Pull Through Modular Jack Wire Termination
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Solution Overview
Problem
Existing modular jacks require tedious and often faulty wire termination due to loose wire orientation and lack of precise alignment, necessitating special tools and being prone to dislodgment during cable movement.
Innovation Solution
A modular jack design featuring a housing with conductive terminals, a wire conduit for tight wire insertion, and a movable pressing portion that secures insulated wires into electrical connection with conductive terminals, facilitating easy and secure termination without the need for special tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ordinary jack designs are used with terminals spaced away from bundled wires, then wire termination is simpler in structure, but wire termination becomes tedious and faulty due to loose orientation and imprecise alignment
Solution Approach 1:
The patent positions the terminal contacts within the cable bundle path before termination, allowing wires to be pulled tight and automatically aligned with the contacts. This preliminary positioning of terminals enables precise wire termination without requiring complex alignment tools or procedures during installation.
Solution Approach 2:
The patent introduces a cable guide structure as an intermediary element that channels and positions the cable bundle, ensuring wires are properly oriented and aligned with the terminal contacts. This intermediary component facilitates precise wire termination while maintaining relatively simple jack structure.
2Manufacturing precision
If special tools are used for wire termination, then wire termination precision improves, but device complexity and installation difficulty increase
Solution Approach 1:
The patent designs the jack with self-aligning terminal contacts that automatically position themselves relative to the pulled-tight wires. The cable guide and terminal positioning work together to enable precise wire termination without requiring special alignment tools or complex installation procedures, allowing standard tools to suffice.
Solution Approach 2:
The terminal contacts are pre-positioned within the cable bundle path during jack manufacturing, creating a self-aligning system that guides wires into proper contact positions during installation. This preliminary configuration eliminates the need for special alignment tools during field installation.
3Productivity
If wires are loosely oriented during installation, then installation speed increases, but connection reliability decreases due to dislodgment during cable movement
Solution Approach 1:
The patent employs a cable guide structure that flexibly channels the cable bundle, maintaining wire orientation and tension as wires are pulled through to the terminals. This flexible guiding mechanism ensures wires remain properly positioned and tensioned during installation and subsequent cable movement, preventing dislodgment while allowing efficient installation.
Solution Approach 2:
The jack structure is pre-configured with terminal contacts positioned to receive and secure pulled-tight wires. The cable guide is pre-formed to maintain wire tension and orientation, ensuring reliable connections are established during installation and maintained during subsequent cable movement without requiring re-termination.
4Device complexity
If terminals are positioned away from cable bundle, then jack structure is simpler, but wire alignment and positioning become more difficult
Solution Approach 1:
The patent positions terminal contacts within the cable bundle path during jack manufacturing, creating a configuration where pulled-tight wires naturally align with the terminals. This preliminary positioning eliminates the need for complex alignment procedures while maintaining simple jack structure, as the terminals themselves serve as the alignment reference points.
Solution Approach 2:
The cable guide acts as an intermediary structure that channels the cable bundle and positions wires relative to the terminal contacts. This intermediary element maintains simple jack structure while ensuring precise wire alignment, as the guide naturally positions wires to engage with the pre-positioned terminals.
Data Source
AI summary
The present invention relates to a pull-through modular jack and method of use thereof. The modular jack allows wires to be fed through the housing and pulled tight prior to terminating. This ensures that the wires terminate with the insulation displacement contact very close to the point at which the wires are still twisted. Termination is made by moving a pressing portion to a pressed position, which then pushes the wires into the insulation displacement contacts that displace the wire insulation to make contact.