Replacement Clip for Broken RJ45 Connector Latch
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Solution Overview
Problem
Broken molded flexible latches in modular plugs, such as RJ45 connectors, render cables unusable, necessitating costly replacement of entire cables due to difficulty in repairing the latch mechanism.
Innovation Solution
A replacement clip with an anchor section and locking tab is designed to securely attach to the modular plug, maintaining mechanical and electrical connections by anchoring onto the cable-end and engaging the socket's interior lip, allowing for the repair of broken locking clips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire cable is replaced when the locking clip breaks, then the connector reliability is restored, but the cost and waste increase significantly
Solution Approach 1:
The replacement clip is designed as a separate, standalone component that can be independently attached to the modular plug body, separating the repair function from the entire cable replacement. This allows only the broken locking mechanism to be replaced while preserving the rest of the cable and connector body.
Solution Approach 2:
Instead of discarding the entire cable when the locking clip breaks, the invention recovers and reuses the modular plug body and cable by attaching a new replacement clip to restore functionality, thereby minimizing waste and maximizing resource utilization.
2Reliability
If the entire cable is replaced when the locking clip breaks, then the mechanical connection is restored, but the time and resources required increase
Solution Approach 1:
The replacement clip is designed as a pre-fabricated, standalone component that can be independently attached to the modular plug body, separating the repair function from the entire cable replacement process. This modular approach enables rapid repair by focusing only on the broken locking mechanism rather than replacing the entire cable assembly.
Solution Approach 2:
The replacement clip is designed and prepared in advance as a ready-to-install component, allowing for quick attachment to the modular plug body when needed, thereby minimizing repair time and enabling rapid restoration of mechanical connections.
3Ease of repair
If a replacement clip is designed with anchor section and locking tab, then the ease of repair is improved, but the device complexity increases
Solution Approach 1:
The replacement clip is designed as a separate, standalone component with distinct functional sections (anchor section for attachment to the plug body and locking tab for engaging the socket), allowing it to be independently manufactured, stored, and installed without complicating the overall connector system architecture.
Solution Approach 2:
The replacement clip acts as an intermediary component that bridges the modular plug body and the socket, providing the locking function without requiring integration into the internal wire assembly or pins, thereby simplifying the repair process while maintaining structural integrity.
Data Source
AI summary
A replacement clip and method for repairing a modular cable connector having a broken locking clip. The replacement clip comprises a substantially u-shaped housing being configured to mount onto a modular connector having a broken clip, the housing having a top surface and a bottom surface opposite from the top surface, the top surface having an arm extension ending in a locking tab, the locking tab being spaced by the arm extension and located at an end opposite from the cable that the connector is connected to, the bottom surface having a slit therein running parallel to the cable, the slit being configured to mount the replacement clip onto the connector, such that, the locking tab securely holds the connector within a socket and such that mechanical and electrical connections between the connector and the socket are maintained.