Modular Jack Middle Shield Insulative Sheet Design

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Solution Overview

Problem

Existing modular jacks are bulky due to thick insulative carriers that occupy significant space and are costly to produce, and they can experience shorting issues under high voltage transmission due to metal plate interactions with conductive components.

Innovation Solution

A modular jack design featuring a middle shield with a conductive plate and a thin insulative sheet for insulation, which reduces size and cost by using a metal plate with a rubber tape affixed to it, preventing shorting and electromagnetic interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thick insulative carrier is used to isolate the metal plate from filtering components, then insulation reliability is improved, but the size of the modular jack increases and manufacturing cost increases

Engineering Contradiction:

Improveinsulation reliabilityVSAvoidsize of modular jack

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent applies this principle by using a thin insulative sheet instead of a thick insulative carrier. The thin sheet provides the necessary insulation between the conductive plate and internal modules while occupying minimal space in the receptacle, thus reducing the overall size of the modular jack while maintaining insulation reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent applies this principle by replacing the expensive insert-molded insulative carrier with a cheaper insulative sheet that is affixed to the conductive plate. This substitution reduces manufacturing cost while still achieving the required insulation function.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Manufacturing precision

If insert molding is used to integrate the metal plate with the insulative carrier, then manufacturing precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improveintegration precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent applies this principle by separating the insulative function from the conductive plate structure. Instead of integrating them through insert molding, the insulative sheet is applied as a separate component, simplifying the manufacturing process and reducing costs.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If a metal plate is used for the middle shield, then electromagnetic shielding effectiveness is improved, but shorting risk increases under high voltage transmission

Engineering Contradiction:

Improveelectromagnetic interferenceVSAvoidshorting prevention

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies this principle by introducing an insulative sheet as an intermediary between the conductive plate and the internal modules. This thin insulative sheet prevents direct contact between conductive components, eliminating the shorting risk while maintaining the electromagnetic shielding effectiveness of the metal plate.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 minimizes size and production costs while ensuring safe operation by effectively isolating internal modules from the conductive plate, reducing electromagnetic interference and preventing shorting.

Implementation Method 1

an insulative sheet affixed to the conductive plate, the insulative sheet facing the internal modules for insulation between the internal modules and the conductive plate

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS9413122B2Modular jack having middle metal plate shielding two adjacent ports

Publication Date: 2016.08.09 FOXCONN INTERCONNECT TECHNOLOGY LTD

AI summary

A modular jack has an insulative housing, two adjacent internal modules, and a middle shield disposed between the adjacent internal modules. The insulative housing has a front wall and a plurality of openings therein configured as pairs of first and second aligned openings, and a receptacle located behind the openings. Each opening is configured to receive a plug connector therein in a front-to-back direction. The middle shield extends towards a front wall of the insulative to define two module receiving cavities each receiving one internal module. The middle shield includes a conductive plate and an insulative sheet affixed thereto. The insulative sheet faces to the internal modules for insulation between the internal modules and the conductive plate. The insulative sheet is very thin that it occupies little space of the receptacle, thereby reducing a size of the modular jack.