plug contacts (42) are arranged into a first group and a second group with each of the plug contacts (42) in the first group being electrically commoned to form a first power circuit and each of the plug contacts (42) in the second group being electrically commoned to form a second power circuit. The first and second power circuits are terminated to different wires (44) of a cable (18).