Twisted-Pair Cable Connector With Modular Cavity Blocks
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Solution Overview
Problem
The existing connectors with twisted-pair cables face limitations in data transmission rate due to increased sensitivity to electromagnetic interference and impedance issues caused by the untwisted region of wires during connection, which requires a longer transition zone and affects handling and insertion efficiency.
Innovation Solution
A connector design where terminals of twisted-pair cables are inserted into separate cavity blocks before twisting, allowing these blocks to be rotated and inserted into the connector housing, reducing the untwisted region and minimizing electromagnetic interference sensitivity, with guiding means to secure the blocks and terminals, enabling a modular system for variable pole configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the wires are untwisted in a region of at least two centimeters to facilitate insertion of terminals into connector housing, then the ease of operation is improved, but the sensitivity to electromagnetic interference signals increases and the impedance is significantly increased
Solution Approach 1:
The connector is divided into a housing and separate cavity blocks. Each cavity block contains cavities for receiving terminals and is inserted into the housing separately. This segmentation allows the twisting operation to be performed on the cavity blocks themselves rather than requiring long untwisted wire regions extending into the housing, thereby reducing electromagnetic interference sensitivity while maintaining ease of terminal insertion.
Solution Approach 2:
Cavity blocks serve as intermediary components between the twisted-pair cables and the connector housing. The cavity blocks receive the terminals of untwisted wires, allow twisting to occur at the cavity block level rather than requiring long untwisted regions, and are then inserted into the housing. This intermediary structure resolves the contradiction by providing a controlled transition zone that minimizes electromagnetic interference while facilitating easy assembly.
2Ease of operation
If the untwisted region of wires is extended to facilitate insertion, then the ease of operation is improved, but the data transmission rate is constrained due to increased electromagnetic interference and impedance
Solution Approach 1:
By segmenting the connector into housing and separate cavity blocks, the invention allows twisting to occur at the cavity block level. This eliminates the need for extended untwisted wire regions that would constrain data transmission rate, while still providing adequate space for terminal insertion and manipulation during assembly.
Solution Approach 2:
The cavity blocks are prepared with cavities for terminals before the actual connector assembly. Wires can be twisted and terminals inserted into these pre-prepared cavity blocks, which are then inserted into the housing as complete units. This preliminary preparation of cavity blocks allows twisting to occur in a controlled manner that maintains signal integrity while facilitating assembly.
3Device complexity
If terminals are directly inserted into cavities of connector housing after twisting, then the device complexity is reduced, but the untwisted region length must be increased affecting electromagnetic interference sensitivity
Solution Approach 1:
The connector is segmented into housing and separate cavity blocks. Each cavity block contains the cavities for terminals and is inserted into the housing as a separate unit. This segmentation allows twisting to occur at the cavity block level with minimal untwisted wire exposure, reducing electromagnetic interference sensitivity while maintaining a relatively simple overall structure through modular design.
Solution Approach 2:
Cavity blocks act as intermediary components that combine the terminal reception function with the twisting control function. By inserting terminals into cavity blocks rather than directly into the housing, the invention creates a controlled environment for wire twisting that minimizes electromagnetic interference while adding only a moderate level of structural complexity through the intermediate cavity block component.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Connector 1 comprising: a plurality of twisted-pair cables 6 each comprising two twisted wires 7, 8, each of said wires 7, 8 being connected to a terminal 23, 24; a plurality of cavity blocks 9, each of said cavity blocks 9 has two cavities 17, 18 for accommodating the terminals 23, 24 of one of said twisted-pair cables 6; a housing 3 having an accommodation chamber 10 for accommodating the plurality of said cavity blocks 9.