Star Quad Cable Plug Connector Spring Tab Alignment
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Solution Overview
Problem
Existing connectors for star-quad cables face challenges in maintaining optimal electrical properties and space efficiency, particularly in high-frequency applications, due to instability and misalignment of signal conductors which can lead to crosstalk and reduced packing density.
Innovation Solution
A connector design featuring spring clips for each signal conductor, with insulating parts having axial holes and grooves to maintain spatial alignment, and a support sleeve for mechanical stability, along with a mating connector with radial elevations for axial tolerance compensation, ensuring precise contact and low space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact elements are arranged in axial bores of an insulating body, then electrical connection is achieved, but space requirement increases and alignment precision deteriorates
Solution Approach 1:
The spring tabs are bent back in the radial direction to face the mating connector, changing the contact orientation from axial to radial. This dimensional change allows compact arrangement while maintaining electrical connection quality
Solution Approach 2:
The spring tabs are made resilient and elastically deformable, allowing them to dynamically adapt to alignment tolerances and maintain reliable electrical contact while enabling compact connector design
2Ease of operation
If signal conductors are allowed to shift during laying, then ease of installation improves, but transmission properties deteriorate due to changed core positions
Solution Approach 1:
The insulating part with bores and the spring tabs are pre-configured to establish and maintain the optimal spatial arrangement of signal conductors before connection, preventing shifts during installation while preserving ease of assembly
Solution Approach 2:
The resilient spring tabs can elastically deform to accommodate installation variations while maintaining the optimal spatial parameters for signal transmission, balancing ease of installation with transmission quality
3Stability of the object's composition
If additional supporting and stabilizing elements are used in star-quad cables, then structural stability improves, but device complexity increases
Solution Approach 1:
The insulating part serves multiple functions: it provides structural support, maintains spatial arrangement of conductors, guides alignment through grooves, and houses the spring tabs. This merging of functions achieves structural stability without increasing overall device complexity
Solution Approach 2:
The insulating part is designed as a multi-functional component that combines mechanical support, alignment guidance, and electrical insulation, eliminating the need for separate supporting elements and reducing structural complexity
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
The solution provides a simple, high-quality electrical connection with low space requirements, suitable for high-frequency applications, while maintaining the optimal transmission properties of star-quad cables through precise alignment and mechanical stability.
Implementation Method 1
the spring tabs on the plug-in side The end protrude beyond the insulating part and are bent over in such a way that the respective bent-over sections of the spring tabs on an outside of the insulating part extend from the plug-side end towards the cable-side end and are resiliently elastically deformable in the radial direction
Data Source
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AI summary
The invention relates to a plug connector for a cable (11) having at least two signal conductors (10), in particular four signal conductors (10), in particular for a star quad cable (11), having a signal conductor part and an insulating part (14) which holds the signal conductor part, wherein the plug connector has a plugging-side end (18) for plug-connection to a complementary plug connector, and a cable-side end (20) for electrical and mechanical connection to the cable (11). According to the invention, the signal conductor part has a spring lug (12) for each signal conductor (10), which spring lugs are each electrically and mechanically connected to a signal conductor (10), wherein the insulating part (14) has an axial hole (16) for each spring lug (12) and a spring lug (12) passes through each of said axial holes, wherein the holes (16) are arranged and formed in such a way that the holes (16) hold the spring lugs (12) at a physical distance from one another, this distance corresponding to the distance of the signal conductors (10) in relation to one another in the cable (11), wherein the spring lugs (12) are formed in such a way that they are longer than the insulating part (14) in the axial direction, wherein the spring lugs (12) project beyond the insulating part (14) at the plugging-side end (18) and are bent over in such a way that the respective bent-over portions (22) of the spring lugs (12) run from the plugging-side end (18) in the direction of the cable-side end (20) on an outer face of the insulating part (14) and can be resiliently elastically deformed in the radial direction.