Compression Plug With Flexible Wiring For Low Profile Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
USB cables are bulky and rigid, making them unsuitable for ultra-low profile mechanical connections due to their physical size constraints, which can be a problem for certain device configurations where a compact and flush connection is required.
Innovation Solution
A compression plug with flexible wiring that includes a design with sloped surfaces, interlocking nubs, and a rubber overmold to facilitate a compact and secure connection, allowing the cable to be bent and laid flat against the device, and potentially integrating wireless communication or conversion services between different plug standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a standard USB cable and plug are used, then electrical connection is achieved, but the device profile becomes bulky and protruding
Solution Approach 1:
The plug is divided into two separate components: a rigid body portion that maintains structural integrity and electrical contacts, and a flexible tail portion that can be bent and compressed to fit low-profile configurations. This segmentation allows the plug to achieve both compact form factor and reliable mechanical connection.
Solution Approach 2:
The tail portion of the plug is designed with flexible wiring that can dynamically adapt its shape through bending and compression. This dynamic flexibility allows the plug to transition from a standard extended configuration to a compressed low-profile configuration, resolving the contradiction between connection reliability and compact form factor.
2Volume of moving object
If the cable is shortened to reduce profile, then device compactness improves, but the diameter and rigidity problems persist
Solution Approach 1:
The tail portion utilizes flexible wiring constructed with thin, flexible conductors that can be bent to small radii. This flexible construction allows the cable to achieve both reduced profile and improved flexibility, enabling small radius bends while maintaining electrical connectivity.
3Strength
If a rigid plug structure is used, then mechanical strength is maintained, but the plug cannot be bent to achieve low-profile configuration
Solution Approach 1:
The plug is segmented into a rigid body portion that provides mechanical strength and structural support, and a flexible tail portion that provides bendability. This segmentation resolves the contradiction by assigning different mechanical properties to different portions of the same component.
Solution Approach 2:
The plug combines rigid materials for the body portion with flexible materials for the tail portion, creating a composite structure that exhibits both strength and flexibility. The rigid body maintains mechanical integrity while the flexible tail enables bending and compression to low-profile configurations.
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
Enables a reduced device profile by allowing the cable to be compressed and laid flat, providing a secure and compact connection for data and power transfer without protruding, suitable for various devices including smartphones and larger electronics.
Implementation Method 1
compression plug with flexible wiring that includes a design with sloped surfaces, interlocking nubs, and a rubber overmold to facilitate a compact and secure connection
Data Source
AI summary
A specialized cable including a compression plug and flexible wiring configured to be connected to a receptacle so that data and/or power signals can be exchanged between the electronic equipment and the device to which the cable is attached. The flexible wiring is a flat set of closely spaced parallel wires separated by insulators (e.g., plastic). The compression plug may include a contact surface (e.g., in an opening or on an exterior surface) that electrically connects to a contact surface in the receptacle. The compression plug may include a sloped or slanted top and bottom in order to facilitate inserting the plug into the receptacle.