RJ45 Connector Housing With External Load Bar for Crimp Stability
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Solution Overview
Problem
The existing RJ45 connector systems face issues with distortion of the plastic housing during the crimping and shearing process, leading to non-compliant connectors and the need for manual cutting of certain wires, which increases the risk of errors and inefficiency.
Innovation Solution
The introduction of a thickened front end wall (External Load Bar or Stiffener) that is integral to the connector housing, which provides mechanical support and is simultaneously cut off during the crimping and shearing operation to maintain precise wire and contact blade positions, along with modifications to the crimping and shearing tool to ensure all wire ends are cut concurrently, improving the connector's fit and data transmission performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a thickened front end wall (External Load Bar) is added to the connector housing, then the mechanical support and stability are improved, but the manufacturing complexity and material usage increase
Solution Approach 1:
The front end wall is segmented into two distinct parts: a thickened External Load Bar portion that provides mechanical support, and a thinner portion that allows proper mating. This segmentation enables the thickened wall to provide stability only where needed without unnecessarily increasing overall complexity or material usage throughout the entire housing.
Solution Approach 2:
The housing wall thickness is made non-uniform, with a localized thickening at the front end wall where mechanical support is most critical during crimping and shearing operations. This local quality approach provides enhanced stability precisely where the External Load Bar is needed while maintaining standard thickness elsewhere, thus avoiding unnecessary complexity and material usage.
2Productivity
If the crimping and shearing tool is modified to cut all wire ends concurrently, then the productivity and consistency are improved, but the device complexity increases
Solution Approach 1:
The crimping and shearing operations are merged into a single concurrent action performed by the modified tool. The tool simultaneously crimps the connector housing and cuts all wire ends in one motion, eliminating the need for separate cutting steps and improving productivity while maintaining acceptable tool complexity through functional integration.
Solution Approach 2:
The tool is designed with pre-positioned cutting edges and wire guide structures that ensure all wire ends are properly aligned and ready for concurrent cutting before the crimping action begins. This preliminary positioning enables the simultaneous cutting operation to occur smoothly without requiring overly complex real-time adjustment mechanisms during the actual cutting process.
3Manufacturing precision
If the External Load Bar is sheared off during the crimping operation, then the manufacturing precision is improved, but the risk of distortion during the process increases
Solution Approach 1:
The tool design incorporates cushioning elements and controlled force application mechanisms that prevent excessive or uneven forces from being applied to the External Load Bar during the shearing process. This beforehand cushioning protects the housing from distortion while still enabling precise cutting of the Load Bar and concurrent crimping operations.
Solution Approach 2:
The crimping and shearing process is designed as a dynamic, coordinated operation where the External Load Bar is gradually sheared off while the housing is simultaneously crimped. The tool applies forces in a controlled sequence and manner that adapts to the changing structural conditions during the operation, maintaining precision while minimizing distortion risk through dynamic force management.
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.