Hybrid Power Connector Layout for High-Current Signal Integration
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Solution Overview
Problem
Conventional communication power modules face challenges in high material costs, complex manufacturing processes, limited space utilization, and inefficient assembling due to the arrangement of signal and power outputs, requiring additional materials and space for copper bars and circuit boards.
Innovation Solution
A hybrid power connector design with power inputs and outputs on opposite sides, utilizing copper sheets with screw-fixing holes, and signal inputs connected to signal outputs through the circuit board trace, optimizing material use and assembly by guiding docking pins for easy connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If large-area copper bars are used on the circuit board for heat dissipation, then heat dissipation capability is improved, but material cost and manufacturing complexity increase
Solution Approach 1:
The patent extracts the high-current power transmission function from the circuit board and relocates it to a dedicated connector with separate power terminals. This removes the burden of handling large currents and associated heat dissipation requirements from the circuit board, eliminating the need for large-area copper bars and complex multi-layer board designs.
Solution Approach 2:
The connector is segmented into distinct power transmission components and signal transmission components. Power inputs and power outputs are separated and dedicated to specific terminals, allowing independent optimization of power handling capabilities without affecting signal integrity or requiring complex integrated solutions.
2Power
If the system output current is increased, then power supply capability is improved, but space requirement and manufacturing complexity increase
Solution Approach 1:
The connector utilizes three-dimensional spatial arrangement of terminals within the housing to accommodate high-current power transmission capabilities. By arranging power inputs and outputs in specific spatial configurations and using vertical stacking of connection layers, the design achieves high power capability without proportionally increasing the footprint area.
3Ease of manufacture
If signal pins and power outputs are located at the rear side of the connector, then connection is simplified, but space utilization and assembling efficiency worsen
Solution Approach 1:
The connector merges signal inputs and power inputs into a unified front-side interface, while power outputs are positioned at the rear. This integrated arrangement allows simultaneous connection of both signal and power lines through a single docking action, eliminating the need for separate assembly operations and improving overall assembling efficiency.
4Reliability
If additional wire is assembled on the sheet metal for grounding, then grounding capability is improved, but material cost increases
Solution Approach 1:
The connector housing and terminal structure serve multiple functions simultaneously: they provide mechanical support, electrical insulation, and integrated grounding paths. The housing itself is designed to function as a grounding element, eliminating the need for separate grounding wires and reducing material requirements while maintaining reliable grounding capability.
Data Source
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AI summary
A connector (1) is disclosed and includes a main body (2), a circuit board (3) and a signal connection socket (4). The main body (2) includes an input side (S1), an output side (S2), power inputs (10), signal inputs (40), power outputs (20) and signal outputs (41). The input side (S1) is opposite to the output side (S2), the power inputs (10) and the signal inputs (40) are arranged on the input side (S1) respectively, the power outputs (20) are arranged on the output side (S2), the power outputs (20) are electrically connected to the power inputs (10), and the signal outputs (41) are disposed on a bottom side (S4) and electrically connected to the signal inputs (40). The bottom side (S4) is connected between the input side (S1) and the output side (S2). The circuit board (3) includes an upper surface (31), and the bottom side (S4) is attached to the upper surface (31). The signal connection socket (4) is disposed on the upper surface (31) and electrically connected to the signal outputs (41) through the circuit board (3).