Power Supply Connector with Segmented Pins for Heat and Size
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Solution Overview
Problem
Conventional power supply connectors for battery packs face challenges in downsizing while maintaining accuracy for low current charging and volumetric efficiency, as well as ensuring reliable heat radiation and connection strength for large current charging, leading to increased size and cost.
Innovation Solution
The power supply connector is designed with positionally divided large current charging connector parts and a low current charging connector part disposed between them, along with flat surface connector pins for increased contact area with the circuit board or metal plate, enhancing heat radiation and connection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large-diameter large current charging connector pin is used, then large current charging capability is achieved, but the volumetric efficiency of the power supply connector is reduced
Solution Approach 1:
The connector pins are divided into two distinct types: large-diameter pins for large current charging and small-diameter pins for low current charging. This segmentation allows each pin type to be optimized for its specific function, with large pins providing high power capability and small pins maintaining compact dimensions, thereby resolving the contradiction between power capability and volumetric efficiency.
2Power
If a large-diameter large current charging connector pin is used, then large current charging capability is achieved, but the cross-sectional area of connecting wiring increases leading to increased heat generation
Solution Approach 1:
Different connector pins are assigned different diameters according to their specific current requirements. Large-diameter pins are used only where high current flows, while small-diameter pins are used for low current applications. This local differentiation optimizes the cross-sectional area of connecting wiring for each specific connection, minimizing heat generation in low current paths while maintaining high power capability where needed.
3Power
If a large-diameter large current charging connector pin is used, then large current charging capability is achieved, but the connecting work becomes difficult and connection strength is reduced
Solution Approach 1:
The connector system is segmented into large-diameter pins for high current applications and small-diameter pins for low current applications. Each pin type has optimized dimensions that facilitate appropriate connection methods - large pins can be securely mounted with screws for strong mechanical attachment, while small pins are easier to handle and connect, thereby improving overall manufacturability and connection strength for each specific application.
4Adaptability or versatility
If two types of insertion parts and two types of connector pins are provided, then both large current charging and low current charging are supported, but the device complexity increases
Solution Approach 1:
The power supply connector is designed with universal functionality to accommodate both large current charging plugs and low current charging plugs through a single connector body. By integrating both large-diameter and small-diameter connector pins within one unified structure, the system achieves multi-functionality, allowing the same connector to serve dual purposes and thereby reducing the need for separate connectors for different charging types.
Data Source
AI summary
A power supply connector is provided, which is applicable to both large current charging and low current charging, the power supply connector being able to not only maintain the accuracy of monitoring low current charging and the volumetric efficiency of a board by appropriately arranging two types of connector parts, but also contribute to the downsizing of the power supply connector and improvement of the reliability thereof by striking a balance between the volumetric efficiency and the heat radiation characteristics, and ensure safety in the use of the power supply connector while reducing the cost. Insertion holes 4 and connector pins 2 that configure a large current charging connector part are disposed in the vicinity of both ends of the power supply connector 1. There are disposed a plug insertion hole 9 and low current charging connector pins 11 that configure a low current charging connector part held between the insertion holes 4 and the connector pins 2.