Hot-Swap Connector Sequencing to Prevent Arc Carbon Deposition
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Solution Overview
Problem
High-power USB connectors face issues with carbon deposition and safety concerns due to electric arcs during hot swapping, leading to increased contact resistance and reduced service life.
Innovation Solution
A connector design with a protrusion elastically connected to the housing base controls the disconnection sequence of conductive and signal terminals, allowing the conductive terminal to remain connected while the signal terminal is disconnected first, and the output voltage is stepped down or stopped to prevent electric arcs and carbon deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the connector is used for high-power power transmission with instantaneous power delivery, then the power transmission efficiency is improved, but carbon deposition is generated at the conductive terminals due to electric arc during unplugging
Solution Approach 1:
The patent applies preliminary action by controlling the power supply system to reduce or stop output voltage before the conductive terminal is fully disconnected from the contact pin. The protrusion mechanism ensures that the signal terminal disconnects first, triggering a voltage reduction sequence that occurs before the conductive terminal separation, thereby preventing electric arc and carbon deposition at the conductive terminal
Solution Approach 2:
The patent segments the disconnection process into two distinct stages: first, the signal terminal disconnects from the contact pin while the conductive terminal remains connected; second, after voltage is reduced, the conductive terminal disconnects. This segmentation allows controlled voltage reduction to occur during the first stage, preventing harmful electric arc during the final separation
2Ease of operation
If the connector allows hot swapping with direct power transmission, then the ease of operation is improved, but the service life is degraded due to accumulated carbon deposition
Solution Approach 1:
The protrusion mechanism performs preliminary action by establishing a disconnection sequence where the signal terminal separates first, triggering voltage reduction before the conductive terminal disconnects. This preliminary voltage reduction protects the conductive terminal from carbon deposition during hot swapping operations, extending the connector's service life while maintaining ease of operation
Solution Approach 2:
The patent implements feedback through the protrusion mechanism that detects the disconnection state of the signal terminal and automatically triggers the voltage reduction sequence. This feedback loop ensures that voltage is reduced in response to the disconnection event, preventing carbon deposition and extending service life without requiring manual intervention
3Speed
If the conductive terminal is disconnected first during unplugging, then the disconnection speed is improved, but electric arc occurs causing safety concerns and temperature rise
Solution Approach 1:
The patent applies inversion by reversing the conventional disconnection sequence. Instead of disconnecting the conductive terminal first for speed, the design disconnects the signal terminal first, which triggers voltage reduction. This inverted sequence prioritizes safety by ensuring voltage is reduced before the conductive terminal separates, preventing electric arc while still achieving rapid disconnection
4Productivity
If the output voltage is not reduced before disconnection, then the power transmission efficiency is maintained, but contact resistance increases due to carbon deposition
Solution Approach 1:
The patent applies preliminary action by reducing the output voltage before the conductive terminal disconnects from the contact pin. This voltage reduction occurs during the first stage of disconnection when the signal terminal has already separated but the conductive terminal remains connected, preventing carbon deposition and maintaining low contact resistance for future connections while minimizing impact on overall power transmission efficiency
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 effectively prevents electric arcs and carbon deposition, prolonging the connector's service life and ensuring safety by maintaining the conductive terminal connection while reducing the voltage during unplugging.
Implementation Method 1
the conductive terminal includes a conductive elastic arm... the signal terminal includes a signal elastic arm
Implementation Method 2
A protrusion elastically connected with the housing base is utilized to control the disconnection sequences
Implementation Method 3
the power supply system connected to the connector controls the output voltage to be decreased or stops the output voltage in advance
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A connector (1, 1a) is disclosed and includes a housing base (10, 10a), a conductive terminal (30), a signal terminal (40) and a protrusion (20, 20a). A sleeve (92) of an electronic device end (9) sleeves on the housing base (10, 10a) through an opening end (12) along a first direction and slides a first displacement distance (D1), plural contact pins of the electronic device end (9) slide into the accommodation space (11) through the opening end (12), and a conductive contact pin (91a) of the electronic device end (9) is interfered with the conductive terminal (30) to form an electrical connection. The protrusion (20, 20a) is elastically connected to the housing base (10, 10a) and penetrates through the housing base (10, 10a). When the sleeve (92) passes through the opening end (12) and slides a second displacement distance (D2) greater than the first displacement distance (D1), the protrusion (20, 20a) is interfered with the sleeve (92) and drives the signal terminal (40), so that the signal terminal (40) pushes against a signal contact pin (91b) of the electronic device end (9) to form an electrical connection.