Rugged Registered Jack Connection with Epoxy Encapsulation

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Solution Overview

Problem

Registered jack (RJ) connections are prone to damage from external forces, making them unsuitable for high-stress environments, as they fail to provide a consistent and durable connection between terminals.

Innovation Solution

A ruggedized RJ connection system is developed, featuring a first layer made of materials like plastic, metal, or silicone that encases a second layer of epoxy, with an o-ring seal to prevent moisture and external elements from entering, and a housing that positions and protects the connection, ensuring durability and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional RJ connections are used, then the connection structure is simple and easy to manufacture, but the connection is vulnerable to damage from external forces and environmental factors

Engineering Contradiction:

Improveconnection durabilityVSAvoidconnection structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a nested protective structure where the RJ connector is enclosed within a first layer (epoxy or silicone), which is then enclosed within a second layer (housing), creating multiple nested protective barriers that enhance reliability without significantly complicating the overall device assembly process

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent uses composite material structures combining different materials with complementary properties: epoxy or silicone as the first layer provides moisture resistance and cushioning, while the rigid housing provides structural protection, creating a composite protective system that addresses multiple failure modes simultaneously

Inventive Principle:

Principle #40Composite materials

2Reliability

If traditional RJ connections are used, then the device complexity is low, but the connection fails to provide consistent performance in high-stress environments

Engineering Contradiction:

Improveconnection consistencyVSAvoidexternal force damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies beforehand cushioning by embedding the RJ connector within a compliant first layer (epoxy or silicone) that provides shock absorption and stress distribution before external forces can reach the connector, preventing damage proactively rather than reactively

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The patent uses a flexible first layer (epoxy or silicone encapsulation) that conforms to the connector shape and provides flexible protection against environmental factors, allowing the structure to absorb thermal expansion and mechanical stress without compromising the connector

Inventive Principle:

Principle #30Flexible shells and thin films

3Ease of manufacture

If the connection is exposed to outside elements, then the manufacturing process is simple, but moisture and external elements can damage the connection

Engineering Contradiction:

Improveencapsulation processVSAvoidmoisture exposure

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by fully encapsulating the RJ connector in the first layer (epoxy or silicone) before final housing assembly, creating a pre-established moisture barrier that simplifies the overall manufacturing process while providing robust environmental protection

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The epoxy or silicone first layer creates an inert, sealed environment around the connector that isolates it from moisture and external elements, providing a controlled protective atmosphere that prevents corrosion and degradation

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a consistent, ruggedized connection that maintains data transmission integrity even in adverse conditions by preventing damage from external forces and environmental factors, ensuring the connection remains functional in high-stress fields.

Implementation Method 1

an o-ring preventing surrounding the first layer

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

a first layer made up of an epoxy material

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS8790140B2Rugged registered jack connection

Publication Date: 2014.07.29 NORTH MILL CAPITAL

AI summary

Systems and methods are disclosed that include a first registered jack and a junction coupled to the first registered jack. These systems and methods also include a first source unit connected to the junction and a first layer encasing at least part of the first registered jack, the junction, and the first source unit. In addition, these systems and methods include an o-ring preventing surrounding the first layer and a housing encasing the first layer and the o-ring.