Optical Cable Connector Housing with Concave Back Post
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Solution Overview
Problem
Existing connector housings for optical cables face issues with durability and security during the crimping process, as they tend to break or fail to fit properly due to the use of metal components with plastic housings, leading to high costs and quality control challenges.
Innovation Solution
A connector housing with a single-piece unitary body and a back post that has a concave shape and protrusions, made of polymeric material, which allows for secure crimping without damaging the housing by distributing crimping pressure effectively and enhancing the pulling strength of the optical cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are used with plastic connector housing to withstand high pressing force during crimping, then the strength and durability are improved, but the plastic housing may not fit properly or break during the crimping process
Solution Approach 1:
The connector housing is constructed from a composite material comprising a plastic housing body and a metal back post that is integrally formed with the plastic housing. The metal back post provides the necessary strength to withstand high crimping forces, while the plastic housing provides structural support and alignment. This composite structure eliminates the problem of plastic housing breaking during crimping while maintaining the required strength.
Solution Approach 2:
The connector housing is divided into two functional segments: a plastic housing body and a metal back post. The metal back post is specifically designed to bear the crimping forces, while the plastic housing provides structural support. This segmentation allows each material to perform its optimal function without compromising the other.
2Reliability
If over-molding the plastic part with metal part is done to solve the fitting issue, then the structural integrity is improved, but the manufacturing cost and quality control requirements increase
Solution Approach 1:
The metal back post and plastic housing are integrally formed as a single unit, eliminating the need for separate over-molding processes. The integral formation is achieved by forming the metal back post within the plastic housing during the molding process, creating a unified structure that maintains structural integrity while simplifying manufacturing and quality control.
3Strength
If the back post is made longer to extend into the jacket of the optical fiber cable, then the securing strength is improved, but the susceptibility to breaking during crimping increases
Solution Approach 1:
The back post features a concave portion at its distal end that creates a localized crimping zone. This concave geometry concentrates the crimping force in a specific area, allowing the back post to be shorter overall while still providing adequate securing strength. The concave portion prevents the back post from breaking by distributing the stress away from the critical regions.
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
Various connector housings for securing an optical cable, as well as methods of use and manufacture thereof are disclosed. A single-piece unitary connector housing body may include a first opening formed in a first end of the housing body, a second opening formed in a second end of the housing body, a bore through the housing body extending from the first opening to the second opening, and a back post surrounding the second opening. The first opening may be configured to receive a terminating optical cable and the second opening may be configured to receive a fiber optic cable. The back post may extend from the second opening in a longitudinal direction and may include a plurality of protrusions thereon. A length of the back post may have a concave shape.