Single Pair Ethernet Connector With Angled IDC Field Termination
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Solution Overview
Problem
Existing single pair Ethernet connectors are complex and costly to manufacture, prone to breakage, and require specialized tools for termination, which complicates field installation and increases resource consumption.
Innovation Solution
A single pair Ethernet plug design featuring a main plug assembly with a wire cap that secures conductors perpendicular to the latch direction, allowing toolless termination and retermination, with a shield wrap and outer cover for easy installation and cost-effective manufacturing, utilizing a snap-together mechanism and IDC contacts for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single pair Ethernet connector is designed with multiple small complex parts to achieve field terminable capability, then ease of operation is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions into integrated components. The main plug assembly integrates the body, latch mechanism, and contact retention features into a single unit. The wire cap combines conductor alignment, insulation displacement contact retention, and cable strain relief into one component, eliminating the need for separate small parts and reducing assembly complexity while maintaining field terminable capability.
Solution Approach 2:
The main plug assembly is designed to perform multiple functions: it provides structural support, implements the latching mechanism for toolless assembly, retains the insulation displacement contacts, and interfaces with the wire cap. This multi-functional design reduces the number of separate components needed, simplifying the overall device while enabling field terminable operation.
2Adaptability or versatility
If a single pair Ethernet connector uses multiple small complex parts to enable customization, then adaptability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The connector is divided into two main separable assemblies: the main plug assembly and the wire cap. This segmentation allows each component to be manufactured independently using standard molding processes, simplifying production. The separable design enables field terminable capability and customization while avoiding the complexity of assembling multiple small parts, thereby reducing manufacturing cost.
Solution Approach 2:
The patent enables customization by allowing the main plug assembly to accommodate different contact configurations and the wire cap to be terminated with different conductor arrangements. This parameter flexibility (contact layout, cable type) is achieved through the modular design rather than through multiple specialized small parts, maintaining ease of manufacture while providing adaptability.
3Reliability
If a single pair Ethernet connector is designed with complex parts for secure termination, then reliability is improved, but ease of operation deteriorates
Solution Approach 1:
The latch mechanism is designed to automatically engage and lock the wire cap to the main plug assembly without requiring tools or complex manual operations. The spring-loaded latch provides automatic feedback and secure termination through simple snap-together motion, achieving both reliability and ease of operation by letting the mechanism serve itself during assembly.
Solution Approach 2:
The patent replaces complex mechanical fastening systems with a simple elastic latch mechanism that uses material elasticity rather than multiple fasteners, screws, or clips. This substitution provides secure termination through the elastic recovery force of the latch while maintaining ease of operation through toolless snap-together assembly.
Data Source
AI summary
A communications connector has a main plug assembly and a wire cap that is configured to terminate a pair of conductors to the pair of contacts by being secured to a side of the main plug assembly in a direction perpendicular to a plane defined by a deflection direction of a latch of the connector. In another embodiment, a communications connector has a main plug assembly and two electrical contacts within the main plug assembly wherein each electrical contact has a first end having a forked receptacle and a second end having an IDC that is configured to have a conductor terminated in a direction perpendicular to a direction of mating insertion and parallel to a plane defined by the contact.