RJ45 Connector Front Wall Structure for Crimping and Wire-End Shearing
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Solution Overview
Problem
The existing RJ45 connector systems face issues with distortion of the plastic housing during crimping and shearing operations, leading to non-compliant connectors and additional manual steps for cutting all wire ends, which affects the precision and efficiency of data transmission.
Innovation Solution
The introduction of a thickened front end wall (External Load Bar) that is integral to the connector housing, providing mechanical support and being simultaneously cut off during the crimping and shearing process, along with modifications to the crimping and shearing tool to ensure all wire ends are cut concurrently, maintains dimensional stability and reduces manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the plastic housing is made thinner to reduce material usage, then manufacturing cost decreases, but the housing loses rigidity and distorts during crimping and shearing operations
Solution Approach 1:
The front end wall is segmented into two functional zones: a thickened load-bearing region (External Load Bar) that provides structural support during crimping and shearing, and a thinner non-load-bearing region that reduces overall material usage. This segmentation allows the housing to maintain rigidity where needed while minimizing material in less critical areas.
Solution Approach 2:
The housing thickness is varied locally rather than uniformly. The front end wall features a localized thickening at the load-bearing zone that provides enhanced strength during manufacturing operations, while other portions of the housing maintain thinner walls to reduce material consumption and cost.
2Manufacturing precision
If manual wire cutting is performed separately from crimping, then precision of wire end alignment is improved, but manufacturing time and labor complexity increase
Solution Approach 1:
The crimping and wire cutting operations are merged into a single integrated manufacturing step. The External Load Bar is designed with a built-in cutting edge that automatically trims wire ends to length during the crimping process, eliminating the need for separate cutting operations and reducing overall manufacturing time while maintaining precision.
Solution Approach 2:
The External Load Bar is pre-configured with cutting edges and guide features that prepare the wire ends for precise cutting during crimping. The wires are positioned and pre-aligned against the Load Bar structure before the actual cutting and crimping action occurs, ensuring proper alignment is established in advance.
3Manufacturing precision
If the connector housing is made more rigid to maintain dimensional stability, then wire and contact blade positioning precision is improved, but the housing material requirements and manufacturing complexity increase
Solution Approach 1:
The housing structure is segmented into rigid load-bearing components (External Load Bar with cutting edges) and more flexible non-critical portions. This allows the connector to achieve dimensional stability and positioning precision where required while avoiding unnecessary rigidity and complexity in other areas.
Solution Approach 2:
Rigidity is applied locally to the front end wall and External Load Bar regions where dimensional stability is critical for wire and contact positioning, while other portions of the housing maintain simpler, more flexible constructions that reduce overall manufacturing complexity.
Data Source
AI summary
An electrical connector, having an elongated plastic housing which is open at its rearward end and has an essentially continuous forward end wall with a flat upper portion, a lower portion of the forward end wall being integrally thickened to project forward beyond its upper portion.