Modular Jack Cover with Resilient Tangs for Fracture Resistance
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Solution Overview
Problem
Existing electrical connectors, such as those described in U.S. Pat. No. 5,679,013, are prone to fracture when customers inadvertently apply downward pressure on modular plugs, compromising their rigidity and reliability.
Innovation Solution
An electrical connector design featuring a pivotally assembled cover with resilient tangs that provide support in both open and closed positions, ensuring secure engagement and minimizing the risk of damage from accidental pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a modular plug is assembled into the connector in a slantwise manner, then the connector can be compact and low-profile, but the connector becomes prone to fracture when downward pressure is applied
Solution Approach 1:
The resilient tangs are pre-positioned to provide upward supporting force against the modular plug before any downward pressure is applied. This preliminary counteracting force prevents the plug from exerting stress on the connector body, eliminating the fracture risk while maintaining the low-profile slantwise configuration
2Reliability
If a cover is added to protect the modular plug, then the connector reliability improves, but the device complexity increases
Solution Approach 1:
The cover is integrated with the resilient tangs into a single unified structure. The tangs are formed as integral parts of the cover, eliminating the need for separate components and reducing assembly steps while maintaining both protective function and structural simplicity
3Shape
If the cover is kept closed to maintain low-profile configuration, then the compactness is improved, but the ease of operation to insert modular plug deteriorates
Solution Approach 1:
The cover is designed as a movable component that can dynamically transition between closed and open states. When a modular plug is inserted, the cover automatically opens to accommodate it, then returns to the closed position afterward. This dynamic behavior maintains compactness during normal operation while enabling easy plug insertion when needed
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 design enhances the connector's rigidity and reliability by maintaining a low-profile configuration while preventing accidental damage from downward pressure, ensuring stable and reliable electrical connections.
Implementation Method 1
At least one resilient tang is located under said cover for providing a supporting force no matter the cover is in the opened position or in the closed position
Data Source
AI summary
Provided is an electrical connector including an insulative base defining a mounting face thereof. A plurality of terminals are secured in said insulative base and each has a contacting section projecting upwards thereof. A detachable cover is pivotally assembled on the insulative base and rotates to an opened position where a mating cavity is defined for receiving a mating plug therein and a closed position where the mating cavity is not large enough for receiving said mating plug. At least one resilient tang is located under said cover for providing a supporting force no matter the cover is in the opened position or in the closed position.