Network Jack Riveting Process for Cost and Assembly
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Solution Overview
Problem
Conventional network jacks have limitations such as a narrow operating voltage range, high cost due to the use of beryllium copper, complex manufacturing processes, and delicate assembly requirements, along with poorly arranged contacts that complicate assembly.
Innovation Solution
A network jack design featuring a circuit board with contacts arranged in specific patterns and distances, where contacts are inserted and bent using a riveting process to protrude from the surface, with a terminal base that facilitates bending and supports contacts, made from phosphor bronze for improved flexibility and reduced cost, eliminating the need for complex bending machines and push foot mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional contacts are made of beryllium copper and formed by punch, then contact strength is sufficient, but manufacturing cost is high and process is complex
Solution Approach 1:
The patent replaces expensive beryllium copper contacts with cheaper phosphor bronze contacts. Although phosphor bronze is less expensive, the riveting process ensures sufficient mechanical strength and electrical conductivity for network jack applications, achieving cost reduction without sacrificing functional performance
Solution Approach 2:
The patent replaces the conventional punch-forming process with a riveting process. Instead of punching contacts from sheets and bending them into shape, the riveting process directly forms contacts by inserting rivets through holes in the circuit board and deforming them to create secure mechanical and electrical connections, simplifying the manufacturing process
2Area of stationary object
If contacts are arranged with small distances between them, then the network jack size is reduced, but the operating voltage range is limited to below 800 volts
Solution Approach 1:
The patent applies different spacing arrangements for different contact pairs based on their functional requirements. Critical contact pairs that handle higher voltages are positioned with greater spacing to prevent arcing, while non-critical pairs maintain closer spacing. This localized quality adjustment allows the network jack to support higher operating voltages while minimizing overall size
Solution Approach 2:
The patent employs asymmetric spacing between contact pairs rather than uniform spacing. By strategically positioning contacts with varying distances based on voltage requirements and signal integrity considerations, the design achieves both compact form factor and high voltage capability, breaking the conventional symmetric arrangement that limits voltage range
3Shape
If conventional manufacturing process with punch and bending machine is used, then contact shape is formed, but the manufacturing process is complex and assembly is delicate
Solution Approach 1:
The patent replaces the two-step process of punching followed by bending with a single riveting operation. The riveting process simultaneously creates the contact shape and secures it to the circuit board, eliminating the need for separate bending machines and reducing manufacturing complexity while maintaining contact geometry requirements
Solution Approach 2:
The patent merges the contact formation and mounting operations into a single riveting process. Instead of separately forming contact shapes and then assembling them, the riveting process accomplishes both tasks in one step by inserting rivets that are deformed to create the contact geometry and secure it to the board, significantly simplifying the manufacturing process
4Ease of manufacture
If rectangular contacts are used, then manufacturing is simplified, but flexibility is insufficient
Solution Approach 1:
The patent changes the material parameters by selecting phosphor bronze with specific compositional ranges (3-10% tin, 0.01-1% phosphorus) that provide optimal balance between flexibility and strength. This material parameter change enables the contacts to achieve sufficient flexibility for assembly and operation while maintaining manufacturing simplicity through the riveting process
Data Source
AI summary
A method for manufacturing a network jack is provided. The method includes steps of: a) providing a circuit board having a first side, plural first contacting areas along the first side, plural second contacting areas and an upper and a lower surfaces; (b) forming first bendable contacts on the plural first contacting areas by using a first riveting process; (c) forming second bendable contacts on the plural second contacting areas by using a second riveting process; and (d) bending each of the second bendable contacts by assembling an acting portion on the circuit board to make the second bendable contacts have at least two arranged directions, wherein the first bendable contacts and the second bendable contacts contact with an external plug and are fixed to the circuit board of the network jack by the first and the second riveting processes.