Modular Jack Removable Sled Contact Array
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Solution Overview
Problem
Conventional modular jacks require replacement of the entire unit when the contact array becomes worn, leading to labor-intensive and costly repairs, and they contribute to electromagnetic interference issues due to their permanent mounting.
Innovation Solution
A modular jack design featuring a removable sled with a contact array that can be easily replaced without disassembling the housing, along with additional components for signal modification, reducing electromagnetic interference and allowing for extended mating cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact array is permanently mounted in the modular jack housing, then the structural integrity and reliability are improved, but the repair complexity and cost increase when the contact array becomes worn
Solution Approach 1:
The contact array is segmented from the housing by placing it on a removable sled. The sled acts as an intermediate carrier that holds the contact array independently, allowing the contact array to be replaced without replacing the entire housing. This segmentation resolves the contradiction by maintaining structural integrity during use while enabling easy repair through sled removal and replacement.
Solution Approach 2:
The contact array is extracted from the permanent housing structure and placed on a removable sled that can be taken out through the opening. This extraction allows the contact array to be separated from the housing for repair purposes while maintaining the housing's structural integrity during normal operation.
2Reliability
If the entire modular jack is replaced when the contact array becomes worn, then the reliability is restored, but the time and cost of repair increase significantly
Solution Approach 1:
By segmenting the contact array from the housing through the removable sled design, only the sled needs to be replaced rather than the entire modular jack. This reduces repair time significantly as technicians can quickly remove the worn sled and install a new one without replacing the entire assembly.
Solution Approach 2:
The sled is designed as a replaceable component with a limited service life. When the contact array on the sled becomes worn, the entire sled is replaced as a disposable unit rather than attempting to repair or replace individual contacts. This approach reduces repair time and simplifies the repair process.
3Stability of the object's composition
If the modular jack is permanently mounted to the circuit board, then the connection stability is improved, but the ability to perform maintenance and repairs worsens
Solution Approach 1:
The modular jack is segmented into three main components: the housing (permanently mounted to the circuit board), the sled (removable from the housing), and the contact array (mounted on the sled). This segmentation allows the housing to remain permanently mounted for stability while the sled and contact array can be easily removed for maintenance through the opening in the housing.
Solution Approach 2:
The sled is extracted from the housing as a removable component, allowing maintenance personnel to access and replace the contact array without removing the entire modular jack from the circuit board. This extraction maintains connection stability while improving maintenance accessibility.
4Productivity
If conventional contact arrays are used with frequent mating cycles, then the initial performance is good, but the contact array becomes worn and damaged within 5,000 cycles
Solution Approach 1:
The sled is designed to be dynamically replaceable rather than fixed. When the contact array shows signs of wear after frequent mating cycles, the sled can be quickly removed and replaced with a fresh one, restoring full productivity without the need for complex repairs or replacement of the entire modular jack.
Solution Approach 2:
The sled is treated as a recoverable component with a defined service life. After accumulating wear from frequent mating cycles (typically 5,000 cycles), the sled is discarded and replaced rather than repaired. This approach maintains high productivity by ensuring the contact array is always in good condition while simplifying the replacement process.
Data Source
AI summary
A modular jack includes a housing having a socket and an opening arranged to receive a modular plug into the socket, and a sled including a contact array arranged within the socket, wherein the sled is removable from the socket through the opening of the housing without disassembling the housing.