Round Plug Connector Shield Assembly for Reliable Cable Grounding
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Solution Overview
Problem
Circular connectors face challenges in achieving safe and easy-to-install shielding, particularly in withstanding mechanical stress and ensuring reliable electrical and mechanical contact while maintaining dust and water tightness.
Innovation Solution
The design incorporates a shield connection with an insulator connecting element and a cable connecting element, connected via a flexible and resilient connecting web, which allows for secure and easy assembly by forming a cuff-like structure around the cable shielding, enabling electrical and mechanical contact with the connector housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circular connectors are constructed in several parts to enable multiple functionalities (electrical contact, mechanical securing, water and dust tightness, insulation, shielding), then the functionality and reliability are improved, but the device complexity and difficulty of assembly increase
Solution Approach 1:
The patent combines the shield connection element with the insulator by integrating the insulator connecting element directly into the insulator structure. This merging reduces the number of separate parts while maintaining the shielding functionality, electrical insulation, and mechanical securing capabilities, thereby improving assembly ease without compromising reliability.
Solution Approach 2:
The insulator is designed to serve multiple functions simultaneously: it provides electrical insulation between contacts, mechanical support for the shield connection, structural integration within the housing, and positioning of the cable section. This multi-functionality reduces the need for separate dedicated components, simplifying the overall device complexity while maintaining comprehensive functionality.
2Reliability
If the shield connection is securely attached to both the insulator and cable shielding, then the shielding reliability is improved, but the ease of assembly deteriorates due to multiple attachment requirements
Solution Approach 1:
The insulator connecting element is integrated directly into the insulator structure, merging two attachment functions into one unified component. This allows the shield connection to be securely attached to both the insulator and cable shielding through a single integrated element, maintaining shielding reliability while significantly improving assembly ease by reducing the number of separate attachment operations required.
3Ease of operation
If the connecting web is designed to be flexible and resilient, then the ease of assembly is improved, but the manufacturing precision may deteriorate
Solution Approach 1:
The connecting web is designed with specific material properties and geometric parameters that provide flexibility and resilience while maintaining adequate manufacturing precision. By optimizing the thickness, length, and material composition of the connecting web, the design achieves the desired flexibility for easy assembly without sacrificing the precision required for proper electrical and mechanical connection, resolving the contradiction between ease of assembly and manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides a reliable and easy-to-assemble shielding mechanism that ensures secure electrical and mechanical contact, enhancing the durability and functionality of circular connectors under mechanical stress while maintaining environmental sealing.
Implementation Method 1
The connecting web (33) is designed to be flexible and/or resilient
Implementation Method 2
The cable has cable shielding, which electrically shields lines inside the cable
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A circular connector (1) has a housing (40) extending from a plug end (10), which is designed to form a plug connection, to a cable end (20) at which a cable (100) with a cable shield (102) is led out of the circular connector (1) in a cable routing direction (K). An insulator (50), in which electrical contacts (60) are arranged, is inserted into the housing (40) of the circular connector (1). A shield connection (30) contacts the cable shield (102) of a cable section (101) of the cable (100) arranged inside the circular connector (1). The shield connection (30) is attached to the insulator (50) by means of an insulator connection element (31) and to the cable shield (102) of the cable section (101) by means of a cable connection element (32). The insulator connecting element (31) is attached to the cable connecting element (32) by means of a connecting bridge (33).