High-Current Connector Design for Adaptive Fast-Charging
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Solution Overview
Problem
Current battery technology is limited by slow charge and discharge processes, which lead to accelerated degradation and potential safety hazards due to slow fast-charging capabilities, and standard connectors can only support relatively low charging currents, failing to meet the demand for high energy density and long usage times in portable devices.
Innovation Solution
The development of high-current electrical connectors with target pads and pins that can support charging currents above 5A, featuring spring-loaded mechanical support, thermal management, and protection circuitry to secure and safely deliver high currents, enabling adaptive fast-charging with multiple pad-pin couples and recessed pads for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rapid charging is implemented to reduce charging time, then charging speed is improved, but battery degradation accelerates and safety hazards increase
Solution Approach 1:
The charging system dynamically adjusts charging parameters based on real-time battery state monitoring. The charger transitions from constant current to constant voltage charging phases, and continuously modulates charging current based on temperature, voltage, and battery health status, enabling fast charging while preventing degradation and safety issues
Solution Approach 2:
The system implements closed-loop feedback control through multiple sensors monitoring battery voltage, current, temperature, and charge state. The charger receives real-time status information from the mobile device and adjusts charging parameters accordingly, preventing over-charging, thermal runaway, and excessive degradation while maintaining optimal charging speed
2Adaptability or versatility
If standard electrical connectors are used, then device compatibility is maintained, but charging current is limited to relatively low levels
Solution Approach 1:
The charging system segments the electrical connection into multiple independent contact paths (multiple pins and pads). Instead of relying on a single connector interface, the system distributes high-current transmission across multiple parallel conductive paths, enabling currents above 5A while maintaining compatibility with standard connector form factors
Solution Approach 2:
The invention transitions from two-dimensional planar contacts to three-dimensional multi-level contact structures. Multiple pins extend at different depths and positions, creating additional conductive pathways that increase current capacity without significantly increasing connector footprint or compromising compatibility
3Power
If multiple pad-pin couples are implemented to support high current, then charging current capacity is improved, but connector complexity increases
Solution Approach 1:
The connector design integrates multiple functions into a single component structure. The same pin array serves both mechanical alignment/support functions and electrical conduction functions. The connector housing provides both structural support and thermal management, reducing the need for separate components and minimizing overall system complexity despite multiple contact points
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 solution allows for fast charging with improved battery lifetime, adaptive charging intervals, and high current input, enhancing device performance while mitigating thermal and safety issues, enabling charging currents up to 60A and providing protection against thermal overloads and short circuits.
Implementation Method 1
Proper mechanical contact in the pad-pin couples can be achieved by spring-loading the connector pads and/or pins
Data Source
AI summary
The present invention discloses devices, for adaptive fast-charging of mobile devices, including: a charge-delivering device for providing electrical power to a charge-receiving device; and at least one electrical-contact pin for enabling electrical current to be transmitted at an amperage greater than about 5 A to the charge-receiving device. Preferably, the charge-receiving device is selected from the group consisting of: an integral power-source component of a mobile device and a slave battery. Preferably, at least one electrical-contact pin is further configured to transmit the electrical current at an amperage selected from the group consisting of: greater than about 10 A, greater than about 20 A, greater than about 30 A, and greater than about 60 A. Preferably, at least one electrical-contact pin is spring-loaded. Preferably, at least one electrical-contact pin includes protection circuitry for protecting against thermal overloads and short circuits. Preferably, the device charger further includes: a receiving-area holder for properly engaging the charge-receiving device.