Removable Load Bar Modular Plug for Consistent Wire Crimping
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Solution Overview
Problem
The termination of network connectors in the field often results in poor connectivity due to inconsistent wire lengths and improper insertion, leading to degraded device performance or failure.
Innovation Solution
A modular plug system with a load bar and plug housing design that includes extensions to guide and secure wires, preventing improper insertion and ensuring consistent crimping, featuring a cavity and openings for easy cable management and crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wires are hand cut to engage with the crimping portion of the plug, then the plug can be terminated in the field, but the wire lengths become inconsistent leading to poor connectivity
Solution Approach 1:
The load bar is pre-configured with precisely positioned holes and wire engagement features before field installation. This preliminary preparation ensures that when wires are inserted in the field, they automatically align with the correct positions, eliminating the inconsistency caused by manual wire cutting and insertion.
Solution Approach 2:
The load bar serves as an intermediary component between the plug housing and the wires. It provides a standardized interface with pre-positioned wire engagement points, mediating the connection process to ensure consistent wire insertion regardless of field conditions or operator skill level.
2Device complexity
If a traditional modular plug is used without a load bar, then the structure is simpler, but wire alignment and crimping precision deteriorate
Solution Approach 1:
The plug assembly is segmented into distinct functional components: the plug housing, the load bar, and the wire engagement features. This segmentation allows the load bar to be specifically optimized for wire alignment and crimping precision, while the housing provides structural support, resolving the contradiction between overall simplicity and localized precision.
3Reliability
If the load bar is fixed in the cavity, then wire engagement is secure, but the load bar cannot be removed for replacement or repair
Solution Approach 1:
The load bar engagement system transitions from a fixed, permanent installation to a dynamic, reversible connection. The engagement features allow the load bar to be securely held during operation while enabling easy removal and replacement when needed, accommodating both reliability and repairability requirements.
Data Source
AI summary
A modular plug system including a plug housing including a top surface, bottom surface and two opposing side surfaces, a front end and an opening opposite the front end, and a cavity extending from the front end to the opening in the back end, a load bar sized to engage the cavity in the modular plug, the load bar including two extensions on an upper surface of the load bar, the extensions sized to engage two openings in the top surface of the plug housing when the load bar is inserted into the cavity.