Stacked Power Card Edge Terminals for Higher Current and Contact Stability
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Solution Overview
Problem
Existing hybrid power card edge connectors face challenges in enhancing power current and mechanical strength while considering material and mass-production costs.
Innovation Solution
A power card edge connector design featuring an insulating housing with stacked inner and outer pieces, each with elastic portions that form multiple contacting points to enhance power current capacity, and a unique configuration to prevent over-movement of the contacting portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If two-piece power terminals are used to enlarge power current and mechanical strength, then power current capacity and mechanical strength are improved, but material cost and manufacturing complexity increase
Solution Approach 1:
The power terminal is divided into an inner piece and an outer piece that are stacked together. The inner piece includes a first retaining portion and a first elastic portion, while the outer piece includes a second retaining portion and a second elastic portion. This segmentation allows the terminal to achieve enhanced mechanical strength and power current capacity through the combined structure of multiple components, while each component can be manufactured separately to control complexity.
Solution Approach 2:
The inner piece is nested within the outer piece, with the first elastic portion positioned inside the second elastic portion. The first contacting portion is surrounded by the second contacting portion, creating a nested configuration that maximizes space utilization and enhances current carrying capacity without proportionally increasing overall size or complexity.
2Power
If two-piece power terminals are used to enlarge power current, then power current capacity is improved, but material cost and manufacturing complexity increase
Solution Approach 1:
The power terminal is segmented into inner and outer pieces with separate elastic portions and contacting portions. This allows the terminal to distribute current through multiple parallel paths (first contacting portion and second contacting portion), thereby enlarging power current capacity while maintaining manageable complexity through modular design.
Solution Approach 2:
The inner piece and outer piece are combined in a stacked configuration where their contacting portions work together to carry current. The first contacting portion and second contacting portion are merged in space to provide multiple current paths, achieving enhanced power capacity through combination rather than through a single complex component.
3Reliability
If elastic portions are designed to be slantwise extending, then contact stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The elastic portions are designed with slantwise extension in specific local areas (the elastic portions themselves) while other areas (retaining portions) maintain simpler geometries. This localized complexity approach improves contact stability where needed without requiring high precision throughout the entire component, reducing overall manufacturing difficulty.
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 improves power current capacity and mechanical strength, ensuring stable connections and efficient power transmission.
Implementation Method 1
the first elastic portion defines a first contacting portion, the second elastic portion is split into a second contacting portion and an abutting portion separated from each other, the first contacting portion and the second contacting portion are arranged side by side in the extending direction and protrude into the card slot, and the first contacting portion is pushable outward to abut against the abutting portion
Data Source
AI summary
A power card edge connector includes: a housing defining a card slot; and a power terminal comprising an inner piece and an outer piece stacked together, the inner piece comprising a first retaining portion and a first elastic portion, the outer piece comprising a second retaining portion and a second elastic portion, the first and second retaining portions attached together, wherein the first elastic portion defines a first contacting portion, the second elastic portion is split into a second contacting portion and an abutting portion separated from each other, the first and second the contacting portions are arranged side by side and protrude into the card slot, and the first contacting portion is pushable outward to abut against the abutting portion.