Reversible DC Charging Connector Layout for 20 A Power
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Solution Overview
Problem
Conventional DC charging connectors are limited by a maximum current of 5 A, which is insufficient for high power consumption electronic devices, and there is a need for improved charging solutions to support higher power levels.
Innovation Solution
The design of high power DC charging connectors and plugs with wider positive and negative boards, resilient boards, and signal terminals, allowing for increased current capacity and structural strength, enabling insertion in either direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional DC charging connectors are used, then the connector size can be reduced, but the maximum current is limited to 5 A which is insufficient for high power consumption devices
Solution Approach 1:
The connector is divided into multiple independent contact boards (first positive board, first negative board, second positive board, second negative board) arranged on different surfaces of the insulation tongue. This segmentation allows each board to be optimized for high current carrying capacity while maintaining a compact overall connector structure that meets size standards.
2Power
If wider positive and negative boards are used to increase current capacity, then the maximum current can be increased to 20 A, but the structural complexity of the connector increases
Solution Approach 1:
Multiple contact boards (first positive board, first negative board, second positive board, second negative board) are integrated onto a single insulation tongue structure. This merging approach consolidates the complex multi-board arrangement into one unified component, reducing assembly complexity while maintaining the high current capacity of 20 A through the combined width of all boards.
3Power
If multiple positive and negative boards are mounted on the insulation tongue, then the current capacity increases, but the manufacturing complexity increases
Solution Approach 1:
The first positive board, first negative board, second positive board, and second negative board are pre-mounted onto the insulation tongue as an integrated assembly. This preliminary action of pre-assembly simplifies the manufacturing process by reducing the number of separate assembly steps required, while still achieving the high current capacity through the multi-board configuration.
Data Source
AI summary
A high power direct-current (DC) charging socket connector and a DC charging plug connector, each of one the DC charging socket and plug connectors has two pair of power electrode boards arranged on the upper and lower rows of a corresponding one of the connectors. The electrode boards on the upper row have only a single one positive board and a single one negative board. The electrode boards on the lower row have only a single one positive board and a single one negative board and are arranged alternatively with the single one positive board and the single one negative board on the upper row. Thus, the DC charging socket and plug connectors can support reverse insertion. Therefore, the width of each board can be as large as possible with the connector size standards to increase the withstand current value to achieve the high power charging effect.