Comb Connector Assembly for High-Current Compact Power Links
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Solution Overview
Problem
Conventional connectors face challenges in balancing the need for a large contact area to handle high currents while maintaining a compact size and low manufacturing costs, especially when connecting power sources to devices or units within devices.
Innovation Solution
The comb type connector design features a base with thin plate terminals made of conductive metal, spaced at uniform intervals, allowing for a large contact area without increasing size, achieved through the use of conductive metal materials like copper or aluminum, and a locking mechanism to prevent unintentional separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large contact area is used to handle high currents, then power transmission capability is improved, but connector size increases
Solution Approach 1:
The connector divides the contact area into multiple thin plate terminals (first thin plate terminals and second thin plate terminals) that are spaced apart from each other. This segmentation allows the total contact area to be distributed across multiple smaller elements, enabling high current handling while maintaining a compact overall connector size.
Solution Approach 2:
The thin plate terminals are arranged in a multi-dimensional configuration, extending in multiple directions from the base. This spatial arrangement allows the contact area to be expanded in three-dimensional space rather than requiring a large two-dimensional footprint, thus achieving high power transmission in a compact volume.
2Power
If a large contact area is used to handle high currents, then power transmission capability is improved, but manufacturing costs increase
Solution Approach 1:
Multiple thin plate terminals are integrated into a single connector assembly, sharing common structural elements such as the base and locking mechanisms. This merging approach allows the connector to achieve high power transmission capability through multiple contacts while avoiding the need to manufacture and assemble separate connectors for each contact, thereby reducing overall manufacturing costs.
3Power
If thin plate terminals are spaced closely to increase contact area, then power transmission capability is improved, but locking reliability decreases
Solution Approach 1:
The locking mechanism is segmented into multiple locking units, each corresponding to specific thin plate terminals. This segmentation ensures that even when terminals are closely spaced, each terminal group has its own dedicated locking unit, maintaining reliable locking while allowing close spacing for increased contact area.
Solution Approach 2:
The locking units are designed with universal functionality to handle multiple thin plate terminals. Each locking unit can engage with corresponding terminals in a standardized manner, providing reliable locking across the entire array of closely-spaced terminals through a consistent, repeatable mechanism.
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
This design enables efficient power transmission in compact electronic devices by providing a large contact area for high currents while maintaining a small size and reducing manufacturing costs, allowing for the easy design and manufacturing of compact devices.
Implementation Method 1
a plurality of second thin plate terminals spaced apart from and overlapping each other on one side surface of the second base, when the first comb type connector approaches, the plurality of second thin plate terminals are alternately inserted into the plurality of first thin plate terminals so as to be conductively connected to the first comb type connector
Data Source
AI summary
Disclosed are a comb type connector and a connector assembly having the same. The disclosed comb type connector comprises: a base made of a conductive metal material; and a plurality of thin plate terminals made of a conductive metal material and which protrude in a thin film shape and are spaced apart from and overlap each other on one side surface of the base.