Snap-on Edge Assembly for Lint-Resistant Device Connection
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Solution Overview
Problem
Existing electrical connectors for handheld devices often protrude, collecting lint and debris and being uncomfortable, and require complex alignment and manual dexterity for attachment and detachment, which is undesirable for user experience.
Innovation Solution
A frame-and-overmold construction with spring-pin and pad contacts, where the external connector includes retention features to grip the device edge, allowing for easy 'clipping on' and 'peeling off' without the need for complex alignment, using injection-molded frames and elastomeric overmolding for precise alignment and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector protrudes from the device edge, then it provides easy access for connection, but it collects lint and debris and becomes uncomfortable to hold
Solution Approach 1:
Instead of having the connector protrude outward from the device edge, the invention inverts the approach by having the connector sit flush with or recessed into the device edge. The retention feature then engages with the device housing to secure the connector in place, eliminating the protrusion that causes lint and debris accumulation while maintaining connection accessibility.
2Manufacturing precision
If the connector requires complex alignment for attachment, then it ensures precise positioning, but it increases manual dexterity requirements and reduces ease of operation
Solution Approach 1:
The retention feature is pre-configured on the connector body with positioning elements that automatically align with corresponding features in the device housing. This preliminary positioning arrangement ensures precise alignment is achieved automatically during attachment without requiring complex manual alignment procedures from the user.
Solution Approach 2:
The connector incorporates self-aligning features such as guide pins or positioning ribs that automatically find and engage with mating features in the device housing. This self-service alignment mechanism eliminates the need for precise manual positioning while ensuring accurate connector placement.
3Ease of operation
If the connector uses a simple grip mechanism, then it reduces manual dexterity requirements, but it may compromise retention strength and reliability
Solution Approach 1:
The retention mechanism is segmented into multiple independent engagement points distributed around the connector body. Each segment provides a portion of the total retention force, and all segments work together to achieve both easy attachment (through simple individual engagements) and high reliability (through cumulative retention strength from multiple points).
Data Source
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AI summary
Some examples of an electrical connection system can be implemented to include mechanical retention directly to the edge of a device or protective case. The first member of the system can include one or more spring pins, located within a rigid frame. After assembly of the spring pins into the rigid frame of the first member, the frame can be overmolded to create an electrical connector at the end of a cable. The second member of the system can include one or more contact pads located within a rigid frame. After assembly of the contact pads into the rigid frame of the second member, the frame can be overmolded to create an electrical connector at the end of a cable. The rigid frame of the first member can include features to locate it to features within the rigid frame of the second member so that the spring pins in the first member align with the contact pads of the second member. The rigid frame of the first member can further include one or more retention features which allow it to grip the edge of a device or protective case into which the second member is mounted. Because of the shape and edge-located retention features of the first member, the resulting system can be easily and quickly mated and de-mated, requiring less manual dexterity and care than conventional mating connector systems.