Connector Assembly Outer Power Terminals Heavy Current
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Solution Overview
Problem
Existing connector assemblies, comprising plug and socket connectors, are limited in their ability to transmit heavy currents due to structural constraints, hindering their application in high-power applications such as rapid charging of electronic devices.
Innovation Solution
The design incorporates a plug connector with outer power terminals and a socket connector with mating power terminals, allowing for simultaneous current transmission through both inner and outer conductive paths, with the outer power terminals being fixedly attached to the circuit board and connected via a cable, enabling stable and increased current transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional elastic sheet type terminal structures are used in plug and socket connectors, then the connector structure remains simple and compact, but the current transmission capability is limited and cannot handle heavy currents
Solution Approach 1:
The connector is divided into multiple terminal types: traditional elastic sheet type terminals for signals and inner power terminals, and new outer power terminals with conducting portions and tail portions. This segmentation allows different terminal structures to handle different current loads, with outer power terminals specifically designed for heavy current transmission while inner terminals handle lighter currents and signals.
Solution Approach 2:
The connector transitions from a single-plane terminal arrangement to a multi-dimensional structure where outer power terminals are positioned on lateral sides of the mating joint, extending beyond the traditional terminal plane. This spatial expansion enables additional current transmission paths without interfering with the traditional terminal arrangement.
2Power
If the connector is miniaturized to meet compact device requirements, then the connector size is reduced, but the auxiliary functions and current transmission capabilities are limited
Solution Approach 1:
The outer power terminals are nested around the traditional mating joint structure, with conducting portions positioned on lateral sides and tail portions extending to the circuit board. This nesting approach allows the connector to maintain a compact overall form factor while incorporating additional power transmission capabilities through the outer terminals that coexist with the traditional inner terminals.
Solution Approach 2:
The connector utilizes three-dimensional space by positioning outer power terminals on lateral sides of the mating joint, extending the terminal arrangement from a single plane to multiple spatial dimensions. This enables increased power transmission capability without proportionally increasing the connector's footprint or volume.
3Power
If outer power terminals are added to the plug connector and mating power terminals to the socket connector, then heavy current transmission is enabled, but the manufacturing process becomes more complex
Solution Approach 1:
The manufacturing process is segmented into distinct stages: traditional terminal manufacturing for inner terminals, separate manufacturing for outer power terminals with their unique conducting and tail portions, and final assembly. This segmentation allows each terminal type to be optimized for its specific function while simplifying the overall manufacturing workflow compared to redesigning the entire terminal structure.
Solution Approach 2:
The outer power terminals are designed with universal mounting features (tail portions for circuit board attachment) that resemble traditional terminal mounting methods, allowing existing manufacturing equipment and processes to be adapted with minimal modification. The conducting portions provide the new heavy current capability while the tail portions interface with existing assembly processes.
Data Source
AI summary
A plug connector includes: a circuit board; a mating joint having an insulating body and multiple conductive terminals provided on the insulating body; at least two outer power terminals; and a cable having at least two outer power lines, multiple inner power lines and multiple signal lines. The conductive terminals are electrically connected to the circuit board, and include multiple inner power terminals and multiple signal terminals. Each outer power terminal has a conducting portion and a tail portion. The tail portion is fixedly provided on the circuit board, and the conducting portion is located on a lateral side of the mating joint. Each outer power line is electrically connected to the tail portion of a corresponding outer power terminal. The inner power lines are electrically connected with the inner power terminals respectively. The signal lines are electrically connected with the signal terminals respectively.