Type-C Charging Connector with Fork Terminals and Cooling Plates
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Solution Overview
Problem
Type-C connectors face challenges in manufacturing cost due to compact terminal design and complex configuration, which increases temperature and makes it difficult to produce a low-cost charging connector with reduced terminal count and a stopper mechanism.
Innovation Solution
A charging connector design featuring fork terminals with cooling plates and a reinforcing shell, providing a stopper mechanism and insulation, with a base part and cutout portions for gripping the circuit board, and an insertion port with reduced opening area to prevent foreign objects, allowing for increased current capacity and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a Type-C connector uses compact terminal members to achieve high integration, then the connector can supply higher power (20V, 5A, 100W), but the current capacity of the common circuit increases temperature
Solution Approach 1:
The connector is divided into two separate circuits: a signal circuit with four terminals for data communication and a power circuit with two terminals (positive and negative) for power supply. This segmentation allows the power circuit to handle higher currents independently without overloading the signal circuit's common ground and power lines, thus preventing excessive temperature rise while maintaining high power capability.
2Reliability
If a Type-C connector includes a stopper mechanism and compact terminal members, then it complies with USB Type-C standard, but the configuration becomes complex and manufacturing cost increases
Solution Approach 1:
The stopper mechanism is extracted as a separate component that can be independently assembled into the connector housing, rather than being integrated into the terminal members themselves. This allows the terminal members to remain simple and compact while the stopper mechanism provides the necessary mechanical constraint, reducing overall complexity and easing manufacturing.
3Ease of manufacture
If a Type-C connector reduces the number of terminals for charging only function, then manufacturing cost can be lowered, but high accuracy process for arranging small terminal members is still required
Solution Approach 1:
The connector uses larger, more robust terminal members for the power circuit that are easier and less expensive to manufacture and assemble than the compact Type-C standard terminals. These terminals can be produced with lower precision requirements while still achieving reliable electrical connection, thereby reducing manufacturing cost without sacrificing functionality.
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 achieves a margin in current capacity and reduces manufacturing costs by using larger volume fork terminals, improved heat dissipation, and a simplified assembly process, while maintaining the Type-C standard compatibility.
Implementation Method 1
the fork terminals may be provided with cooling plates
Data Source
AI summary
A charging connector comprising: a pair of power supply terminals for pinching power supply terminals of a Type-C plug connector complying with the USB connector standard from both sides, and a pair of grounding terminals and for pinching qrounding terminals of the plug connector from both sides; wherein the power supply terminals and the grounding terminals are configured by fork terminals.