Single-Pair Connector Coupler With Anti-Rotation Contact Assembly
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Solution Overview
Problem
Existing connectors for single twisted pairs of conductors lack efficient solutions for compact and effective data and power transmission, as they often require four pairs of conductors and are not optimized for single pair configurations.
Innovation Solution
A coupler design featuring a housing with a contact sub-assembly that includes a pair of coupling contacts, anti-rotation features, and crush ribs to establish an interference fit, allowing for secure and efficient data and power transmission between two connectors connected to a single pair of conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional Ethernet connectors with four pairs of conductors are used, then data transmission reliability is improved through differential signaling, but device complexity and cable bulk increase
Solution Approach 1:
The patent extracts the essential function of data transmission from the traditional four-pair Ethernet configuration and implements it using only a single twisted pair of conductors. The coupler design removes unnecessary components and structures, retaining only the critical elements needed for single-pair data and power transmission, thereby reducing complexity while maintaining functionality.
Solution Approach 2:
The single twisted pair connector and coupler are designed to perform multiple functions simultaneously - data transmission, power delivery, and signaling - all through a single pair of conductors. This multi-functional approach eliminates the need for separate connectors for different functions, reducing overall device complexity compared to traditional multi-pair Ethernet systems.
2Device complexity
If single pair connectors are used, then device complexity is reduced, but connection stability and signal reliability may worsen
Solution Approach 1:
The contact sub-assembly is nested within the housing structure, with the coupling contacts positioned centrally and secured through interference fits with crush ribs. This nested configuration provides structural stability and protects the electrical contacts while maintaining a compact, simple overall design. The anti-rotation feature is also nested within the contact sub-assembly to prevent misalignment.
Solution Approach 2:
The coupler incorporates preliminary alignment features including the anti-rotation feature and interference fit mechanisms that are pre-configured to ensure proper connection orientation and stability before actual data transmission begins. These features prevent connection errors and ensure reliable contact engagement from the outset.
3Volume of moving object
If compact single pair connectors are designed, then device size is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The coupler design incorporates asymmetric features such as the anti-rotation element with width greater than the body portion, and asymmetric positioning of the coupling contacts within the housing. These asymmetric elements provide built-in alignment guidance that compensates for normal manufacturing tolerances, ensuring proper connection orientation without requiring extremely tight manufacturing precision.
Solution Approach 2:
The design utilizes interference fit parameters and crush rib geometry that are optimized to provide self-aligning characteristics during assembly. The dimensional parameters of the contact sub-assembly and housing are specifically designed to create beneficial interference fits that guide proper positioning, reducing the impact of manufacturing variations on final alignment.
4Strength
If interference fit with crush ribs is used, then connection strength is improved, but manufacturing complexity increases
Solution Approach 1:
The coupling contacts, anti-rotation feature, and crush ribs are merged into a single integrated contact sub-assembly that is manufactured as one piece or pre-assembled unit. This merging eliminates the need for separate assembly steps for these components, reducing manufacturing complexity while maintaining the strong interference fit connection. The integrated design allows the sub-assembly to be installed as a single component into the housing.
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
Enables reliable and compact data and power transfer over a single twisted pair of conductors, reducing complexity and increasing versatility in communication networks.
Implementation Method 1
one or more crush ribs to create an interference fit with an interior surface of the housing
Implementation Method 2
A single twisted pair of conductors can be used to transmit data and/or power over a communications network
Implementation Method 3
Differential signaling techniques, where each signal is transmitted over a balanced pair of conductors, are used because differential signals may be affected less by external noise sources
Data Source
AI summary
A coupler includes a housing and a contact sub-assembly. The housing includes a channel having openings at first and second ends of the housing. The first end receives a first connector having a first pair of contacts and the second end receives a second connector having a second pair of contacts. The contact sub-assembly includes exactly one pair of coupling contacts and a body portion supporting the pair of coupling contacts. The contact sub-assembly is positioned centrally within the housing and includes an anti-rotation feature and one or more crush ribs to create an interference fit with an interior surface of the housing. The pair of coupling contacts serve to couple the first and second connectors for both power and data transmission. In certain embodiments, contacts sub-assembly utilizes a circuit board to electrically couple contacts.