Layered Plug Interface Contacts for Communication Jacks

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Communications jack plug interface contacts face mechanical stress and positional issues due to repeated insertions of plugs with different numbers of contacts, leading to potential distortion and failure in maintaining pre- or post-insertion positions, especially when plugs with fewer contacts are inserted, causing intermittent or lost electrical contact.

Innovation Solution

The use of multiple conductive layers with the same material, which can move longitudinally relative to each other and are restrained in the thickness direction, along with a dielectric layer or flexible printed circuit board, to distribute mechanical stress and maintain contact normal force while preventing permanent set and ensuring reliable electrical contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a single thick plug interface contact is used, then the contact has sufficient mechanical strength, but it is prone to permanent deformation after repeated insertions of plugs with different contact configurations

Engineering Contradiction:

Improvemechanical strength of plug interface contactVSAvoidposition retention reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The plug interface contact is divided into multiple thin conductive layers (first conductive layer, second conductive layer, etc.) stacked together. Each layer can move independently to accommodate different plug configurations, preventing permanent deformation while maintaining sufficient collective mechanical strength. This segmentation allows the contact structure to flex and adapt without the permanent set that plagues single-thick contacts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conductive layers are designed to be movable relative to each other along the longitudinal direction, creating a dynamic structure that can adapt to different plug insertion scenarios. The layers can shift positions independently to maintain proper contact alignment, transforming the rigid single-contact structure into a flexible multi-layer system that responds to varying mechanical stresses.

Inventive Principle:

Principle #15Dynamics

2Reliability

If multiple conductive layers are used to improve reliability, then position retention improves, but the device complexity increases

Engineering Contradiction:

Improvecontact reliabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple conductive layers are merged into a single integrated assembly that functions as one plug interface contact. The layers are stacked and restrained together, combining their individual capabilities into a unified structure that maintains contact reliability while presenting a compact, manageable form factor that doesn't excessively increase device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductive layers are implemented as thin, flexible films that can bend and move independently. This thin-film approach allows multiple layers to be packed into a compact space without significantly increasing the overall footprint or complexity of the jack structure, while still providing the reliability benefits of multiple independent contact elements.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the conductive layers are restrained in thickness direction, then electrical contact stability improves, but longitudinal movement flexibility decreases

Engineering Contradiction:

Improveelectrical contact stabilityVSAvoidlongitudinal movement adaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The restraint mechanism is applied selectively to each conductive layer individually rather than to the entire contact assembly as a rigid unit. Each layer can be restrained at different positions and with different restraint forces, allowing the structure to maintain electrical contact stability while still permitting the necessary longitudinal movement flexibility for adapting to different plug configurations.

Inventive Principle:

Principle #1Segmentation

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

This configuration enhances the mechanical robustness and reliability of plug interface contacts, reducing the risk of distortion and maintaining consistent electrical contact across various plug configurations, thereby improving the durability and performance of communication jacks.

Implementation Method 1

the conductive layers are able to move longitudinally relative to each other at least one end of the conductive layers

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a dielectric layer may be disposed between the conductive layers

Methodology Applied

Scientific EffectDielectric insulation: Dielectric

Data Source

PatentUS7874877B2Communication jack having layered plug interface contacts

Publication Date: 2011.01.25 PANDUIT CORP

AI summary

A communication jack, system using the jack, and method of fabricating the jack are disclosed. The jack includes a cavity configured to accept a communication plug to form a communication connector. The jack includes a plurality of plug interface contacts that extend into the cavity such that a plug inserted into the cavity makes electrical contact with the plug interface contacts at plug/jack interfaces of the plug interface contacts. One or more of the plug interface contacts is formed from multiple conductive layers. The conductive layers are movable relative to each other at least one end. A dielectric layer or flexible printed circuit board may be disposed between the conductive layers.