Shielded Wire-to-Wire Connector With Retained Offset Contacts
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Solution Overview
Problem
Traditional methods for connecting wires are tedious, inefficient, and prone to failure, posing safety hazards due to the risk of wires disconnecting unexpectedly.
Innovation Solution
A wire-to-wire connector system featuring a shielded housing with retention features and offset contact portions, allowing for quick and reliable connections between male connectors using electrical contacts with prongs that are securely retained within the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional wire connection methods (stripping, twisting, securing) are used, then the connection process can be completed with simple tools, but the process is tedious and time-consuming
Solution Approach 1:
The patent introduces a connector as an intermediary device between two wires. This connector includes contact portions that receive and secure the stripped wire ends, eliminating the need for manual twisting and securing. The connector serves as a mediator that simplifies the connection process while maintaining electrical continuity and mechanical strength.
Solution Approach 2:
The connector is divided into distinct functional segments: contact portions for receiving wires, a body for structural support, and retention features for securing the contact portions. This segmentation allows for specialized design of each component to optimize its function while enabling efficient assembly and connection procedures.
2Reliability
If wires are stripped and twisted together for connection, then the connection can be made with minimal components, but the connection is prone to falling apart or shorting out
Solution Approach 1:
The connector acts as a reliable intermediary that provides a secure mechanical and electrical connection between wires. The retention features within the connector body firmly hold the contact portions, preventing them from falling apart. The insulating properties of the connector body also prevent shorting out between adjacent contacts.
Solution Approach 2:
The connector utilizes composite construction combining conductive materials for contact portions and insulating materials for the connector body. This composite approach ensures both electrical conductivity where needed and electrical isolation where required, enhancing overall connection reliability while managing structural complexity through material differentiation.
3Reliability
If offset contact portions are used in the electrical contact, then consistent electrical contact is ensured, but the manufacturing process becomes more complex
Solution Approach 1:
The contact portions are designed with an offset arrangement rather than a symmetric configuration. This asymmetric design ensures that contact portions at different positions on the connector make reliable electrical contact with their corresponding mating contacts. The offset positioning compensates for manufacturing tolerances and ensures consistent electrical connection despite variations in assembly alignment.
Data Source
AI summary
A single pair Ethernet connector includes first and second housings, first and second electrical contacts, and a shield to encase the connected first and second housings. The first and second housings each include a first mating portion and a conjoined second mating portion, the first mating portion having a female interface on a first side and the second mating portion extending in a direction opposite the first side. The first and second electrical contacts each include a base having opposing first and second ends, a first portion extending from the first end, and a second portion extending from the second end. The female interface on the first side of the first housing receives the first portion of each of the first and second electrical contacts and the female interface on the first side of the second housing receives the second portion of each of the first and second electrical contacts.