Plug-in Adapter for Versatile PCB Connections
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Solution Overview
Problem
Existing solutions for connecting electronic units with cables to printed circuit boards require multiple connectors and manual reconfiguration, which are costly and prone to errors, especially when dealing with different types of plugs and lead configurations like RJ-45 and screw terminals in telecommunications systems.
Innovation Solution
A plug-in adapter with a base body featuring two receiving chambers for plugs and patch panels, connected by contact bodies and locking elements, allowing for secure and versatile connections with color-coded crossed leads, manufactured using injection molding technology with flame-resistant materials and corrosion-resistant coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple connectors (RJ-45, screw terminals) are provided on the printed circuit board for different plug types, then various plug types can be connected directly, but the device complexity and cost increase
Solution Approach 1:
The adapter base body serves multiple functions: it houses receiving chambers for different plug types (RJ-45, screw terminals), contains the contact elements, and provides the connection interface to the patch panel. This multi-functional design eliminates the need for multiple separate connectors on the printed circuit board, reducing complexity while maintaining versatility
Solution Approach 2:
The adapter acts as an intermediary device between the cable plug and the patch panel connection. Instead of directly connecting various plug types to the patch panel, the adapter mediates this connection by receiving different plug types in its base body and establishing the appropriate electrical connections through its contact elements, thereby simplifying the overall system architecture
2Adaptability or versatility
If manual reconfiguration of connecting leads is performed on site, then connection flexibility is achieved, but the risk of faults and errors increases
Solution Approach 1:
The adapter is pre-configured with contact elements arranged in specific patterns (including crossed connections) before deployment. This preliminary configuration of connection paths eliminates the need for on-site manual reconfiguration, thereby maintaining connection flexibility while significantly reducing the risk of installation errors and faults
Solution Approach 2:
The adapter employs color coding of contact elements or housing features to indicate different connection configurations (e.g., crossed vs. straight connections). This visual identification system allows installers to quickly select the correct adapter type without manual reconfiguration, improving reliability while maintaining adaptability to different connection requirements
3Adaptability or versatility
If a multiway connector is provided on the printed circuit board for reconfiguration, then lead crossing is enabled, but the cost increases due to unused connector parts
Solution Approach 1:
The connection functionality is segmented from the printed circuit board and transferred to the removable adapter. The adapter base body contains only the necessary contact elements for specific connection patterns (e.g., 2-out-of-4 crossed connections), eliminating the need for a full multiway connector on the board. This segmentation reduces manufacturing costs by avoiding unused connector parts while maintaining lead crossing capability through the adapter
4Productivity
If injection molding is used to manufacture the adapter base body, then manufacturing efficiency and consistency are improved, but the requirement for flame-resistant materials with specific properties increases complexity
Solution Approach 1:
The adapter base body is manufactured using injection molding with flame-resistant plastic materials that meet specific safety standards (e.g., UL 94 V-0). This manufacturing approach provides high productivity and consistency while the material properties (flame resistance, mechanical strength, electrical insulation) are optimized through material selection and formulation, balancing manufacturing efficiency with performance requirements
Data Source
AI summary
A card edge connector allows a modular jack to be electronically connected to a PCMCIA Type III communications card. The card edge connector includes a modular jack with a main body portion having a top surface, a bottom surface, a front surface and a rear surface. A receptacle is disposed entirely within the front surface of the modular jack and the receptacle is sized and configured to receive a RJ series connector plug such that no portion of the plug extends through either the top surface or the bottom surface of the modular jack. A connector attached to the rear surface of the modular jack and the connector includes a socket sized and configured to receive a portion of a printed circuit board disposed within the communications card. Desirably, the card edge connector includes at least one contact pin including a plug engaging portion that extends into the receptacle and a printed circuit board engaging portion that extends into the socket.