Flexible Electronic Connector for Constrained Insertion
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Solution Overview
Problem
Rigid USB connectors face challenges with insertion into constrained receptacles and are prone to damage from external forces, lacking versatility and durability.
Innovation Solution
An electronic connector design featuring a flexible region with a flexible beam made of polymer material, allowing up to +/- 90 degrees of flexing, combined with a rigid contact carrier and embedded leads, for improved insertion and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid USB connector is used, then the connector provides structural strength and EMI protection, but it becomes difficult to insert into constrained receptacles and lacks versatility
Solution Approach 1:
The connector is divided into distinct rigid and flexible segments. The rigid portion provides structural strength and EMI protection, while the flexible portion enables adaptation to constrained receptacles. This segmentation allows each part to fulfill its specific function without compromising the other.
Solution Approach 2:
The connector transitions from a completely rigid structure to a dynamic structure with flexible elements that can bend and adapt. The flexible portion allows the connector to change its shape during insertion, enabling it to navigate constrained paths while the rigid portion maintains structural integrity.
2Stability of the object's composition
If a rigid USB connector is used, then the connector maintains structural integrity, but it is prone to damage from external forces applied during insertion or use
Solution Approach 1:
The flexible portion acts as a cushioning element that absorbs external forces applied during insertion or use. This flexible buffer protects the rigid structural components from damage by dissipating impact forces before they reach the fragile internal components.
Solution Approach 2:
The connector incorporates flexible material that can deform under external forces and return to its original shape. This flexibility allows the connector to withstand bending and twisting forces that would otherwise damage a completely rigid structure, thereby improving reliability.
3Reliability
If a metal shell is used in the USB connector, then the connector gains EMI protection and durability, but it increases the overall rigidity and reduces flexibility
Solution Approach 1:
The metal shell is applied selectively to only the portions of the connector that require EMI protection, while leaving other portions flexible. This segmented approach allows the connector to maintain EMI shielding where needed while preserving flexibility in the regions that require bending capability.
Solution Approach 2:
Different portions of the connector have different material properties tailored to their specific functions. The metal shell provides EMI protection and structural strength where needed, while the flexible portions use elastomeric materials that allow bending and adaptation. Each local region has the quality it needs for its specific purpose.
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 flexible region enables easier insertion into curved or constrained receptacles and absorbs external forces, enhancing the connector's durability and usability.
Implementation Method 1
The flexible region is formed of a flexible polymer material having sufficient flexibility so as to support flexing of the plug up to an angle of at least +/- 10 degrees from a natural state
Implementation Method 2
the flexible region enables easier insertion into curved or constrained receptacles and absorbs external forces, enhancing the connector's durability and usability
Data Source
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AI summary
An electronic connector includes a housing and a plug extending from the housing. The plug includes at least one flexible region that provides flexing of the plug. In some example embodiments, the plug also includes at least one rigid region. The plug has at least one interconnect. Each interconnect includes a lead and a contact. The contacts are exposed on an exterior surface of the plug, such exposure being provided so as to enable electrical coupling between the plug and an electronic receptacle into which the plug may be removably inserted.