Snap-Fit Modular Cable Exit Assembly for Warpage-Free Molding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Molding of single-piece cable exit assemblies is complex, requires high-pressure injection, and results in warpage issues and design limitations, such as poor retention of corrugated tubes, leading to potential failure in customer tests.

Innovation Solution

A modular cable exit assembly comprising a receptacle housing and a cable exit adapter, assembled via a snap-fit connection, allowing for standardized molding of the housing and adaptable molding of the adapter to orientation and customer needs, with retention ribs for improved tube retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a single-piece cable exit assembly is molded, then the structure is integrated and compact, but the molding process becomes complex and requires high-pressure injection

Engineering Contradiction:

Improvestructural integrationVSAvoidmolding process complexity

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The cable exit assembly is divided into separate components: the receptacle housing and the cable exit adapter. This segmentation allows each part to be molded independently using simpler, lower-pressure processes, while still achieving the functional integration of a single-piece design through assembly.

Inventive Principle:

Principle #1Segmentation

2Shape

If high-pressure injection molding is used for single-piece assemblies, then the integrated shape is achieved, but warpage issues occur and correct positioning becomes difficult

Engineering Contradiction:

Improveintegrated cable exit shapeVSAvoidcable exit positioning accuracy

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

By separating the cable exit adapter from the receptacle housing, each component can be molded independently without the warpage problems associated with high-pressure injection of integrated structures. The positioning accuracy is then ensured through mechanical features like ribs and grooves that guide precise assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Positioning ribs and grooves are pre-formed on the receptacle housing before assembly. These features prepare the housing in advance to receive the cable exit adapter at the correct orientation and position, ensuring manufacturing precision without requiring complex high-pressure molding.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If a single-piece design is used, then the structure is simplified, but retention ribs for corrugated tubes cannot be formed on 45° or 180° cable exits

Engineering Contradiction:

Improveassembly structureVSAvoidcorrugated tube retention capability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The cable exit adapter is separated from the receptacle housing, allowing retention ribs for corrugated tubes to be independently formed on the adapter regardless of the cable exit angle (45° or 180°). This segmentation enables the retention features to be added without complicating the overall assembly structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Retention ribs are added locally to the cable exit adapter at specific positions where corrugated tube retention is needed. This local modification does not require changing the overall simple assembly structure, but provides the necessary adaptability for different cable configurations and angles.

Inventive Principle:

Principle #3Local quality

4Ease of manufacture

If standardized molding kits are used for receptacle housing, then production costs are reduced, but customization of cable exit orientation becomes limited

Engineering Contradiction:

Improveproduction costVSAvoidcable exit orientation options

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The system is segmented into a standardized receptacle housing and customizable cable exit adapters. The housing can be produced using standardized molding kits, reducing production costs. Meanwhile, different cable exit adapters with various orientations and configurations can be attached to the same housing, providing customization without increasing housing production complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The receptacle housing is designed as a universal base that can accommodate multiple types of cable exit adapters with different orientations and configurations. This multi-functionality allows a single standardized housing design to serve multiple customer needs through adapter interchangeability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP4336667A1Modular cable exit assembly

Publication Date: 2024.03.13 TE CONNECTIVITY GERMANY GMBH

Figure 1
Figure 2A~2B
Figure 3~4

AI summary

The present invention refers to a modular cable exit assembly comprising a receptacle housing and a cable exit adapter, wherein the receptacle housing includes one or more contact cavities for electrical terminals for connection to at least one cable and a coupling portion, and wherein the cable exit adapter comprises a body and an exit collar for accommodating a portion of said at least one cable coming out of the receptacle housing. According to the invention, the body and the coupling portion are configured to be coupled by means of a snap-fit connection. The present invention also refers to a method for assembling the modular cable exit assembly.