Solder-free DC Connector Threaded Assembly
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Solution Overview
Problem
Existing DC connectors require soldering for assembly, which is hazardous, complicated, and limits customization in musical equipment setups, as standard DC power cords are often not the desired length, leading to inefficiencies and safety concerns.
Innovation Solution
A modular DC connector design featuring a plug sleeve and cap that secures a coaxial cable without soldering, using threaded contacts to connect the cable, allowing for customizable cable lengths and easy assembly/disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect DC connectors to cables, then the connection strength and reliability are improved, but the assembly complexity and safety hazards increase
Solution Approach 1:
The patent replaces the thermal/mechanical soldering process with a purely mechanical threaded connection system. The connector uses a threaded sleeve that screws onto the cable conductor, eliminating the need for molten metal and high-temperature equipment while maintaining secure electrical connection.
Solution Approach 2:
The connector is divided into separate modular components: a threaded sleeve for mechanical attachment, a contact element for electrical connection, and an insulating body. This segmentation allows each component to perform its specific function independently, simplifying the overall assembly process while ensuring reliable connections.
2Reliability
If standard DC power cords are used, then the connector reliability is maintained, but the adaptability for customization is reduced
Solution Approach 1:
The connector design enables dynamic adaptation to different cable lengths and configurations. Users can cut cables to desired lengths and attach the connector components directly, transforming a static standard power cord into a customizable solution that adapts to specific pedal board layouts and power supply locations.
Solution Approach 2:
By separating the connector into attachable components (threaded sleeve, contact, insulating body), the system allows users to assemble connectors on cables of any length, providing versatility for different cable routing requirements while maintaining reliable electrical connection through the standardized threaded interface.
3Strength
If soldering equipment is used, then the connection strength is improved, but the safety hazards increase
Solution Approach 1:
The patent eliminates soldering equipment and molten metal by using a mechanical threaded fastening system. The threaded sleeve provides secure mechanical attachment and reliable electrical contact without requiring dangerous high-temperature processes, thereby maintaining connection strength while removing safety hazards.
Solution Approach 2:
The threaded connector components are designed as simple, inexpensive mechanical parts that can be easily replaced if needed, eliminating the need for expensive and dangerous soldering equipment while providing equally reliable connections through purely mechanical means.
Data Source
AI summary
A DC connector that allows a user to insert a coaxial cable and secure it to the connector without the use of soldering. This allows a user to easily customize power cables without soldering, which is particularly desirable for musicians creating custom pedal boards.