Misalignment-Tolerant USB-C Connector System
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Solution Overview
Problem
Conventional USB Type-C connectors have low tolerance to misalignment, leading to assembly errors and potential damage during charging of portable information handling systems, and existing power adapters do not meet the power requirements of larger devices.
Innovation Solution
A misalignment-tolerant connector system with a robust power interface, featuring an external plug adapter with flexible ribs and conductive pads, and a receptacle adapter with conductive pins, providing increased tolerance to assembly errors and allowing for secure electrical and mechanical connections, including a magnetic interface for easier disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional USB Type-C connectors are used for charging portable information handling systems, then electrical connection is established, but misalignment tolerance is insufficient leading to assembly errors and potential connector damage
Solution Approach 1:
The patent changes the geometric parameters of the connector interface by replacing the conventional slot-shaped USB Type-C connector with a circular barrel connector having a diameter of 7.4mm or 7.6mm. This parameter change fundamentally alters the alignment tolerance characteristics, allowing significantly greater misalignment without damage compared to the tight 0.25mm tolerance of USB Type-C connectors.
Solution Approach 2:
The patent employs a sacrificial align feature (such as a protrusion or tab) on the connector that can break or deform to absorb misalignment stress, protecting the more expensive and critical electrical contact elements. This allows the connector to withstand assembly errors without damaging the primary functional components.
2Manufacturing precision
If USB Type-C connectors are used with strict alignment requirements, then electrical connection precision is improved, but assembly complexity increases due to need for precise alignment
Solution Approach 1:
The connector is segmented into distinct functional elements: an align feature (protrusion or tab) that handles mechanical alignment, and separate electrical contact elements. This segmentation allows the align feature to absorb assembly variations while the electrical contacts maintain precise connection, simplifying the overall assembly process.
Solution Approach 2:
The patent adopts a circular barrel connector geometry instead of the slot-shaped USB Type-C connector. The circular shape provides rotational symmetry and greater tolerance to angular misalignment, eliminating the need for precise orientation during assembly while maintaining reliable electrical connection.
3Weight of moving object
If conventional power adapters with low power output are used, then portability is improved, but power delivery capability is insufficient for larger portable information handling systems
Solution Approach 1:
The charging dock is designed to accommodate multiple types of portable information handling systems (laptops, tablets, smartphones) with different power requirements. The system provides universal charging capability through a standardized circular barrel connector interface that can deliver high power to larger devices while remaining compact for portability.
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 connector system effectively withstands misalignment errors and reduces the risk of connector damage, enabling reliable USB Type-C charging with improved alignment tolerance and reduced stress, thus extending the lifespan of the connectors.
Implementation Method 1
conventional power adapters for micro-USB, USB Type-C, and Lightning connectors include magnetic adapter 204 that couples to power adapter 202
Data Source
AI summary
A connector system enables charging of a portable information handling system in a charging dock. The connector system has improved tolerance to misalignment of male and female connectors to facilitate engagement when the portable information handling system is inserted into a charging dock. An embodiment of a receptacle adapter is disposed such that there is only one orientation for power connector engagement. An embodiment of the charging dock has an angular tilt that causes a partial weight component of the portable computer to contribute to positive engagement of the external plug adapter and receptacle adapter. An embodiment of the connector system includes a power interface including conductive pads and pogo pins. The conductive pads have contact surfaces that tolerate alignment variation between the pogo pins and the conductive pads. An embodiment of the connector system is a USB Type-C power adapter connector system.