RJ-45 Jacks with Deflection Limiters for RJ-11 Compatibility
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Solution Overview
Problem
RJ-45 communications jacks are often damaged when RJ-11 style plugs are accidentally inserted due to over-deflection of jackwire contacts, leading to permanent deformation and insufficient contact force for RJ-45 plugs, which can result in poor performance and failure to meet industry standards.
Innovation Solution
The design of RJ-45 communications jacks includes a housing with a plug receiving cavity featuring a first guide and channel that redirects RJ-11 plugs downward, and jackwire contact deflection limiters to prevent over-deflection and protect the contacts, allowing both RJ-11 and RJ-45 plugs to be used without damaging the jack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If RJ-45 jack is designed to accept RJ-11 plugs, then compatibility and ease of operation are improved, but jackwire contacts may be over-deflected causing permanent deformation and reliability degradation
Solution Approach 1:
The patent applies preliminary anti-action by incorporating deflection limiters that preemptively prevent over-deflection of jackwire contacts before permanent deformation can occur. These limiters are positioned to engage the housing of RJ-11 plugs before the contacts can be damaged, thus preventing the harmful effect while maintaining compatibility.
Solution Approach 2:
The deflection limiters serve as intermediary elements between the RJ-11 plug housing and the jackwire contacts. They mediate the interaction by limiting the force transmission to safe levels, allowing RJ-11 plugs to be used without directly transmitting damaging forces to the contacts.
2Adaptability or versatility
If RJ-45 jack accepts both RJ-11 and RJ-45 plugs, then adaptability is improved, but structural complexity increases due to additional protective features
Solution Approach 1:
The patent implements universality by designing a single jack structure that can accommodate both RJ-11 and RJ-45 plugs. The deflection limiters are positioned to work with both plug types, providing protective functionality while maintaining compatibility with multiple connector standards without requiring separate jack designs.
Solution Approach 2:
The patent applies local quality by adding deflection limiters only at specific locations where RJ-11 plug contact occurs, rather than redesigning the entire jack structure. This localized modification provides the necessary protection and compatibility while minimizing the increase in overall structural complexity.
3Reliability
If jackwire contacts are made more resilient to prevent permanent deformation, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-positioning deflection limiters that prevent over-deflection before it can occur during plug insertion. This preemptive measure protects the contacts from exceeding their safe deflection range, maintaining reliability without requiring the contacts themselves to be manufactured with higher precision or enhanced resilience.
Data Source
AI summary
RJ-45 style communications jacks include a housing having a plug receiving cavity that is defined, at least in part, by opposed upper and lower surfaces. A first guide protrudes from the upper surface into the plug receiving cavity. A first channel is formed in the lower surface. The width of this first channel is greater than the width of a housing of an RJ-11 style communications plug but less than a width of a housing of an RJ-45 style communications plug. Moreover, the length of the first channel is sufficient to allow the RJ-11 style communications plug to be fully inserted within the plug receiving cavity.