Nickel-Copper Power Connector Terminals
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Solution Overview
Problem
Existing power connectors, particularly those used in portable devices, face challenges in carrying larger currents due to high electrical resistance and rapid temperature increase, which can be harmful to the connectors and devices.
Innovation Solution
A power connector design featuring conductive terminals made of nickel-copper with resilient contact arms forming concentric circles, providing a higher electrical conductivity than phosphor-copper contacts, and incorporating a shield for heat dissipation, allowing for reduced electrical resistance and efficient current carrying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphor-copper contacts are used in power connectors, then manufacturing cost is reduced, but electrical conductivity is insufficient leading to rapid temperature increase when carrying large current
Solution Approach 1:
The patent changes the material parameter of the conductive contacts from phosphor-copper to nickel-copper alloy, which has higher electrical conductivity. This material substitution directly addresses the temperature increase issue by reducing electrical resistance and associated Joule heating when carrying large currents
Solution Approach 2:
The patent uses nickel-copper composite material for the conductive contacts, combining the advantages of both metals: copper provides high electrical conductivity while nickel adds strength and thermal stability. This composite material solution resolves the contradiction between current carrying capacity and temperature control
2Reliability
If conventional power connector design is used, then device complexity is low, but current carrying capacity is insufficient for high-performance portable devices
Solution Approach 1:
The patent segments the conductive contacts into multiple resilient arms (typically four arms per contact) arranged in concentric circles. Each arm independently carries current and provides spring pressure, distributing the current load and improving overall current carrying capacity while maintaining a relatively simple overall structure
Solution Approach 2:
The patent employs a nested structure where the first conductive contact's resilient arms form an outer circle and the second conductive contact's resilient arms form an inner circle. This concentric arrangement allows both contacts to be integrated in a compact space, enhancing power transmission performance without significantly increasing device complexity
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 nickel-copper terminals effectively manage higher current loads with lower temperature increases, meeting the demand for high-performance power connectors by reducing electrical resistance and enhancing heat management.
Implementation Method 1
the conductive terminals are made of metal plate with electrical conductivity higher than 30% IACS
Data Source
AI summary
A power connector comprises an insulative housing (1), a first and a second conductive terminals (3, 4) arranged in the housing, each terminal comprising a main body (31, 41), a plurality of resilient contact arms (32, 42) extending forwardly from the main body. The resilient contact arms (32, 42) of the first and the second conductive terminals respectively form an outer circle and an inner circle, and the conductive terminals (3, 4) are made of metal plate with electrical conductivity higher than 30% IACS.