Spring Contact Angular Rotation for Modular Connector Stress Absorption
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Solution Overview
Problem
High-frequency modular connectors face stress issues due to repetitive use and improper plug insertion, leading to overstress and potential permanent deformation of spring contacts, which compromises contact integrity and electrical performance.
Innovation Solution
A jack assembly design featuring a printed circuit board that extends between the top and bottom faces, allowing angular rotation and incorporating a secondary spring mechanism to absorb stress, with output contacts acting as a secondary spring to distribute deflection forces and maintain contact force without overstressing the spring contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the spring contact is made as short as possible, then the electrical length is reduced improving high-frequency performance, but the spring contact becomes more susceptible to overstress and permanent deformation
Solution Approach 1:
The spring contact is divided into multiple segments along its length, with each segment capable of independent deflection. This segmentation allows the contact to absorb stress through progressive bending of individual segments rather than requiring the entire contact to deflect, thereby maintaining reliability while keeping the overall length short for high-frequency performance.
Solution Approach 2:
The spring contact incorporates a progressive deflection mechanism where the contact point moves along the curved path as force is applied. This dynamic response allows the contact to adapt its effective length during operation - shorter under light load for optimal electrical performance, and progressively engaging more of its length under higher stress to prevent overstress and permanent deformation.
2Reliability
If the spring contact provides sufficient contact force for reliable electrical contact, then electrical reliability is improved, but the spring contact requires more deflection capability which increases physical length
Solution Approach 1:
The spring contact features varying cross-sectional dimensions along its length, with thicker sections providing higher stiffness where full contact force is needed, and thinner sections providing greater flexibility where deflection is required. This local variation in quality allows the contact to maintain sufficient force for reliable electrical contact while achieving the necessary deflection capability without increasing overall length.
Solution Approach 2:
The spring contact utilizes changes in material properties or geometric parameters along its curved path. By varying parameters such as thickness, width, or material composition at different locations, the contact can provide high force output where needed while maintaining the ability to deflect sufficiently, thereby achieving both reliable electrical contact and adequate deflection capability within a compact length.
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 design minimizes physical and electrical length of spring contacts, reducing the risk of overstress and maintaining reliable electrical connections while improving high-frequency performance by distributing deflection forces effectively, thus preventing permanent deformation and ensuring contact integrity.
Implementation Method 1
The spring contact defines a flexible curvature along a length of the spring contact
Implementation Method 2
the printed circuit board connects to the jack assembly at a pivot point allowing for angular rotation of the printed circuit board within the cavity
Implementation Method 3
Output contacts connected to the printed circuit board are accessible outside of the jack housing, and the output contacts are sufficiently flexible to define a secondary spring within the jack assembly for absorbing stress forces transmitted from the spring contact to the printed circuit board
Data Source
AI summary
A jack assembly includes a top face and a bottom face defining a cavity there between for receiving a plug. The jack assembly includes a printed circuit board extending between the top and bottom faces of the jack assembly. At least one spring contact is connected to the printed circuit board and extends into the cavity. The spring contact defines a flexible curvature along a length of the spring contact, and the printed circuit board connects to the jack assembly at a pivot point allowing for angular rotation of the printed circuit board within the cavity. The angular rotation allows the jack assembly to absorb stress forces on the spring contacts. Secondary springs may be included in the jack assembly to further absorb spring contact stress forces.