Electrical Connector Brittle Membrane for Deformation Alerts
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Solution Overview
Problem
Electrical connectors can become misshapen due to continued use, potentially affecting electrical devices by damaging contacts and structural aspects, and existing systems lack an effective way to alert users of such anomalies.
Innovation Solution
An electrical connector system featuring a brittle, conductive membrane disposed between the outer shield and contacts, which changes state upon deformation, activating an alert device like an RFID tag or LED to signal anomalies when the connector is mated with an electrical device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a membrane is used to detect connector deformation, then anomaly detection capability is improved, but device complexity increases due to additional components
Solution Approach 1:
The patent combines the membrane structure with the electrical alert device into an integrated assembly. The membrane is positioned within the connector housing and electrically connected to the alert device, creating a unified anomaly detection system rather than separate components. This merging reduces overall device complexity while maintaining detection capability.
Solution Approach 2:
The membrane acts as an intermediary element between the connector structure and the alert device. It translates physical deformation into electrical signal changes by making or breaking contact with the alert device circuitry, enabling indirect detection of connector anomalies without requiring direct sensing of the connector body.
2Loss of information
If an alert device is added to signal anomalies, then user awareness of connector condition is improved, but manufacturing cost increases
Solution Approach 1:
The alert device is designed to be passively activated by the connector's own deformation. When the connector becomes misshapen, the membrane naturally moves and triggers the alert device without requiring external power sources, sensors, or additional active components. This self-service approach reduces manufacturing costs while maintaining user awareness.
Solution Approach 2:
The membrane is constructed from inexpensive materials such as thin plastic or metal foil, making it a low-cost component that can be easily manufactured and replaced. The simplicity of the membrane structure and its use as a disposable-like element in the detection system helps control manufacturing costs while effectively conveying information to the user.
3Measurement precision
If the membrane is made brittle for detection purposes, then detection sensitivity is improved, but membrane durability decreases
Solution Approach 1:
The membrane exhibits different mechanical properties in different regions or contexts. It is designed to be brittle enough to break upon connector deformation for sensitive detection, while being protected by the connector housing and positioned strategically to minimize exposure to conditions that would cause premature failure during normal use.
Solution Approach 2:
The membrane is pre-positioned and pre-stressed within the connector assembly during manufacturing. It is arranged to be in a stable, intact state during normal connector operation, and only transitions to a broken state when the connector undergoes abnormal deformation. This preliminary positioning ensures the membrane remains durable during normal use while maintaining detection sensitivity.
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
The system passively detects and alerts users of connector anomalies, ensuring safe and proper connection by emitting signals when the connector is compromised, thereby preventing potential damage to electrical devices.
Implementation Method 1
the membrane is formed of a brittle, conductive material... the membrane in a normal state connects to the alert device to short the alert device. The membrane in an alerted state disconnects from the alert device
Data Source
AI summary
An electrical connector includes a housing including a main body and an outer shield extending from the main body. One or more electrical contacts extend into an interface chamber within the outer shield. A membrane is coupled to the housing. An alert device is coupled to the housing. The membrane in a normal state connects to the alert device to short the alert device. The membrane in an alerted state disconnects from the alert device so that the alert device is not shorted, and wherein the alert device outputs an alert signal when the alert device is not shorted.