Multi-Contact Audio Jack Assembly with Scalloped Terminals
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Solution Overview
Problem
Conventional audio jacks suffer from signal loss due to a single point of contact, which results in poor audio quality and increased stress on the connector, leading to potential disconnection.
Innovation Solution
A stereo audio jack assembly with integral connectors and a metal bias providing uniform clamp pressure, featuring scalloped terminals to engage a larger surface area of the audio plug, and a notched insulator ring to maintain terminal position, ensuring a resistance-free connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If a single point of contact is used in conventional audio jacks, then the connector structure is simple, but the contact surface area is insufficient resulting in poor audio quality and signal loss
Solution Approach 1:
The single contact point is segmented into multiple contact points arranged in a circular pattern. The contact surface is divided into multiple discrete contact elements that simultaneously touch the plug, increasing total contact area while maintaining a relatively simple overall connector structure.
Solution Approach 2:
The contact arrangement transitions from a single-point (zero-dimensional) contact to a multi-point distributed contact pattern. The contacts are arranged in a circular pattern around the central axis, utilizing the radial dimension to increase contact surface area without significantly increasing the axial length of the connector.
2Reliability
If greater force is applied by the contact to improve electrical connection, then the electrical connection quality improves, but the stress on the connector increases causing potential disconnection
Solution Approach 1:
The total contact force is segmented and distributed across multiple contact points instead of concentrating it at a single point. Each contact point applies a portion of the total force, achieving sufficient electrical connection quality while reducing the stress burden on any single contact element and the overall connector structure.
Solution Approach 2:
The force distribution is optimized locally at each contact point. The contacts are positioned and dimensioned to provide appropriate local pressure for reliable electrical connection, while the overall force distribution across all contacts prevents excessive stress on the connector body and ground connection.
3Reliability
If a single prong contact is used, then the connector design is simple, but the ground connector can become off center and lose contact
Solution Approach 1:
The single ground contact is segmented into multiple ground contacts arranged symmetrically around the central axis. This segmentation provides redundant contact paths and ensures that if one contact becomes slightly misaligned, other contacts maintain the ground connection, significantly improving contact stability.
Solution Approach 2:
The contact arrangement uses symmetric geometry (circular pattern of contacts) to compensate for potential asymmetries in plug insertion. The symmetric distribution of contacts around the center ensures that the ground connection remains stable even when the plug is slightly off-center during insertion or use.
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 solution reduces signal loss and maintains consistent pressure on the audio plug, enhancing audio quality and reliability by providing multiple contact points and uniform pressure distribution.
Implementation Method 1
A metal bias with four terminals spaced 90 degrees apart is positioned within the passageway to engage the outer surface of the audio plug. The metal bias applies uniform clamp pressure to maintain consistent electrical contact.
Data Source
AI summary
Disclosed is a stereo audio jack assembly that reduces or eliminates signal loss with an audio plug. The jack assembly employs a support housing having a passageway sized to receive the audio plug with an insulated first connector having first and second terminal strips, each formed integral to a first disk base and positioned to engage the grooved tip of an audio plug when engaged. A second isolated connector includes a terminal strip positioned to engage one side of an audio plug sleeve when engaged. And a third isolated connector includes a terminal strip positioned to engage another side of an audio plug sleeve when engaged to allow for a stereo connection by having distinct contacts.