Audio Jack Connector Compact Design via Intersecting Contacts
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Solution Overview
Problem
Existing audio jack connectors face challenges in minimizing size for space-saving purposes while maintaining effective contact configurations.
Innovation Solution
The audio jack connector design includes an insulative housing with intersecting first and second contacts, featuring a first contacting portion that protrudes into the receiving channel via an interspace between flexible upper and lower beams, and a hook portion securing the upper beam to prevent deflection, allowing for a reduced transverse size without contact interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If contacts are arranged to intersect in the transverse direction to save space, then the transverse size of the audio jack connector is reduced, but the contacts may interfere with each other causing grounding contact deflection and unreliable signal transmission
Solution Approach 1:
The second contact is divided into an immovable contact (retained in the insulative housing) and a movable contact (with flexible upper and lower beams). This segmentation allows the contacts to be positioned closely for space saving while the movable contact can deflect independently to maintain reliable electrical connection without interfering with the immovable contact.
Solution Approach 2:
The second contact incorporates flexible upper and lower beams that can dynamically deflect when the audio plug is inserted. The movable contact is designed to move within a predetermined range, allowing it to adapt to insertion forces and maintain stable electrical connection. The hook portion provides dynamic securing that allows controlled deflection while preventing excessive movement.
2Reliability
If the first contacting portion extends into the receiving channel to ensure reliable contact with the audio plug, then signal transmission reliability is improved, but the transverse size increases reducing space efficiency
Solution Approach 1:
The first contacting portion extends into the receiving channel not in the transverse direction but in the longitudinal direction (along the insertion axis). This dimensional change allows the contact to reach the audio plug for reliable signal transmission while keeping the transverse footprint minimal. The contact arrangement utilizes the depth dimension of the receiving channel rather than expanding the width.
3Adaptability or versatility
If the upper beam is made flexible to allow contact deflection, then contact adaptability is improved, but the upper beam may deflect excessively causing contact interference
Solution Approach 1:
The hook portion is pre-configured to engage with the insulative housing and provide preliminary counter-action to limit the deflection of the flexible upper beam. This pre-established constraint prevents excessive deflection before it can cause contact interference, while still allowing sufficient flexibility for the movable contact to adapt to insertion forces and maintain reliable electrical connection.
Data Source
AI summary
An audio jack connector (100) includes an insulative housing (1), a first contact (21) and a second contact (22) retained in the insulative housing. The insulative housing defines a receiving channel (14). The first contact includes a first retaining portion (211), a first soldering portion (212) bent from the first retaining portion, and a first contacting portion (213) extending from the first retaining portion. The second contact includes a second contacting portion (221) extending into the receiving channel, an upper beam (222) and a lower beam (223) forkedly extending from the contacting portion, a hook portion (224) formed at the distal end of the upper beam and secured with the insulative housing, and a second soldering portion (225) bent from the lower beam. An interspace (226) is defined between the upper beam and the lower beam. The first contacting portion protrudes into the receiving channel via the interspace.