Network Connector Assembly Self-Aligning Board Members
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Solution Overview
Problem
Existing network connectors require multiple installation steps and tests, leading to high failure rates and reduced production yields due to the complexity of connections and assembly processes.
Innovation Solution
A network connector design featuring upper and lower board members with alignment pins and off-center coupling pins that secure to a printed circuit board, along with a housing that forms network couplers, allowing for self-alignment and pressure-fit assembly, reducing the number of assembly steps and increasing production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple installation steps and tests are used to verify individual portions and complete assembly, then assembly precision can be improved, but device complexity and production time increase significantly
Solution Approach 1:
The network connector is divided into modular components (housing, board member with contacts, shielding can) that can be manufactured and tested independently, then assembled together. This segmentation allows verification of individual portions without requiring complex multi-step assembly processes for the entire device.
Solution Approach 2:
The board member features self-aligning contacts and integrated positioning structures that automatically align with corresponding features in the housing during assembly. This self-alignment mechanism reduces the need for multiple adjustment and verification steps, simplifying the assembly process while maintaining precision.
2Reliability
If multiple installation steps and tests are implemented, then reliability of individual connections can be improved, but productivity decreases due to high failure rates and rework
Solution Approach 1:
The design incorporates built-in alignment features, positioning pins, and tolerance-compensating structures that prevent misalignment and connection errors before they occur. This preventive approach reduces failure rates during assembly, eliminating the need for repeated tests and rework, thereby improving both reliability and productivity.
Solution Approach 2:
The self-aligning contact structure automatically ensures proper connection positioning through integrated mechanical features, making the assembly process self-verifying. This reduces dependency on multiple external tests and increases production yield by minimizing failures.
3Adaptability or versatility
If traditional network connector designs are used, then compatibility with existing systems is maintained, but assembly complexity increases due to multiple required installation steps
Solution Approach 1:
Multiple traditional connector components (contacts, shielding, positioning features) are merged into an integrated board member assembly that maintains compatibility with existing network standards while simplifying the installation process. The integrated design eliminates the need for separate installation steps for individual components.
Solution Approach 2:
The connector incorporates self-aligning and self-securing features that automatically perform alignment and positioning functions during installation, reducing the skill level and number of steps required for proper assembly while maintaining compatibility with standard network infrastructures.
Data Source
AI summary
A network connector assembly with an upper board member includes one or more upper coupling pins and a lower board member includes one or more lower coupling pins. The upper board member and lower board member each a plurality of sets of contact pins disposed on a respective top surface. A housing can be disposable over the upper board member and the lower board member forming one or more network couplers. Each of the one or more network couplers configured to receive one set of contact pins.