Rotatable Electrical Plug Module for Thick Conductors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical plug modules, such as RJ45 plugs, face challenges in accommodating thicker individual conductors due to limited spatial dimensions, making it difficult to fit conductors with diameters over 1.6 mm, and the existing connection methods are time-consuming, complex, and not easily reversible for repairs.
Innovation Solution
An electrical plug module design featuring a first housing with terminal contacts and insulation displacement contacts, and a second housing with wire receiving openings in separate planes, allowing for rotation between open and closed positions to accommodate conductors up to 1.7 mm in diameter, using cutting devices integrated into shield plates to ensure precise cutting and secure connections without additional tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the housing dimensions are kept small, then the plug module is compact, but only thin individual conductors can be fitted
Solution Approach 1:
The patent arranges wire receiving openings in at least two separate planes within the housing, effectively utilizing three-dimensional space. This dimensional arrangement allows thicker individual conductors to be accommodated without increasing the overall housing dimensions, as conductors are distributed across multiple planes rather than competing for space in a single plane.
2Ease of operation
If insulation displacement contacts are used, then connection is simplified, but individual conductors cannot exceed 1.6 mm external diameter
Solution Approach 1:
The patent combines insulation displacement contacts with specifically designed wire receiving openings that provide localized mechanical support and guidance for thicker conductors. The wire receiving openings are configured to accommodate conductors with external diameters greater than 1.6 mm, while the insulation displacement contacts handle the electrical connection function, creating a differentiated local quality that addresses both connection simplicity and conductor size adaptability.
3Volume of moving object
If diagonal cutter is used for cutting conductors, then fitting space is reduced, but cutting precision is poor
Solution Approach 1:
The patent integrates cutting devices directly into the shield plates, merging the cutting function with the existing structural component. This integration eliminates the need for separate diagonal cutters, maintaining compact fitting space within the housing while achieving precise cutting through the dedicated cutting device geometry that is specifically designed for accurate conductor length preparation.
4Productivity
If pressed together terminal connections are used, then quick fitting is achieved, but connections cannot be undone
Solution Approach 1:
The patent employs a rotatable housing design where the first housing and second housing can rotate relative to each other between open and closed positions. This dynamic mechanism allows the plug module to transition between a closed state for secure electrical connection and an open state for easy disconnection and repair, maintaining both fitting speed and connection reversibility through controlled rotational movement.
Data Source
AI summary
An electrical plug module includes a first housing and a second housing. The first housing has terminal contacts and insulation displacement contacts arranged therein. Each of the insulation displacement contacts is electrically connected to one of the terminal contacts. The second housing has wire receiving openings for receiving individual conductors of a cable. The wire receiving openings correspond to the insulation displacement contacts and are arranged in at least two separate planes. The first housing and the second housing are rotatable relative to one another between an open position and a closed position. The individual conductors are insertable into the wire receiving openings in the open position and are electrically connected to the insulation displacement contacts in the closed position.