Flexible TRS Connector for Thin Devices
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Solution Overview
Problem
Current audio connectors, such as TRS and TRRS connectors, are prone to breaking when inserted or extracted with forces that intersect their insertion axis, limiting the design of thinner and smaller electronic devices and providing a poor user experience due to orientation difficulties and wobble during insertion.
Innovation Solution
A flexible audio plug connector made from materials like thermoplastic elastomers or superelastic nitinol, allowing the connector to bend along the insertion axis and relieve strain during off-angle mating events, returning to its original shape without temperature change, and incorporating a flexible inner member and dielectric materials for strain relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard rigid audio connectors (TRS/TRRS) are used, then electrical connection reliability is maintained, but the connector is prone to breaking when inserted or extracted with forces that intersect the insertion axis
Solution Approach 1:
The connector incorporates a flexible body made from elastomeric material that can bend and deform when subjected to off-axis insertion or extraction forces. This flexibility allows the connector to absorb lateral stresses without breaking, while still maintaining reliable electrical connection when properly mated.
Solution Approach 2:
The patent changes the physical state and mechanical properties of the connector body by using elastomeric materials with specific durometer values (e.g., 40-70 Shore A). This parameter change enables the connector to exhibit both flexibility for stress absorption and sufficient rigidity for maintaining electrical contact.
2Length of moving object
If connector size is reduced to enable thinner and smaller electronic devices, then device form factor is improved, but the connector becomes even more prone to breaking when inserted or extracted with intersecting forces
Solution Approach 1:
The flexible elastomeric body allows miniaturized connectors to absorb off-axis forces through bending and deformation, compensating for the reduced structural margin available in smaller connectors. This enables safe use in thin devices where standard rigid connectors would be too fragile.
Solution Approach 2:
The connector uses composite construction combining elastomeric flexible material for the body with rigid conductive elements for electrical contacts. This composite approach provides both the flexibility needed for stress absorption and the electrical performance required for reliable connection.
3Length of moving object
If USB-style connectors are used to reduce size, then connector dimensions are improved, but orientation determination becomes difficult and insertion precision deteriorates
Solution Approach 1:
The flexible connector maintains asymmetric geometric features and contact arrangements that provide tactile feedback during insertion, enabling users to easily determine correct orientation. The flexibility enhances this by allowing the connector to conform slightly to the receptacle, improving alignment precision.
4Shape
If connector diameter is reduced from 3.5mm to 2.5mm, then device thickness is reduced, but the connector becomes even more susceptible to breakage from off-axis forces
Solution Approach 1:
The elastomeric flexible body in 2.5mm connectors compensates for the reduced diameter by providing enhanced flexibility that allows the connector to bend and absorb lateral forces without breaking, making subminiature connectors suitable for thin devices.
Solution Approach 2:
The patent optimizes material parameters including durometer values and cross-sectional geometry of the flexible body to achieve the right balance between flexibility for stress absorption and structural integrity for maintaining connection reliability in reduced-size connectors.
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 design reduces the risk of connector breakage during improper insertion or extraction, enhances user experience by ensuring precise alignment, and allows for the creation of smaller, thinner electronic devices with larger displays.
Implementation Method 1
Portions of the body and/or sleeve are made from a flexible material that allows the plug connector to bend with respect to the insertion axis. Bending in this manner relieves strain if the plug connector is inserted into or extracted from the corresponding receptacle connector under a force applied to the plug connector in a direction that intersects the insertion axis
Implementation Method 2
A flexible audio plug connector made from materials like thermoplastic elastomers or superelastic nitinol, allowing the connector to bend along the insertion axis and relieve strain during off-angle mating events, returning to its original shape without temperature change
Data Source
AI summary
The present invention relates generally to connectors such as audio connectors and in particular to flexible audio connectors that can be used in place of standard audio connectors currently used. A portion or all of the plug connector may comprise a flexible material that allows the connector to bend with respect to an insertion axis and prevent the connector from breaking when inserted or extracted improperly. A method of assembly is provided and may be used for assembling embodiments of the plug connector. The connector is configured to mate with a corresponding receptacle connector along an insertion axis.