Multi-Stage Multi-Pole Connector Design for Form Factor Compatibility
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Solution Overview
Problem
Conventional connector systems are prone to breakage and durability issues due to fragile prongs or recessed terminals, and their small form factor leads to alignment problems and reduced durability during repeated mating cycles.
Innovation Solution
A single-axis, multi-pole connector design featuring a hollow base plug portion and tip plug portion with conductive lines, where the base and tip portions share a common longitudinal axis but differ in diameter, increasing the likelihood of proper form factor alignment with receptacles and enhancing secure physical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-axis multi-pole connector design is used, then the probability of form factor compatibility with receptacles increases, but the device complexity increases due to multiple conductive contacts and isolated poles
Solution Approach 1:
The connector body is segmented into multiple isolated poles, each containing a conductive contact. These poles are electrically isolated from one another, allowing independent signal transmission channels. This segmentation enables the connector to maintain multiple form factors simultaneously while managing complexity through modular isolation of conductive elements.
Solution Approach 2:
The single-axis multi-pole connector is designed to mate with various receptacle types (e.g., 2.5mm, 3.5mm, 6.35mm diameters) through its multi-pole configuration. The same connector body can interface with different receptacle form factors, providing universal compatibility across multiple applications and reducing the need for multiple specialized connectors.
2Reliability
If conventional prong connectors are used, then electrical signal transmission is achieved, but the connectors are prone to breakage and durability issues
Solution Approach 1:
Instead of using fragile protruding prongs that extend outward and are susceptible to breakage, the invention inverts the design by using recessed conductive contacts within isolated poles. The mating receptacle provides the corresponding protruding elements, reversing which component has the vulnerable protruding features and significantly improving the durability of the connector assembly.
Solution Approach 2:
The connector design incorporates recessed conductive contacts that are protected within the connector body structure. This recessed configuration provides inherent protection against mechanical stress and impact before failure can occur, cushioning the conductive elements from direct exposure to external forces that would cause breakage in conventional prong designs.
3Ease of operation
If multi-prong connectors with small form factor are used, then connectivity is achieved, but alignment problems occur during insertion
Solution Approach 1:
The multi-pole connector incorporates asymmetric features such as a keyway or offset pole arrangement that prevents incorrect rotational alignment. The asymmetric configuration ensures the connector can only be inserted in the correct orientation, eliminating alignment problems during insertion while maintaining compact form factor.
Data Source
AI summary
A multi-stage, multi-pole connector provides improved connectivity with electronic devices having mating receptacles of differing form factors. In one aspect, the connector includes a hollow base plug portion, a hollow tip plug portion, and a series of conductive lines extending within the base plug portion and the tip plug portion. Both the base plug portion and the tip plug portion share the same longitudinal axis and are each formed with one or more discrete conductive contacts electrically isolated from one another. The tip plug portion extends axially from the base plug portion and has a smaller outside diameter along the length of the tip plug portion than the average outside diameter along the length of the base plug portion. This configuration causes the connector to step down in form factor to a smaller cross-sectional size moving from the base plug portion to the tip plug portion.