Plug Connector Angled Tabs Strain Relief
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Solution Overview
Problem
Existing electrical plug connectors lack an effective and versatile strain relief mechanism that can independently manage cable tension without transferring force to electrical connections, particularly in harsh environments like motor vehicles.
Innovation Solution
A plug connector design featuring a separate, rotatable holding element with angled tabs and spring arms that securely engage the cable sheathing, allowing for adjustable tensioning and reliable strain relief, while enabling secure electrical contact to the cable shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate holding element is used for cable strain relief, then the strain relief effectiveness and cable holding force are improved, but the device complexity and number of components increase
Solution Approach 1:
The holding element integrates multiple functions: it provides strain relief through angled tabs that penetrate cable sheathing, maintains electrical contact through spring arms that contact cable shielding, and enables secure mounting through a rotatable locking mechanism. By combining these functions into a single component, the patent reduces overall device complexity while maintaining reliability.
Solution Approach 2:
The holding element serves multiple purposes simultaneously: it acts as a strain relief mechanism, an electrical contact element, and a mounting component with locking capability. This multi-functionality allows a single component to replace what would traditionally require multiple separate parts, thereby improving strain relief effectiveness without proportionally increasing device complexity.
2Ease of operation
If the holding element is made rotatable with locking mechanism, then the ease of operation and cable installation are improved, but the device complexity increases
Solution Approach 1:
The holding element transitions from a static component to a dynamic one with rotational movement. The rotatable design allows the element to be inserted, rotated to engage the locking mechanism, and locked into position. This dynamic behavior simplifies cable installation operations while the locking mechanism provides secure retention.
Solution Approach 2:
The locking mechanism is designed to automatically engage when the holding element is rotated into the correct position. The spring arms and angled tabs work together with the rotation motion to self-lock the element without requiring additional manual operations or complex control systems, thereby improving ease of operation.
3Strength
If angled tabs are used to penetrate cable sheathing, then the holding force and strain relief are improved, but the risk of cable damage and manufacturing precision requirements increase
Solution Approach 1:
The angled tabs are designed with specific geometric parameters (angle, length, thickness) that optimize the penetration force and holding strength. By carefully controlling these parameters, the tabs can penetrate the cable sheathing sufficiently to provide strong holding force while minimizing the risk of excessive penetration that could damage internal cable structures.
Solution Approach 2:
The holding element design incorporates the angled tabs in a configuration that distributes the penetration force over a larger area and controls the penetration depth beforehand. This prevents excessive force concentration that could damage the cable, while still providing sufficient holding force for effective strain relief.
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 robust and adjustable strain relief, preventing excessive cable penetration and enhancing holding force, ensuring reliable electrical connectivity and durability across various cable diameters and environments.
Implementation Method 1
a spring-mounted catch projection of the holding element passing over a stop face of the locking piece during the rotation and the catch projection thereby being pushed in the radial direction from a starting position. After passing over the stop face, the catch projection springs back into the starting position
Data Source
Figure 1~4
Figure 2
Figure 3
AI summary
The invention relates to a plug connector (1) with a housing (11) for accepting an electrical cable (22) with at least an electric wire (21) and a sheathing (23). On the housing, a holding element (4) is fixed that has a holding tab (31,32,33,34,35), the holding tab being arranged inclined at an angle to a longitudinal direction of the electrical cable, and an edge of the holding tab being provided for engaging in the sheathing of the cable.