Plug Connector Housing Leaf Spring Strain Relief
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Solution Overview
Problem
Existing connector designs face challenges in providing reliable strain relief for cables, particularly in accommodating cable diameter tolerances, and often require multiple parts, which increases complexity and cost.
Innovation Solution
A connector housing with a leaf spring element that includes a central part and side parts bent at acute angles, allowing for elastic deflection to securely fasten the cable, accommodating diameter variations and providing tension and pressure resistance with a minimal number of parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional strain relief means with brackets and screws is used, then reliable cable clamping is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functions (cable clamping, strain relief, and positioning) into a single integrated housing structure. The housing includes integrated features such as the cable duct with recesses and protrusions that work together to secure the cable without requiring separate brackets, screws, or additional clamping components.
Solution Approach 2:
The housing structure serves multiple purposes: it provides mechanical protection, cable strain relief, precise cable positioning, and electrical shielding integration. The same housing components that provide structural support also create the cable duct geometry that secures the cable, eliminating the need for dedicated strain relief devices.
2Manufacturing precision
If cable diameter tolerance is not compensated, then manufacturing precision is maintained, but strain relief reliability deteriorates
Solution Approach 1:
The housing incorporates dynamic elements that allow for cable diameter variations. The cable duct includes flexible positioning mechanisms such as elastomeric elements and geometric features that can adapt their position or shape within manufacturing tolerances to maintain reliable cable engagement despite variations in cable diameter.
Solution Approach 2:
The design allows for parameter variations within defined tolerance ranges. The cable duct geometry is designed with specific tolerance specifications that accommodate cable diameter variations, and the strain relief mechanism is configured to maintain effective clamping force across this parameter range through features like adjustable positioning elements or compliant materials.
3Adaptability or versatility
If multiple separate parts are used for strain relief, then adaptability to different cable diameters is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent integrates multiple adaptability features into a single molded housing component. Rather than using separate adjustable parts, the housing is designed as one piece with built-in geometric features (recesses, protrusions, elastomeric elements) that provide cable accommodation across a range of diameters, simplifying manufacturing and assembly.
Solution Approach 2:
The housing incorporates elastomeric elements or flexible portions within the rigid housing structure. These flexible components can deform or compress to accommodate different cable diameters while maintaining secure engagement, providing adaptability without requiring multiple discrete parts or complex adjustment mechanisms.
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 provides a cost-effective, reliable, and secure strain relief mechanism that adapts to various cable diameters, ensuring both tensile and compressive strength while being easy to manufacture and attach, with the option to adjust the number of leaf spring elements for enhanced performance.
Implementation Method 1
The respective first and second side parts are elastically bent from the respective central part via respective first and second bending edges
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a plug housing comprising at least one leaf spring element (5) in a cable duct, which has a central part (50) and a respective first (52) and second lateral part (52b) which are bent in relation to said central part, wherein, from the central part (50), the first lateral part (52) is elastically bent via a first bending edge (51) and the second lateral part (52b) is elastically bent via an opposing second bending edge (51b) on the central part (50), wherein the central part (50) extends substantially parallel to the cable duct, wherein, in relation to the central part (50), the first (52) and the second lateral part (52b) adopt a respective variable acute angle and a variable respective height, wherein the first (52) and second lateral part (52b) narrow the cable duct such that, in an assembled state of the plug housing, with the cable inserted, a respective end section of the first (52) and second lateral part (52b) press against the cable with a respective elastic force and thereby bring about the strain- and pressure-resistant securing of the cable.