Right Angle Twisted Pair Connector Guide Element
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Solution Overview
Problem
Manufacturing a twisted pair cable with a right angle connector is challenging due to the tendency of wires to separate and untwist, especially when bent sharply, which can lead to electrical discontinuity and failure to meet Category 5e specifications.
Innovation Solution
A guide element is introduced that gradually transitions from a circular to a rectangular cross-sectional shape along its length, guiding the twisted pairs into a connector while maintaining their twisted configuration, thereby minimizing untwisting and ensuring proper alignment with the connector's electrical connection elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cable is bent sharply to form a right angle connector, then the connector achieves compact space utilization, but the twisted pairs tend to separate and untwist causing electrical discontinuity
Solution Approach 1:
A guide element is introduced as an intermediary component between the cable and connector. This guide element has a curved path that gradually transitions from a first orientation to a second orientation (90 degrees), guiding the twisted pairs through the bend without allowing them to untwist or separate. The guide element maintains the twisted pair configuration throughout the transition, ensuring electrical continuity while achieving the right angle connector configuration.
Solution Approach 2:
The guide element employs a curved geometric path instead of a sharp angle. The curved transition allows the twisted pairs to follow a smooth arc, maintaining their twisted configuration. The curvature radius is specifically designed to be sufficient to prevent untwisting while still achieving compact connector dimensions.
2Ease of manufacture
If the twisted pairs are unraveled for connection to contacts, then the connector assembly is simplified, but the cable fails to meet Category 5e specification requirements
Solution Approach 1:
The guide element is positioned and configured before the final connection assembly. It pre-establishes the proper orientation and spacing of the twisted pairs as they enter the connector, so that when they are subsequently connected to the contacts, they are already in the correct configuration. This preliminary guidance ensures both ease of assembly and compliance with Category 5e specifications regarding twist maintenance.
Solution Approach 2:
The guide element provides localized guidance only in the critical transition region where the twisted pairs enter the connector. In this specific local area, it maintains the twisted configuration and proper spacing. Once the pairs enter the connector body and reach the contact points, the guidance function transitions to standard connection procedures, allowing for simplified assembly in the connection zone while maintaining specification compliance in the transition zone.
Data Source
AI summary
The invention relates to a twisted pair cable and connector combination comprising a cable having a plurality of twisted pairs, each twisted pair comprising a first conductor and a second conductor, an electrical connector having an electrical connection element for each conductor of the cable and a window through which the conductors of the cable enter the connector, wherein each conductor in the cable is electrically coupled to a one of the electrical connection elements in the electrical connector, and a guide element disposed adjacent the window for guiding the twisted pairs into the connector, the guide element having a distal end and a proximal end and a length there between, the guide element curved over the length and including at least one channel running along the length of the guide element body for each twisted pair, the guide element gradually transitioning over the length from a first cross sectional shape wherein said channels are disposed in a pattern relative to each other corresponding to the relative positions of the twisted pairs in the cable to a second cross sectional shape wherein the channels are disposed in a pattern relative to each other corresponding to the relative positions of the electrical connection elements of the connector.