Plug Connector Assembly with Nested Strain Relief Structure
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Solution Overview
Problem
Existing plug connector assemblies lack effective anti-pullout mechanisms for cables, leading to potential disconnection and failure.
Innovation Solution
A plug connector assembly featuring a mating member with a latch and insulative body, an internal member with recessing portions, and a strain relief member with projecting portions to increase the pulling force of the cable, along with a manufacturing method that includes molding and soldering steps to enhance cable retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional cable assembly structure is used without additional retention mechanisms, then the device complexity is low, but the cable anti-pullout performance is insufficient
Solution Approach 1:
The patent implements a nested structure where the internal member is positioned within the housing, and the strain relief member is positioned within the internal member. The projecting portions of the strain relief member fit into recessing portions of the internal member, creating a nested arrangement that provides cable retention without requiring separate external retention components, thus improving reliability while controlling complexity.
Solution Approach 2:
The patent divides the cable retention function into multiple segmented components: the housing provides basic structural support, the internal member provides intermediate retention with recessing portions, and the strain relief member provides additional retention with projecting portions. This segmentation allows each component to contribute specifically to cable anti-pullout performance while maintaining modularity.
2Reliability
If multiple retention components are added to improve cable retention, then the cable anti-pullout performance is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines multiple retention functions into an integrated assembly where the internal member and strain relief member work together as a unified retention system. The projecting portions and recessing portions are designed to interlock, merging the retention functions of multiple components into a single assembled unit that provides enhanced cable retention while simplifying the manufacturing process through functional integration.
Solution Approach 2:
The strain relief member is designed with projecting portions that automatically engage with the recessing portions of the internal member during assembly. This self-aligning, self-retaining mechanism reduces the need for additional fastening steps or complex assembly procedures, allowing the components to self-assemble into the correct configuration and improving ease of manufacture.
3Strength
If the strain relief member with projecting portions is molded to enclose the internal member and cable, then the pulling force resistance is increased, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by providing recessing portions only at specific locations on the internal member where cable retention is most critical, rather than uniformly across the entire surface. Similarly, the strain relief member has projecting portions positioned strategically to engage with these recessing portions. This localized approach provides high pulling force resistance at critical points while reducing overall manufacturing precision requirements compared to a fully engaged surface design.
Data Source
AI summary
A plug connector assembly includes a mating member, a cable, an internal member, and a strain relief member. The mating member includes an insulative body, some terminals, a latch, and an insulative member. The latch includes a base portion, a latching arm extending from a respective side of the base portion, and a latching portion projecting from an end thereof The internal member has some recessing portions on an surface thereof The strain relief member has some projecting portions filling the recessing portions. A method of assembling the plug connector assembly comprises molding an internal member to enclose a respective part of the mating member and molding plural recessing portions on an outer surface of the internal member, and molding a strain relief member to enclose a respective part of the internal member and molding plural projecting portions on the strain relief member to fill the recessing portions.