Lightweight Tactical Handset Integrating Connector Into Handle
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Solution Overview
Problem
Standard tactical communication handsets are bulky, resource-intensive, and costly due to their ruggedized design, which includes a terminal cavity that creates multiple failure points, reduces structural integrity, and increases manufacturing complexity, leading to the entire handset being discarded when damaged.
Innovation Solution
A lightweight tactical communication handset design that eliminates the terminal cavity by directly molding the pin contact electrical connector and connection wires into the handle, simplifying assembly and reducing weight, while maintaining durability and communication quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a terminal cavity is included in the housing for assembling wire joints and connection wires, then the handset can be assembled with traditional wiring methods, but the structural integrity is reduced and multiple failure points are created
Solution Approach 1:
The patent merges the terminal cavity function directly into the handle body by molding the pin contact electrical connector integrally with the handle. This eliminates the separate terminal cavity space and integrates the wiring structure into the housing itself, thereby maintaining structural integrity while achieving the same electrical connection function.
Solution Approach 2:
The patent extracts and eliminates the terminal cavity component entirely from the design. By removing this unnecessary space and integrating the connector directly into the handle, the design reduces failure points while maintaining ease of manufacture through simplified assembly.
2Reliability
If the handset is designed as a permanently assembled consumable product for rugged conditions, then reliability in harsh environments is improved, but the entire handset must be discarded when damaged
Solution Approach 1:
The patent segments the handset into replaceable modular components: the handle housing with integrated connector, the coiled cable, and the earphone/microphone assembly. This allows individual components to be replaced rather than discarding the entire handset, reducing waste and costs while maintaining reliability through standardized connections.
Solution Approach 2:
The patent enables selective replacement of damaged components (handle, cable, or earphone assembly) while recovering and reusing intact components. This approach maintains system reliability in harsh environments while reducing the need to discard entire handsets, aligning with sustainability goals.
3Ease of manufacture
If connection wires and coiled cables are used with wire joints, then electrical connections can be established between components, but the weight and complexity of the handset increase
Solution Approach 1:
The patent merges the electrical connection function directly into the handle by molding the pin contact electrical connector as an integral part of the handle body. This eliminates separate wire joints and reduces the number of discrete connection components, thereby reducing weight while maintaining full electrical connectivity between the coiled cable and internal components.
Solution Approach 2:
The patent replaces traditional mechanical wire joint assemblies with an integrally molded electrical connector. This substitution eliminates the need for separate wire joints and reduces assembly complexity, resulting in a lighter overall structure while maintaining reliable electrical connections.
Data Source
AI summary
A tactical communication handset that is lighter, easier to assemble, and more durable than standard tactical handsets is disclosed. The communication handset includes a housing, an earphone, a microphone, a push-to-talk (PTT) switch, a pin contact electrical connector, and connection wires. The housing includes an earphone cavity, a microphone cavity, a PTT switch cavity, and a pin contact electrical connector cavity; however, the housing does not include a terminal cavity. The connection wires may be installed with a metal ring terminal or soldered at terminals. The pin contact electrical connector may be a 5-pin or a 6-pin contact electrical connector. The six-pin contact electrical connector enables simultaneous activation of the earphone and microphone of the communication handset.