Electrical Connector Stepped Surface Design Prevents Dirt Short Circuits
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Solution Overview
Problem
Existing electrical connectors, such as Type C male connectors, are prone to short circuits due to dirt accumulation between conductive terminals, which can cause micro currents and potential short circuits.
Innovation Solution
The electrical connector features a stepped surface design with conductive terminals where the surfaces of the first and second contact portions do not protrude beyond the corresponding surfaces of the extension portion, reducing dirt accumulation and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the conductive terminal surfaces are higher than the tongue surface, then the contact area is increased, but dirt accumulates between adjacent conductive terminals causing short circuit risks
Solution Approach 1:
The tongue is segmented into a base portion and an extension portion that protrudes from the base portion. This segmentation creates a stepped surface structure where the extension portion forms a lower surface between adjacent conductive terminals, preventing dirt accumulation while maintaining the elevated contact surfaces of the terminals themselves.
Solution Approach 2:
The design transitions from a single-level flat surface to a multi-level stepped surface structure. The extension portion creates a vertical dimension difference, forming a lower surface that acts as a drainage path for dirt and debris, eliminating the harmful accumulation zone between terminals while preserving adequate contact area.
2Ease of manufacture
If the conductive terminal surfaces are higher than the tongue surface, then easier cleaning is achieved, but dirt accumulates in the recessed areas causing micro currents
Solution Approach 1:
The design converts the potential harm of recessed areas (which could trap dirt) into a beneficial drainage feature. The lower surface of the extension portion acts as a slope that guides dirt and debris away from the contact areas toward the base portion, transforming what would be a trapping zone into an evacuation path that prevents micro current generation.
3Device complexity
If a flat surface design is used, then manufacturing is simpler, but adjacent conductive terminals generate micro currents due to dirt accumulation
Solution Approach 1:
The design applies different surface qualities to different regions: the conductive terminal surfaces maintain elevated positions for adequate contact area, while the extension portion creates a localized lower surface specifically in the regions between terminals. This local variation prevents dirt accumulation exactly where it would cause micro currents, without complicating the overall structure or affecting terminal functionality.
Data Source
AI summary
The present disclosure an electrical connector having an insulating body and a number of conductive terminals. The insulating body includes a base portion and an extension portion. The extension portion includes a first surface and a second surface. The conductive terminals include a number of first contact portions located on a same side of the first surface and a number of second contact portions located on a same side of the second surface. At least part of surfaces of the first contact portions do not protrude beyond the first surface. At least part of surfaces of the second contact portions do not protrude beyond the second surface. As a result, the electrical connector of the present disclosure can avoid a short circuit problem between adjacent conductive terminals due to accumulation of a certain degree of dirt.