Multicore Cable Connector With Integrated Strain Relief
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Solution Overview
Problem
Current connector systems for building wiring, such as those with RJ-11, RJ-45, and EC-7 designs, are complex and prone to error, especially at frequencies above 100 MHz, and require complex assembly processes, including soldering and additional strain relief devices, which are time-consuming and costly.
Innovation Solution
A ready-made multi-core cable with a simplified connection component featuring a resilient locking groove plate, a strain relief member, and a housing cover made from elastic materials, allowing for tool-free assembly and eliminating the need for soldering or additional strain relief devices, with a strain relief part that forms an electrical shield and secures the cable sheath.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connector systems (RJ-11, RJ-45, EC-7) are used for building wiring, then electrical connection functionality is achieved, but the assembly process becomes complex and error-prone
Solution Approach 1:
The patent combines multiple functions into a single integrated connector design. The housing integrates the strain relief member, locking groove plate, and contact elements into one unified structure, eliminating the need for separate assembly steps for multiple components. This merging reduces assembly complexity while maintaining reliable electrical connections.
Solution Approach 2:
The connector incorporates self-aligning and self-securing features. The locking groove plate automatically engages with the mating connector, and the strain relief member self-adjusts to cable tension, reducing the need for precise manual alignment and complex fastening procedures during assembly.
2Productivity
If traditional connector assembly methods are used, then electrical connections are established, but production time increases and error rates rise
Solution Approach 1:
The connector is designed with modular segments that can be independently manufactured and then quickly assembled. The housing, strain relief member, and contact elements are separate modules that snap together in a standardized sequence, enabling rapid assembly while maintaining consistent quality through repeatable joining processes.
Solution Approach 2:
The patent employs elastic materials with specific resilience parameters that enable tool-free assembly. The locking groove plate and strain relief member are made from materials with optimized elastic properties that allow them to deform during insertion and then lock into place, enabling fast assembly without specialized tools while ensuring reliable connection.
3Strength
If additional strain relief devices and soldering processes are used, then mechanical strength and electrical connection are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The strain relief function and mechanical strength provision are merged into the housing structure itself. The integrated strain relief member provides both cable strain relief and mechanical anchoring in a single component, eliminating the need for separate strain relief devices and reducing assembly steps while maintaining strength.
Solution Approach 2:
The patent replaces traditional soldering processes with mechanical connection mechanisms. The locking groove plate and elastic housing provide secure electrical and mechanical connections through resilient mechanical engagement, eliminating the need for thermal soldering processes and associated fixtures, tools, and quality control steps.
4Reliability
If complex connector systems are used, then shielding and electrical connection are achieved, but assembly requires special tools and procedures
Solution Approach 1:
The connector features self-aligning contact elements and automatic locking mechanisms. The housing and locking groove plate are designed to self-position during insertion, and the elastic materials provide self-adjusting force, enabling assembly without special tools or skilled operators while maintaining high electrical connection quality.
Solution Approach 2:
The patent uses composite construction combining conductive materials for electrical contacts with elastic insulating materials for the housing and locking mechanisms. This composite approach integrates electrical connection and mechanical securing functions in a single assembly operation without requiring separate steps for different material types.
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 solution enables quick, uncomplicated assembly of connectors without special tools, reducing error rates and production time, allowing for flexible market responses and potentially automated production, while ensuring reliable electrical connections and shielding.
Implementation Method 1
a locking groove plate (15), which is resiliently attached to an insulator plate (17)
Implementation Method 2
the strain relief consisting of the strain relief part and the housing cover is at least partially made of an electrically shielding material—possibly made of metal or with a metal coating—and forms an electrical shield with other shielding housing parts
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
The invention relates to a prefabricated multicore cable having a connection component which: has a housing 10 with an inner housing termination part 20 and a pivotable housing cover 13, which housing is designed to receive and fasten a connection block 40 with a fitted cable 60 and also a connection printed circuit board 30 with connected plug contacts 34 and mounted insulation-displacement terminal contacts 54 for cable cores 62 to make contact with in the connection block 40, a connection printed circuit board 30 with inserted insulation-displacement terminal contacts 34 for the cable cores and also bent socket contacts, an insulation plate 17, for protecting the printed circuit board base, with a latching groove plate which is elastically connected by means of a spring connection 14; a connection block 40 for connecting the individual cores 62 of a cable 60 to the insulation-displacement terminal contacts 34 and having passage openings 44, which run approximately in the extent of the cable, for the cores 62 and insulation-displacement terminal contact guides which run perpendicular to the passage openings 44 and through which insulation-displacement terminal contacts 34 which are mounted on the printed circuit board 30 make contact with the conductors, which are accommodated in the passage openings 44, of the cores 62 after the core insulation is severed, and a strain-relief means, which can be inserted into the housing 10, for the connected cable, having a latching groove plate 15 and a strain-relief part 19, and also to a method for the production thereof.