Network Jack With Varied Contact Spacing And Phosphor Bronze

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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 flexibility issues and random contact arrangements.

Innovation Solution

A network jack design featuring a circuit board with varied distances between contacting areas, circular contacts made of phosphor bronze, and a terminal base that bends contacts during assembly, eliminating the need for a bending machine and reducing material costs, while providing better flexibility and support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the distance between two contacts of the same pair is reduced, then the network jack can operate at higher voltages, but the manufacturing precision requirements increase

Engineering Contradiction:

Improveoperating voltage rangeVSAvoidcontact spacing precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The circuit board is divided into multiple contacting areas with different distances from the first side, creating distinct groups of contacts (first contacts and second contacts) with different spacing characteristics. This segmentation allows different contact pairs to have different voltage ratings based on their position, resolving the contradiction by providing both high-voltage capability (for contacts needing larger spacing) and compact design (for contacts where smaller spacing is acceptable).

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different contacting areas on the circuit board are designed with different local qualities - specifically, different distances from the first side. This creates zones with different electrical characteristics, allowing the network jack to accommodate both high-voltage and low-voltage contacts in the same device, thereby expanding the overall operating voltage range without requiring uniform high precision across all contacts.

Inventive Principle:

Principle #3Local quality

2Reliability

If beryllium copper is used for contacts, then the electrical performance is improved, but the manufacturing cost increases

Engineering Contradiction:

Improveelectrical performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The material parameter of the contacts is changed from beryllium copper to phosphor bronze. This parameter change maintains adequate electrical performance while significantly reducing material cost and improving ease of manufacture, as phosphor bronze is a more cost-effective material that is easier to work with during the manufacturing process.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If contacts are formed by punching and mounted separately, then the manufacturing flexibility is improved, but the device complexity increases

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidassembly complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The circuit board is designed to integrally form both the contacting areas and the acting portion (bending portion). This merging of functions eliminates the need for separate mounting and bending operations, reducing assembly complexity while maintaining manufacturing flexibility. The acting portion is formed as part of the circuit board structure itself, allowing contacts to be bent during assembly without requiring external bending machines.

Inventive Principle:

Principle #5Merging (Combining)

4Stability of the object's composition

If rectangular contacts are used, then the structural stability is improved, but the flexibility decreases

Engineering Contradiction:

Improvecontact structural stabilityVSAvoidcontact flexibility

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The contacts are designed with circular cross-sections instead of rectangular shapes. This curvilinear geometry provides superior flexibility and elasticity compared to rectangular contacts, allowing the contacts to bend and return to their original shape more effectively. The circular shape maintains structural stability while dramatically improving the flexibility needed for the bending operation during assembly.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS7498529B2Network jack and manufacturing method therefor

Publication Date: 2009.03.03 PENG JOHN

AI summary

A network jack is provided. The network jack includes a circuit board, first contacts, second contacts and an acting portion. The circuit board has a first side, plural first contacting areas arranged along the first side and plural second contacting areas. The plural first contacting areas are between the plural second contacting areas and the first side, and plural distances between the first side and each of the plural second contacting areas are various. The first contacts are mounted on the first contacting areas and the second contacts are mounted on the second contacting areas. The acting portion bends the second contacts.