Data Cable Module with Polygonal Shielding for Cat.7A
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Solution Overview
Problem
Existing data cable connection modules are prone to radiation leaks due to non-continuous shielding, limiting their use to Cat.7 speeds and making them unsuitable for narrower cable ducts, with complex and labor-intensive assembly processes and limited interchangeability.
Innovation Solution
A data cable connection module with a polygonal fixing element and contact module featuring latching elements for easy replacement, complete surrounding screening, and automated assembly capabilities, allowing for higher transmission speeds up to Cat.7A and simplified handling and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If non-continuous shielding with metal plates in star shape is used, then device complexity is reduced, but radiation leaks occur and transmission speed is limited to Cat.7A
Solution Approach 1:
The shielding structure is divided into multiple independent metal plates arranged in a star shape, with each plate shielding a specific wire pair. This segmentation allows for simplified assembly while maintaining effective electromagnetic shielding through the distributed arrangement of shielding elements.
Solution Approach 2:
The metal plates are nested within the insulator housing, with the star-shaped shielding structure positioned inside the sleeve element. The shielding plates are arranged concentrically around the cable cores, creating a nested configuration that provides comprehensive shielding without requiring complex external structures.
2Ease of operation
If circular wire contact design is used, then ease of operation is improved, but automatic assembly becomes difficult or impossible
Solution Approach 1:
The fixing element is designed with an asymmetric polygonal cross-section (e.g., hexagonal or octagonal) instead of a circular shape. This asymmetric geometry provides flat surfaces and corners that enable automated gripping and positioning by robotic assembly systems, while still maintaining easy manual operation through the polygonal shape's inherent geometric features.
Solution Approach 2:
Latching elements are introduced as intermediary components between the fixing element and contact module. These latching elements provide standardized engagement points that facilitate both automatic assembly through robotic manipulation and easy manual replacement, serving as a mediator between the conflicting requirements of automation and ease of operation.
3Manufacturing precision
If special tools are required for connection module attachment, then manufacturing precision is improved, but productivity is reduced and interchangeability is limited
Solution Approach 1:
The connection module incorporates self-aligning and self-latching features that enable automatic attachment without requiring specialized tools. The polygonal fixing element and corresponding contact module design provide inherent positioning and securing mechanisms that maintain manufacturing precision while enabling high-speed automated assembly through standard robotic manipulators.
Solution Approach 2:
The standardized connector face and universal latching mechanism are designed to work with multiple contact module types and configurations. This universal design allows a single fixing element to accommodate various contact modules (e.g., RJ45, TERA, GG45) without requiring tool changes or specialized equipment, thereby improving both productivity and interchangeability while maintaining attachment precision.
Data Source
Figure 1
Figure 2~5
Figure 3
AI summary
The module has a front socket face (9) for an external connector according to requirements. A fixing element connection-socket face is provided with module socket contacts (12) guided in an end insulator block (31). A fixing element (3) and a contact module (7) are formed such that the fixing element and the contact module are in engagement with cutting clamping contacts (14) by producing an electrical connection between the module socket contacts, so that wire strands (1) of the fixing element stay in electrical conductive connection with sliding contacts (10) of the module. An independent claim is also included for a method for packing a data cable connection module.