Plug Connector Radial Deformation for Jacket Strain Relief
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Solution Overview
Problem
Conventional plug connectors for twisted-pair cables face increased interference from external fields and high manufacturing and assembly costs due to the need for shielding and complex strain relief structures.
Innovation Solution
A plug connector design featuring two housing sections that radially deform to fix the cable jacket in place, eliminating the need for shielding and complex strain relief, with a snap-lock connection securing the sections and maintaining the twisted arrangement of wires up to the contact elements, allowing the housing to be made entirely of electrically insulating plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If shielding is integrated in the plug connector housing to protect against external field interference, then interference protection is improved, but manufacturing costs and device complexity increase
Solution Approach 1:
The patent removes the shielding component from the housing structure entirely. Instead of integrating shielding within the housing, the solution extracts this function and relies on the natural shielding effect of the twisted-pair cable configuration itself, thereby simplifying the housing to be made exclusively of electrically insulating plastic without additional shielding layers or metallic components.
Solution Approach 2:
The twisted-pair cable configuration serves a dual function: both as the signal transmission medium and as the shielding mechanism. The twisting of the wire pairs provides inherent protection against external alternating magnetic fields and electrostatic interference, eliminating the need for separate shielding structures in the plug connector housing.
2Object-affected harmful factors
If shielding is integrated in the plug connector housing to protect against external field interference, then interference protection is improved, but manufacturing costs increase
Solution Approach 1:
The patent removes the shielding component from the housing structure entirely. Instead of integrating shielding within the housing, the solution extracts this function and relies on the natural shielding effect of the twisted-pair cable configuration itself, thereby simplifying the housing to be made exclusively of electrically insulating plastic without additional shielding layers or metallic components.
Solution Approach 2:
The patent employs a cost-effective approach by using standard electrically insulating plastic materials for the housing instead of expensive metallic or composite shielding materials. The simplified housing structure can be manufactured using conventional injection molding processes, significantly reducing manufacturing costs while maintaining adequate interference protection through the cable's inherent twisted-pair configuration.
3Reliability
If a complex strain relief structure is integrated to prevent tensile strain transfer, then connection reliability is improved, but device complexity and assembly complexity increase
Solution Approach 1:
The patent combines the strain relief function with the housing structure itself. The housing is designed to receive and secure the cable jacket in a manner that naturally prevents tensile strain from being transferred to the contact elements. This integration eliminates the need for separate, complex strain relief components while maintaining connection reliability.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support, electrical insulation, and strain relief. The housing is designed to receive and secure the cable jacket in a manner that naturally prevents tensile strain from being transferred to the contact elements, thereby eliminating the need for additional dedicated strain relief components.
4Reliability
If a complex strain relief structure is integrated to prevent tensile strain transfer, then connection reliability is improved, but assembly complexity increases
Solution Approach 1:
The patent combines the strain relief function with the housing structure itself. The housing is designed to receive and secure the cable jacket in a manner that naturally prevents tensile strain from being transferred to the contact elements. This integration eliminates the need for separate, complex strain relief components while maintaining connection reliability.
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
This design reduces unit costs by eliminating shielding and complex structures while maintaining effective interference protection and transmission properties, ensuring the twisted arrangement of wires is preserved without additional shielding, thus maintaining good transmission properties.
Implementation Method 1
a part of at least of one of the housing sections provided for receiving a portion of the cable jacket is radially deformed in order to fix the cable jacket in place
Implementation Method 2
The housing sections are, in an end position, secured against disconnection in the longitudinal direction of the plug connector by a snap-lock connection
Implementation Method 3
as a result of the relative movement a projection on one of the housing sections engages in a recess in the other housing section, the housing sections are, in the end position, secured against disconnection transversely to the longitudinal direction of the plug connector
Data Source
AI summary
A plug connector having a housing and at least one contact element which is fixed within the housing and is designed for connection to a wire of a cable, which wire is partially surrounded by a jacket, wherein the housing comprises two housing parts which are designed in such a way that they are fitted to one another in order to assemble the plug connector and are connected by being moved in the longitudinal direction of the plug connector until they reach an end position, wherein, owing to the movement, a part of at least of one of the housing parts, which part is provided for receiving a portion of the jacket, is radially deformed in order to fix the jacket.