Electrical Connector Anti-Mismating Protrusion Design
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Solution Overview
Problem
Existing electrical connectors, such as RJ-45 receptacles, are prone to damage from improper insertion of smaller sized plugs like RJ-11, due to the complexity and high cost of current blocking mechanisms.
Innovation Solution
An electrical connector design featuring an insulative housing with protrusions aligned with terminals, preventing smaller plugs from entering by guiding full-sized plugs and blocking undersized ones through strategically placed protrusions and receiving grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a blocking portion is added to prevent incorrect insertion of smaller plugs, then terminal protection is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies local quality by adding blocking portions only at specific locations where smaller plugs would incorrectly insert, rather than redesigning the entire terminal structure. The blocking portions are strategically positioned at the front end of specific terminals to intercept smaller plugs while maintaining normal operation for correctly sized plugs.
Solution Approach 2:
The terminal structure is segmented into distinct functional portions: a contacting portion for electrical connection, a blocking portion for preventing incorrect insertion, and a fixing portion for mechanical retention. This segmentation allows each portion to perform its specific function independently, simplifying the overall design while maintaining protection capabilities.
2Reliability
If blocking portions are added to each terminal, then incorrect insertion prevention is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the blocking function with the existing terminal structure by integrating blocking portions into the terminal body during the same molding process. This combines multiple functions (electrical contact, mechanical retention, and insertion prevention) into a single integrated component, reducing the number of separate parts and assembly steps.
Solution Approach 2:
The terminal is designed as a multi-functional component that simultaneously provides electrical contact, mechanical retention through fixing portions, and insertion prevention through blocking portions. This universal design eliminates the need for separate blocking mechanisms, reducing manufacturing complexity and cost.
Data Source
AI summary
An electrical connector (100) for permitting insertion of a full sized plug (200) and for preventing insertion of a smaller sized plug (300) includes an insulative housing (1) defining a receiving cavity (101) through a front face (10) thereof and a plurality of receiving grooves (12) extending in a mating direction of the plug at one inner side (11) of the receiving cavity and a plurality of terminals (2). Each terminal defines a fixing portion (21) received and retained in the receiving groove, a contacting portion (22) extending into the receiving cavity from a front end of the fixing portion and a soldering portion (23) extending from a rear end of the fixing portion. The electrical connector further defines at least one protrusion (121) discrete with the terminal, the at least one protrusion is in front of and aligns with one contacting portion of the outmost terminals.