RJ45 Connector External Load Bar for Precise Wire Shearing
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Solution Overview
Problem
The existing RJ45 connector systems face issues with distortion and misalignment during the crimping and shearing process, 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 sheared off concurrently with wire ends, providing stabilizing support and allowing all wire ends to be cut simultaneously, along with modifications to the crimping and shearing tool to ensure precise alignment and cutting of all wire ends, and the use of thicker insulation wires to maintain dimensional stability and improve data transmission rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thickened front end wall (External Load Bar) is added to provide stabilizing support, then manufacturing precision and alignment are improved, but device complexity increases
Solution Approach 1:
The front end wall is segmented into a thickened portion (External Load Bar) and a regular portion. The thickened portion is specifically positioned to provide stabilizing support during crimping and shearing operations, while the regular portion maintains standard dimensions. This segmentation allows the stiffening function to be localized without increasing the overall complexity of the entire connector housing.
Solution Approach 2:
The front end wall exhibits local quality variation through the thickened External Load Bar region. This localized thickening provides enhanced structural support and stability precisely where needed during manufacturing operations, while other portions of the housing maintain their original thin-walled construction. This resolves the contradiction by improving manufacturing precision only in the critical area without unnecessarily increasing overall device complexity.
2Productivity
If all wire ends are cut simultaneously during crimping, then productivity is improved, but manufacturing precision deteriorates due to distortion and misalignment
Solution Approach 1:
The External Load Bar is prepared in advance with a predetermined thickness and geometry that provides stabilizing support during the simultaneous cutting operation. This preliminary structural preparation enables all wire ends to be cut simultaneously without causing distortion or misalignment, thus improving productivity while maintaining manufacturing precision.
Solution Approach 2:
The thickness parameter of the front end wall is changed in the External Load Bar region to provide additional structural support. This parameter change enables the simultaneous cutting of all wire ends by preventing distortion, thereby improving productivity without sacrificing cutting precision. The thickened portion acts as a rigid support structure during the shearing operation.
3Manufacturing precision
If the connector housing is made more rigid to support wires and contacts, then manufacturing precision is improved, but ease of manufacture deteriorates due to material constraints
Solution Approach 1:
The connector housing is segmented into regions of different wall thicknesses. The front end wall contains a thickened External Load Bar portion that provides the necessary rigidity for positioning precision, while other portions of the housing maintain thinner walls for ease of manufacture. This segmentation allows differential rigidity distribution without requiring the entire housing to be molded with high complexity.
Solution Approach 2:
The housing exhibits local quality variation through the thickened front end wall region. This localized thickening provides enhanced rigidity and positioning precision only where structurally necessary, while maintaining ease of manufacture in other regions. The mold can be designed to accommodate this local variation without requiring complex multi-material or multi-step molding processes.
4Manufacturing precision
If thicker insulation wires are used to maintain dimensional stability, then manufacturing precision is improved, but weight increases
Solution Approach 1:
The structural support function is segmented from the wire insulation to the External Load Bar in the front end wall. This segmentation allows the use of standard-thickness insulation wires without requiring thicker insulation for dimensional stability, as the External Load Bar provides the necessary structural support. Consequently, the connector weight is minimized while maintaining manufacturing precision.
Solution Approach 2:
The External Load Bar acts as an intermediary structural element that provides dimensional stability and support during manufacturing operations. This intermediary structure eliminates the need to increase wire insulation thickness for structural purposes, thereby maintaining minimal connector weight while achieving the required manufacturing precision and dimensional stability.
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.