Modular Jack Assembly Segmented Contacts for Wear Reduction
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Solution Overview
Problem
Existing electrical connectors face challenges in accurately assembling first and second contacts onto a printed circuit board, leading to premature wear and increased maintenance and repair costs due to rubbing issues during assembly.
Innovation Solution
A modular jack assembly with a connecting module featuring a base and mating portion, L-shaped pins, and conductive traces between pins and contacts, allowing for easy electrical connection between a daughter board and mother board, reducing assembly complexity and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If first and second contacts are assembled to a base of connecting module in a line to expose from channels of printed circuit board, then electrical connection is achieved, but assembly accuracy requirements are maximum and rubbing occurs leading to premature wear
Solution Approach 1:
The patent divides the connecting module into separate components: a base with first contacts and a second contacts assembly with second contacts. These are assembled separately and then connected through the printed circuit board channels, reducing the precision required for single-piece assembly while maintaining reliable electrical connection.
Solution Approach 2:
The printed circuit board channels serve as an intermediary structure that guides and positions the first and second contacts during assembly. This mediator component facilitates accurate alignment and connection without requiring maximum assembly precision, preventing rubbing and premature wear.
2Manufacturing precision
If high production quality and assembly accuracy are maintained, then assembly precision is improved, but rubbing of contacts in channels cannot be completely excluded leading to premature wear
Solution Approach 1:
The patent designs the connecting module with a base structure that provides cushioning and protection for the contacts during assembly. The base absorbs assembly variations and prevents direct rubbing between contacts and channel walls, thereby protecting contact durability even when assembly accuracy varies.
3Ease of operation
If modular jack assembly is designed with connecting module for easy connection, then ease of assembly is improved, but device complexity may increase
Solution Approach 1:
The connecting module is segmented into a base with first contacts and a second contacts assembly, allowing these components to be pre-assembled and tested separately. This segmentation enables easier final assembly by reducing the number of steps required during main production, while the modular structure manages complexity through standardized sub-components.
Data Source
AI summary
A modular jack assembly (100) for being mounted to a mother board includes an insulative element (10) and an electrical unit (20) mounted to the insulative element. The electrical unit has a housing (21), a terminal module (23) assembled to the housing, a daughter board (27) attached to a side portion of the housing, a LED (Light Emitting Diode) (271) disposed on the daughter board and a connecting module (25) mounted bellow the housing. The connecting module has a base (251) and a mating portion (259) extending from the base, a number of pins (250) assembled to the base, and a number of contacts (257) located to the mating portion and mounted to the mother board. The contacts electrically connect with the LED by electrically connecting to the pins.