Electrical Jack Connector Leaf Spring Roll Interference Fit
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Solution Overview
Problem
Traditional electrical connectors using high-beryllium copper resilient leaf springs have a small contacting surface, low conductivity, and high heat generation, leading to reduced resilience over time, which affects their reliability and performance.
Innovation Solution
An electrical jack connector featuring a resilient conductive leaf spring roll with a conductive inner and outer sleeve, where the protruding terminals are fixedly clamped between a through-hole in the outer sleeve and the inner sleeve, providing an interference fit and a compact, high-conductivity structure with a larger contact area, and a method for fabricating this connector involving rolling and deforming the leaf spring roll with interference fits and surface electroplating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If high-beryllium copper resilient leaf springs are used, then the connector structure is simple, but the contacting surface is small, conductivity is low, and heat generation is high
Solution Approach 1:
The resilient leaf spring is segmented into multiple parallel spring leaves (first spring leaf, second spring leaf, etc.), each contributing to the contacting surface. This segmentation increases the total contact area and improves heat dissipation while maintaining structural simplicity through modular arrangement
Solution Approach 2:
The invention uses copper or copper alloy materials for the spring leaves, which provide both mechanical resilience and high electrical conductivity. This composite approach combines structural integrity with excellent electrical and thermal properties, resolving the contradiction between simple structure and reliable performance
2Ease of manufacture
If traditional resilient leaf spring structure is used, then manufacturing is simple, but the contacting surface is small and resilience reduces over time
Solution Approach 1:
The spring structure is divided into multiple parallel leaves that can be manufactured separately and then assembled. This segmentation allows for standardized production of individual leaves while achieving a larger total contacting surface area, improving both manufacturability and reliability
Solution Approach 2:
The multiple spring leaves are nested or stacked together in a compact arrangement, with each leaf contributing to the contact surface. This nested structure maintains a compact form factor while providing cumulative contact area, and the modular design simplifies manufacturing and assembly
3Device complexity
If single conductive outer sleeve is used, then cost and complexity are reduced, but alignment precision may be affected
Solution Approach 1:
The conductive outer sleeve features a tapered inner surface with specific lead angles, creating a self-aligning conical geometry. This curved, tapered structure guides the inner sleeve and spring assembly into proper alignment during insertion, achieving precise positioning through geometric constraint rather than complex multi-component structures
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 solution results in improved durability and performance with reduced temperature rise, low voltage drop, and enhanced cohesion, suitable for energy-intensive applications like solar and wind energy, with a single integral conductive outer sleeve reducing misalignment, impedance, and cost while maintaining reliability and aesthetics.
Implementation Method 1
the through-hole in the conductive outer sleeve has an interference fit with the conductive inner sleeve which sleeved into the through-hole and the protruding terminals
Implementation Method 2
the conductive outer sleeve and/or the conductive inner sleeve comprise surface electroplated layer
Data Source
AI summary
An electrical jack connector and fabrication method thereof. The connector includes an resilient conductive leaf spring roll (1) which mates with a plug, a conductive inner sleeve (2) and a conductive outer sleeve (3) sleeved outside of the roll from inside to outside. Bending and protruding terminals of the resilient conductive leaf spring roll (1), which protrude out of two ends of the conductive inner sleeve (2), are fixedly clamped between a through-hole in the conductive outer sleeve (3) and the outside surface of the conductive inner sleeve (2).