Dual-Orientation Plug Connector with External Contacts
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Solution Overview
Problem
Current audio and data connectors are limited by size, orientation specificity, and debris collection, which hinder the miniaturization of electronic devices and result in inconsistent connections and potential breakage.
Innovation Solution
Design of plug connectors with reduced length and thickness, 180-degree symmetry for intuitive orientation, external contacts, and absence of internal cavities to prevent debris collection, along with retention features and ground contacts for secure and reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard audio connectors (3.5mm or 2.5mm) are used, then reliable electrical connection is achieved, but device size and thickness are increased
Solution Approach 1:
The connector is divided into separate functional elements: a flat connector body with contacts on its surface, and a separate tab for engagement. This segmentation allows the connector to be integrated flush with the device surface, reducing overall device thickness while maintaining reliable electrical connections through the distributed contact arrangement.
Solution Approach 2:
The connector transitions from traditional cylindrical 3.5mm or 2.5mm formats to a flat planar structure. By moving the contacts from internal cylindrical positions to external flat surfaces, the connector achieves the same electrical connection function with dramatically reduced thickness, enabling integration into thin portable devices.
2Adaptability or versatility
If polarized connectors with angled features are used, then connection orientation is controlled, but user insertion difficulty and orientation confusion increase
Solution Approach 1:
The connector body is designed with asymmetric corner rounding - two diagonally opposite corners are rounded while the other two remain sharp. This asymmetric feature provides automatic orientation guidance during insertion without requiring angled shells or complex mechanical guides, making it intuitive for users while maintaining precise orientation control.
3Reliability
If connectors with internal cavities are used, then contact protection is achieved, but debris collection and connection interference occur
Solution Approach 1:
Instead of placing contacts inside a protected cavity as in traditional connectors, the contacts are inverted to be positioned on the external flat surface of the connector body. This inversion eliminates the enclosed cavity where debris could accumulate, while the contacts remain protected by their flush integration with the device surface and optional protective plates.
Solution Approach 2:
The internal cavity structure is completely removed from the design. By extracting the cavity concept and replacing it with a flat planar structure where contacts sit on the surface, the design eliminates the harmful space where debris could collect while maintaining contact protection through alternative means such as flush mounting and protective plates.
4Device complexity
If connectors without retention features are used, then simple structure is maintained, but connection stability and wobble reduction are insufficient
Solution Approach 1:
The retention function is merged with the connector body itself through integrated retention features such as notches or protrusions formed as part of the flat connector structure. This integration maintains simplicity by avoiding separate retention mechanisms while providing stable connection and wobble reduction through the geometric interlocking with the receptacle.
Data Source
Figure 1A~2B
Figure 3A~4
Figure 5~6
AI summary
A dual orientation plug connector having a connector tab with first and second major opposing sides and a plurality of electrical contacts carried by the connector tab. The plurality of contacts may include a first set of external contacts formed at the first major side and a second set of external contacts formed at the second major side. The first plurality of contacts may be symmetrically spaced with the second plurality of contacts and the connector tab may be shaped to have 180 degree symmetry so that it can be inserted and operatively coupled to a corresponding receptacle connector in either of two insertion orientations. A receptacle connector corresponding to the plug connector.