RJ45 Plug With Offset IDC Rows For Compact Shielded Cable Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors for shielded data cables are not compact enough and require complex installation processes, limiting their use in industrial and office environments, especially for connecting multiple wires without increasing the overall height or requiring additional tools.
Innovation Solution
A connector design featuring an electrically conductive housing with two shells, a printed circuit board, and a loading piece, where insulation displacement contacts are arranged in two offset rows to accommodate up to eight wires, and a resilient shield contact ensures all-around shielding without additional measures, allowing for easy assembly without tools and compact dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If insulation displacement contacts are arranged in two rows offset from one another to accommodate eight wires, then the connector can support up to eight-wire connections, but the overall height of the connector increases
Solution Approach 1:
The patent transitions from a single-row arrangement to a two-row offset arrangement of insulation displacement contacts, utilizing the vertical dimension to accommodate eight wires while managing the height increase through strategic positioning and offset design of the rows
Solution Approach 2:
The connector is divided into two separate shells that can be assembled together, with the printed circuit board and contacts arranged in a segmented layout that optimizes space utilization and reduces overall height while maintaining eight-wire capability
2Reliability
If a separate stamped and bent sheet metal part is provided for transferring shielding, then shielding transfer is achieved, but the device complexity increases
Solution Approach 1:
The shielding transfer function is integrated into the housing structure itself through the electrically conductive material of the shells, eliminating the need for separate shielding components and simplifying the overall device while maintaining effective shielding
Solution Approach 2:
The electrically conductive housing serves multiple functions simultaneously: providing mechanical protection, enabling shielding transfer, and establishing electrical connections, thereby reducing the need for dedicated separate components
3Length of stationary object
If the connector is designed with compact dimensions, then the overall height is reduced, but the ease of installation may be compromised
Solution Approach 1:
The connector is divided into two shells that can be separately prepared and then assembled together, allowing for easier installation of the cable into one shell while the other shell is attached, maintaining compact dimensions without compromising installation ease
Solution Approach 2:
The cable can be pre-installed into one shell before the final assembly with the second shell, allowing for easier cable management and insertion while maintaining the compact overall structure
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 a compact, easy-to-install connector that supports up to eight-wire connections with minimal crosstalk, allowing signal transmission up to 250 MHz and compatibility with various industrial protective housings, while ensuring reliable shielding and reduced external dimensions.
Implementation Method 1
a resilient shield contact is used, which is conductively connected to the housing. When the shells are assembled, the data cable fixed in one shell by the strain relief is pressed with its shielding against the shield contact in the other shell
Implementation Method 2
a resilient shield contact is used, which is conductively connected to the housing
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A plug for shielded data cables, in particular an RJ45 plug, has an electrically conducting housing, which can be assembled from a first shell (1) and a second shell (2). An electrically insulating plug body (4) accommodates plug contacts (302). A printed circuit board (3), which can be inserted into the housing, bears the plug contacts (302) and insulation displacement contacts (303, 304) and conductively connects them to one another. The printed circuit board (3) is insulated from the housing (1) by a non-conducting foil (301). The wires of the data cable to be connected can be inserted into a loading piece (5), wherein the wires are accommodated in two planes one above the other in the loading piece (5). The data cable can be mounted in the loading piece (5) and the second shell (2). When the shells (1, 2) are assembled, the insulation displacement contacts (303, 304) make contact with the wires of the data cable which are accommodated in the loading piece (5).