Charging Interface Male Plug Asymmetry and PCB Integration
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Solution Overview
Problem
Existing charging interfaces for rechargeable devices are prone to damage and incorrect usage, leading to potential electrical issues and user safety concerns due to delicate male prongs and brittle solder connections, which can result in inoperable or damaged devices.
Innovation Solution
A charging interface with a non-directional male plug formed from circuit board substrate, which is slidably and electrically interconnected with a female socket in multiple orientations, reducing stress on the circuit board and eliminating the risk of bending or breaking, and featuring a dual-surface configuration for stable electrical contact regardless of orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional male prongs and female slots are used in the charging interface, then electrical connection can be established, but the male prongs can be bent or broken when incorrectly inserted, resulting in an inoperable charging interface
Solution Approach 1:
The charging interface uses an asymmetric design where the male plug has a single solid structure that can only be inserted in one correct orientation into the female socket. This asymmetric geometry prevents incorrect insertion while ensuring reliable electrical connection, eliminating the problem of bent or broken male prongs associated with traditional symmetric multi-prong designs
2Reliability
If the device portion of the charging interface is soldered to the circuit board, then electrical connection is established, but the soldered connections can be cracked or damaged when the charging interface is plugged and unplugged, causing loss of electrical contact
Solution Approach 1:
The male plug is integrally formed with the circuit board substrate, creating a unified structure where the charging interface is an inherent part of the circuit board rather than a separate component. This merging eliminates the need for separate soldered connections between the male plug and circuit board, preventing crack formation during plugging and unplugging operations
3Reliability
If a unique charging interface design is used for each rechargeable device, then accidental use of wrong charger is prevented, but the charging interface becomes more complex and harder to manufacture
Solution Approach 1:
The charging interface uses a universal asymmetric socket design that can accommodate multiple different male plug configurations. This allows a single female socket design to work with various device types while maintaining safety against incorrect charger usage, reducing design complexity compared to creating unique interfaces for each device
Data Source
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AI summary
A novel charging interface for rechargeable devices is disclosed herein. The present charging interface has a male plug, formed from circuit board material, which electrically and slidably interconnects with a female socket in at least two orientations. The female socket has electrically conductive biasing means which retain the male plug within the female socket. The charging interface provides electrical contact between the master circuit board of a rechargeable device and a power source.