The problem with audio jacks . . .

• Short in-service life
• Loss of electrical continuity
• Headset plugs falling out
• Intermittency, crackling etc
• Too weak (jacks breaking off PCB's)
• Mechanical damage/ debris
• PAX abuse

Poor reliability is caused by the use of cheap, commercial connectors.

Cheap connectors used inside the jack modules are not designed for the rigours of an aircraft environment and are rarely designed to last beyond 5,000 insertions.

Because of their poor design, most jacks will fail due to mechanical fatigue of one of the terminals due to what is known as 'work hardening'.

The picture shows a cut away view of a standard jack that has failed. The damage was really done during manufacture. The terminal was bent into shape, and this has caused hardening of the metal in the locality of the bend making it brittle. Over a period of time, as headset plugs are pushed in and out, the metal terminal bends back and forth and 'work hardens' even more until a fatigue fracture forms. The result is that the jack terminal no longer conducts the audio signal, and the headset plug becomes loose in the jack. This problem normally occurs on one terminal first (usually the one feeding the left channel) leading to the familiar loss of audio in one ear.

So, how do we solve this problem?

Our Solution

• Conventional wisdom says make everything bigger and stronger...
  • Tight fit = Good electrical contact.
  • Stronger materials = stronger design = high reliability.
• IFPL Innovation says...
  • Quality of electrical contact is independent of mechanical retention.
  • Reduce mechanical stresses by better design!

Key points about our jacks

• Flared entry- prevents headset snagging
• Strong, formed terminals- do not fatigue - maintain constant contact pressure - even with loose fitting plug
• Clearance hole- clears debris, and broken tips
• 6 point PCB attachment- provides strong PCB attachment
• Gold plated terminals- low resistance electrical contact, no tarnishing

The Result

• A jack that has been successfully tested in excess of 100,000 headset insertions !
  
  
• A jack that will reduce headset breakages !
  
  
• A jack that will reduce your seat maintenance costs !
  
  
• A jack that will keep your passengers happy !

If you would like to improve the reliability of your IFE system, save money AND keep your passengers happy, contact us for more information.

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