Modular Jack Oblique PCB Mounting for Structural Robustness
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Solution Overview
Problem
Existing modular jacks lack a robust structure, particularly in their internal printed circuit board arrangement, which affects their durability and mounting stability.
Innovation Solution
A modular jack design featuring an insulative housing with a unique oblique printed circuit board arrangement, where the upper portion is positioned in front of the lower portion, and a set of footer pins and mating terminals that integrate with the housing for enhanced stability and reduced manufacturing costs through automated assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the printed circuit board is arranged vertically as in prior art, then the assembly process is simplified, but the structural robustness and mounting stability are insufficient
Solution Approach 1:
The patent transitions from traditional vertical PCB arrangement to an oblique arrangement at approximately 45 degrees, utilizing the third dimension (depth) more effectively. This dimensional change allows the PCB to extend from the front wall toward the rear wall at an angle, creating a more robust triangular support structure with the housing walls while maintaining compact footprint.
Solution Approach 2:
The PCB is positioned asymmetrically within the housing, with its upper portion closer to the front wall and lower portion closer to the rear wall. This asymmetric oblique placement optimizes the distribution of mechanical stresses and creates inherent structural reinforcement, rather than using a symmetric vertical or horizontal arrangement.
2Stability of the object's composition
If the printed circuit board is arranged horizontally or obliquely as in some prior art, then structural stability is improved, but the assembly process becomes more complex and manufacturing costs increase
Solution Approach 1:
The PCB is pre-positioned in its final oblique orientation during the housing molding process or in a preliminary assembly step, with的定位 features (such as mounting holes and support structures) pre-formed in the housing. This eliminates the need for complex post-assembly adjustments or specialized tooling, allowing standard automated assembly equipment to install the PCB at the correct angle without additional complexity.
3Duration of action of stationary object
If traditional vertical PCB arrangement is used, then manufacturing processes are simpler, but the overall device durability and robustness are reduced
Solution Approach 1:
The oblique PCB arrangement creates a triangular bracing effect with the housing walls, providing inherent mechanical reinforcement and stress distribution before any failure can occur. This geometric configuration acts as a structural cushion, dispersing mechanical loads and reducing the risk of damage from external forces, thereby enhancing durability without requiring additional reinforcement components.
Data Source
AI summary
A modular jack (100) includes an insulative housing (1), a printed circuit board assembly (3), a set of mating terminals (2) and a set of footer pins (4). The insulative housing (1) defines a mating port (16) and a mounting port (19) located behind thereof. The printed circuit board assembly are mounted in the mounting port in an oblique manner. The footer pins are directly assembled to the insulative housing for omitting an insulative carrier and reduce a process assembling the footer pins with the insulative carrier.