Power Interface Manufacturing via Punching Shear and Integrated Pins
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Solution Overview
Problem
The manufacturing processes of mobile terminals are cumbersome and costly, hindering market competitiveness due to complex and expensive production methods.
Innovation Solution
A power interface design with a housing, connection body, and power pins that are solid and integrated to enhance current-carrying capacity, featuring a specific cross-sectional area and thickness to support high charging efficiency, and a method for manufacturing these components using fine blanking or punching shear processes to reduce costs and simplify production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing processes are used for mobile terminals, then manufacturing flexibility is maintained, but manufacturing complexity increases and costs rise
Solution Approach 1:
The patent merges the power pin and connection body into a single integrated component. The power pin is formed as an integral part of the connection body through injection molding, eliminating the need for separate assembly steps. This integration simplifies the manufacturing process, reduces the number of parts, and lowers production costs while maintaining manufacturing flexibility.
Solution Approach 2:
The connection body serves multiple functions: it provides structural support, houses the power pins, enables electrical connection to the circuit board, and facilitates assembly with the housing. This multi-functionality reduces the number of separate components needed, simplifying the overall manufacturing process and reducing complexity.
2Power
If power pins are made with larger cross-sectional area to increase current-carrying capacity, then charging efficiency improves, but device size increases
Solution Approach 1:
The patent optimizes the power pin geometry by adjusting its cross-sectional shape and dimensions. The power pin features a specific cross-sectional area that is optimized to provide high current-carrying capacity while maintaining a compact form factor. The connection body is designed with precise dimensional parameters that allow the power pins to be closely spaced, maximizing power capacity within a limited volume.
3Manufacturing precision
If multiple processing steps are used to manufacture power pins, then manufacturing precision improves, but production time increases
Solution Approach 1:
The patent incorporates the power pins directly into the connection body during the injection molding process. The power pins are formed as integral parts of the connection body, eliminating the need for subsequent separate manufacturing and assembly steps. This preliminary action ensures precise dimensional accuracy and positional alignment while significantly reducing production cycle time.
Solution Approach 2:
The manufacturing process merges the formation of the power pins and connection body into a single injection molding operation. This integration eliminates multiple processing steps, reduces assembly operations, and maintains high manufacturing precision through the inherent accuracy of injection molding while accelerating production.
Data Source
AI summary
A method for manufacturing a power interface is provided. The method may includes: providing a pin workblank and disposing the pin workblank on a first mold; and performing a punching shear process on the pin workblank by a second mold, thereby forming a power pin of the power interface without a process of removing burrs. A power interface is also provided.