Audio Plug Core Structural Member Design
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Solution Overview
Problem
Traditional audio plugs have structural limitations due to their manufacturing technique, which results in limited resistance to bending or other forces applied to the plug, leading to potential mechanical failure.
Innovation Solution
The design incorporates a structural member, such as a cylindrical metal component, encapsulated by an insulating dielectric layer, with conductive contact pads and traces that extend along the plug axis, providing enhanced structural integrity and electrical coupling, while preventing shorting through the use of insulating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional injection-molded plastic core with thin leads is used, then manufacturing simplicity is maintained, but structural integrity and resistance to bending forces deteriorate
Solution Approach 1:
The patent employs a composite structural core comprising multiple thin wall sections arranged in a star-like pattern, where each wall section provides structural support. This composite configuration combines the advantages of thin-walled sections (ease of manufacture, material efficiency) with enhanced overall structural integrity through their geometric arrangement, resolving the contradiction between manufacturing simplicity and resistance to bending forces.
Solution Approach 2:
The structural core is segmented into multiple thin wall sections radiating from a central region, with each section providing localized support. This segmentation allows the core to maintain structural integrity through distributed support while remaining easy to manufacture using injection molding techniques, as each wall section can be independently formed.
2Ease of manufacture
If multiple thin leads separated by injection-molded plastic are used, then ease of assembly is maintained, but mechanical strength and durability worsen
Solution Approach 1:
The patent merges the structural support function and electrical insulation function into a single integrated structural core component. The thin wall sections of the core provide both mechanical support for the contact elements and electrical insulation between them, eliminating the need for separate support structures and insulation materials, thus maintaining ease of assembly while significantly improving mechanical strength and reliability.
Data Source
AI summary
Plugs with core structural members and methods for manufacturing plugs with core structural members are provided. A plug can include a core structural member that may increase the structural integrity of the plug. The plug can further include contact pads and traces, and each trace can electrically couple with one of the contact pads and extend along a plug axis towards the proximal end (e.g., base section) of the plug. In orientation-specific embodiments, the traces may be disposed on the surface of the plug. However, in other embodiments, the traces may be disposed below but near the surface of the plug. The plug may also include one or more insulating layers to prevent contact pads and traces from shorting.