Double-Row Power Connector Layout for High Current and Soft Plugging
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Solution Overview
Problem
The staggered single-row design of power terminals in existing power connectors limits the current-carrying capacity and results in a harder plugging force, failing to meet the increasing demands for higher power transmission requirements.
Innovation Solution
The power connector design includes multiple power terminals with elastic arms arranged in a staggered and symmetric configuration, forming double rows of contact points to increase current-carrying area and reduce heat generation, while ensuring a softer insertion and extraction force through peak-staggered contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If power terminals are arranged in a staggered single-row design, then the device complexity is reduced, but the current-carrying capacity is limited
Solution Approach 1:
The patent transitions from a single-row staggered design to a double-row design where elastic arms are arranged in two parallel rows on opposite sides of the mating slot. This dimensional change from one row to two rows effectively doubles the current-carrying area while maintaining the staggered configuration benefits, directly resolving the contradiction between simplicity and current-carrying capacity.
2Ease of manufacture
If power terminals use a single-row staggered configuration, then the manufacturing process is simplified, but the power transmission capacity is insufficient
Solution Approach 1:
The patent combines two rows of elastic arms working together to achieve higher power transmission capacity. Each row maintains the simple staggered configuration for ease of manufacture, while the combination of both rows provides the increased current-carrying area needed for high power transmission, thus resolving the contradiction between manufacturing simplicity and power capacity.
3Force
If contact surfaces are arranged in a single row, then the insertion force is concentrated, but the plugging force becomes harder
Solution Approach 1:
The patent segments the contact surfaces into two separate rows on opposite sides of the mating slot. This segmentation distributes the insertion force across two rows rather than concentrating it in one row, resulting in a softer plugging force during insertion and extraction operations, directly addressing the contradiction between force concentration and ease of operation.
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 design enhances current transmission capacity and reduces heat generation while providing a softer plugging force by increasing the contact area and optimizing the insertion and extraction process.
Implementation Method 1
The first elastic arm includes a first contact surface; the second elastic arm includes a second contact surface; the third elastic arm includes a first deflecting portion; the fourth elastic arm includes a second deflecting portion
Data Source
AI summary
A power connector includes an insulating body, a first power terminal, a second power terminal, a third power terminal and a fourth power terminal. The first power terminal includes a first elastic arm having a first contact surface. The second power terminal includes a second elastic arm having a second contact surface. The third power terminal includes a first deflecting portion and a third contact surface. The fourth power terminal includes a second deflecting portion and a fourth contact surface. The first contact surface and the third contact surface are disposed at intervals along a first direction to form double rows of contact points. The second contact surface and the fourth contact surface are disposed at intervals along the first direction to form double rows of contact points.