Modular Power Connector With Configurable Cable Exit and Latch
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Solution Overview
Problem
Existing charging connectors for mobile devices are prone to damage due to stress, strain, bending, pulling, or impact, and are costly to redesign for different applications.
Innovation Solution
A modular and configurable supply charging device with a separable interface between the front and rear housings, featuring interchangeable rear ends to change cable exit directions, and a latching mechanism for secure coupling with the mobile device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed, non-modular charging connector design is used, then manufacturing and redesign costs are high for different applications, but the connector lacks adaptability to various charging configurations
Solution Approach 1:
The charging connector is divided into separate modular components: a front housing containing the contact assembly and a rear housing containing the cable assembly. These modules can be independently manufactured and then assembled together, allowing different configurations to be created by combining the same front housing with different rear housing variations, thereby reducing overall manufacturing costs while increasing adaptability.
Solution Approach 2:
The front housing with the contact assembly is designed as a universal component that can work with multiple types of rear housings and cable configurations. This universal interface allows a single front housing design to support various charging applications by simply changing the rear housing or cable assembly, eliminating the need to redesign the entire connector for different applications.
2Strength
If the housing is made as a single integrated piece, then manufacturing is simpler, but the connector cannot be easily configured for different applications and is more prone to damage from stress and strain
Solution Approach 1:
The housing is segmented into a front housing and a rear housing that are separable and can be independently replaced. This segmentation allows the front housing (containing precision contact components) to be protected from damage by separating it from the rear housing (containing the cable connection point) that absorbs mechanical stress, pulling, and bending forces. Each module can be optimized for its specific function without compromising the other.
Solution Approach 2:
The contact assembly is extracted into a separate, replaceable module within the front housing. This allows the contact assembly to be independently replaced if damaged, without needing to replace the entire housing. The separation enables targeted repair and replacement, reducing overall device complexity while improving strength and durability.
3Adaptability or versatility
If the cable exit is fixed in one direction, then the connector structure is simpler, but it cannot accommodate different cable routing requirements for various applications
Solution Approach 1:
The connector design incorporates dynamic configurability through interchangeable rear housing modules that can be attached to the front housing. Each rear housing module is designed with a specific cable exit direction (e.g., right angle, straight through, angled), allowing the connector to adapt its cable routing configuration based on the specific application requirements. The modular attachment mechanism enables quick reconfiguration without complex structural changes.
Solution Approach 2:
The cable exit direction parameter is changed by selecting different rear housing modules rather than redesigning the entire connector structure. By varying the rear housing configuration while keeping the front housing constant, the system achieves multiple cable routing orientations (different angles and directions) without increasing overall device complexity. This parameter-based approach allows flexible adaptation to different applications.
Data Source
AI summary
A supply charging device includes a supply power connector having a supply housing having a mating end mated with a receive power connector of the mobile device along a mating axis. The supply housing includes a front housing and a rear housing separate and discrete from the front housing coupled to the front housing at a separable interface. The rear housing includes a cable chamber and the front housing includes a contact chamber. The supply charging device includes a latch latchably coupled to the receive power connector. The supply charging device includes a contact assembly held by the rear housing with pins of contacts received in the contact chamber. The supply charging device includes a cable assembly coupled to the contact assembly and extending from the cable end.