Interlocking DC Barrel Plug Structure for 300 W Low-Profile Power
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Solution Overview
Problem
Conventional DC power connectors face challenges in providing adequate power capacity while maintaining a low z-height, especially with the transition to thinner USB-C connectors, which can only supply up to 100 W, failing to meet the power needs of advanced portable devices.
Innovation Solution
The improved barrel connector plug design uses copper or copper alloy for the inner and outer bodies, with a dielectric insulating barrel, and incorporates an inter-locking feature for increased structural rigidity, allowing for higher power capacity and reduced z-height by enhancing electrical conductivity and preventing disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional DC power connectors are used, then adequate power capacity can be provided, but the z-height becomes too large for thin portable devices
Solution Approach 1:
The connector components are nested concentrically with the inner body centered within the outer body, and the insulating barrel positioned between them. This nested arrangement maximizes space utilization and minimizes the overall z-height while maintaining adequate power capacity through proper material selection and dimensional optimization.
Solution Approach 2:
The patent specifies precise dimensional parameters for the inner body, outer body, and insulating barrel to achieve the optimal balance between power capacity and low z-height. By carefully controlling thickness, diameter, and length parameters, the connector achieves 300W power capacity in a compact 4.5mm profile.
2Length of moving object
If USB-C connectors are used to reduce z-height, then portability is improved, but power capacity is limited to 100 W
Solution Approach 1:
The connector uses composite construction with copper or copper alloy for the inner and outer bodies to maximize electrical conductivity and power capacity, while the insulating barrel provides dielectric isolation. This composite material approach enables the low-profile connector to achieve 300W power capacity, three times higher than USB-C limits.
3Ease of manufacture
If the connector components are made loose-fitting, then assembly is easier, but structural rigidity and reliability decrease
Solution Approach 1:
The connector is divided into three separable components (inner body, insulating barrel, outer body) that can be assembled independently. The threaded engagement mechanism allows each component to be manufactured separately with standard tolerances, then reliably joined through screw threads that provide both ease of assembly and strong structural connection.
Solution Approach 2:
The inner body, insulating barrel, and outer body are pre-assembled as a unit before final installation into the device. This preliminary assembly ensures proper alignment and rigidity is established before the connector is installed, maintaining both manufacturing ease and structural reliability.
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
The design achieves up to 300 W of power with a maximum current of 17 A in a 4.5 mm barrel connector plug, providing improved power capacity and reliability while maintaining a low profile, suitable for high-power, low-profile portable devices.
Implementation Method 1
The inner body and the outer body are formed from a first base metal or metal alloy having an electrical conductivity ranging between 30% International Annealed Copper Standard (IACS) and greater than or equal to 99% IACS
Implementation Method 2
an insulating barrel, which is coupled between the inner body and the outer body to electrically isolate the inner body from the outer body, wherein the insulating barrel is formed from a dielectric material
Data Source
AI summary
The present disclosure provides embodiments of direct current (DC) power connectors and methods to manufacture the same. More specifically, the present disclosure provides a connector plug with improved power capacity and structural rigidity. The connector plug includes an inner body and an outer body coupled to transmit power through the DC power connector, wherein the inner body is concentrically arranged within the outer body, and an insulating barrel that is coupled between the inner body and the outer body to electrically isolate the inner body from the outer body. The inner body and outer body comprise a base metal or metal alloy having an electrical conductivity ranging between 30% International Annealed Copper Standard (IACS) and greater than or equal to 99% IACS. In addition, the inner body, outer body and insulating barrel comprise an inter-locking feature, which increases the structural rigidity of the connector plug and prevents disassembly when the inner body, outer body and insulated barrel are assembled together.