Foldable Electrical Connector Housing for Compact USB Ports
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Solution Overview
Problem
Current electrical connectors for small electronic devices, such as flash drives and MP3 players, face challenges in fitting within compact spaces due to thickness and rigidity, making them inconvenient for carrying in wallets or similar small personal spaces, and existing solutions either result in bulky or fragile connectors.
Innovation Solution
A foldable electrical connector-housing system comprising a first and second end panel with exposed contacts that span from one edge to the opposite edge, allowing the panels to fold and rotate, creating a connector thickness compatible with USB ports, enabling a compact and functional USB connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a standard USB connector is used, then electrical connection functionality is achieved, but the thickness and rigidity make it difficult to fit in small personal spaces
Solution Approach 1:
The connector housing is designed with a foldable structure that transitions from a rigid flat state during storage to a three-dimensional folded state during use. The hinge mechanism allows the housing to dynamically change its shape, enabling it to fit in small spaces when not in use while providing sufficient thickness for proper electrical connection when deployed.
Solution Approach 2:
The connector components are nested within the foldable housing structure. The male connector and female connector are positioned within the folded panels, with the housing layers nesting together to create the necessary connection thickness while maintaining a compact overall form factor when unfolded.
2Volume of moving object
If the housing is made thinner to fit in small spaces, then portability is improved, but structural integrity and connector functionality deteriorate
Solution Approach 1:
The housing employs thin flexible panels that can be folded without breaking. These thin film structures provide the necessary flexibility for portability while maintaining sufficient structural integrity when folded into the three-dimensional connector configuration, allowing the housing to be both thin and strong.
Solution Approach 2:
The housing is divided into multiple panel segments connected by hinges. This segmentation allows each panel to remain thin and flexible individually, while the assembled folded structure provides the necessary structural integrity for connector functionality. The segmented design enables the housing to achieve both compactness and strength.
3Ease of operation
If a protruding arm connector is used, then USB connection is achieved, but the connector becomes bulky and potentially fragile
Solution Approach 1:
The male and female connector components are merged into a single integrated foldable housing structure. Rather than having separate protruding arms, the connectors are combined within the folded panels, eliminating bulk and reducing fragility by creating a unified structure where the housing itself provides the connection interface.
Solution Approach 2:
The connector transitions from a static protruding arm design to a dynamic foldable structure. The connector panels can fold into place during connection and fold back during storage, allowing the connector to adapt its shape rather than maintaining a permanent bulky protruding form that is susceptible to damage.
Data Source
AI summary
A method of manufacture of a foldable electrical connector-housing system includes: providing a first end panel having an outer first end panel side with first end panel contacts that substantially span from one edge of the outer first end panel side to an opposite edge of the outer first end panel side; providing a second end panel having an outer second end panel side, the second end panel and the first end panel with the outer second end panel side facing away from the outer first end panel side and the first end panel contacts exposed in a folded configuration; mounting an electronic component between the outer first end panel side and the outer second end panel side; and connecting a conductor to the first end panel contacts and the electronic component.