Patent Application
20240097357
The present disclosure relates to contact pads with modifications to surfaces thereof for enhanced electrical connectivity.
A power-receiving unit may be configured to receive an electrical current from a power-supplying unit in order to perform a particular function. For instance, the power-receiving unit may have electrical contacts configured to engage with corresponding electrical contacts of the power-supplying unit so as to receive the electrical current. However, an electrical connection between the power-receiving unit and the power-supplying unit may be unstable and/or inconsistent.
At least one embodiment relates to an electrical contact pad (e.g., for a power-receiving unit). In an example embodiment, the electrical contact pad includes a conductive component including at least one surface discontinuity configured to enhance an electrical connection therewith.
In an example embodiment, the conductive component has a planar segment with the at least one surface discontinuity.
In an example embodiment, the at least one surface discontinuity includes one or more structurally-vulnerable portions configured to serve as focused points of contact during an establishment of the electrical connection.
In an example embodiment, the one or more structurally-vulnerable portions are configured to physically yield during the establishment of the electrical connection.
In an example embodiment, the at least one surface discontinuity includes one or more edges.
In an example embodiment, the at least one surface discontinuity includes a rim.
In an example embodiment, the at least one surface discontinuity is a machined portion of the conductive component that is configured to receive an electric current.
In an example embodiment, the at least one surface discontinuity is an opening in a surface of the section.
In an example embodiment, the opening is a recess.
In an example embodiment, the recess is a dimple.
In an example embodiment, the opening is a through hole in the conductive component.
In an example embodiment, the opening has a shape of a circle.
In an example embodiment, the circle has a diameter between 0.3 mm to 0.5 mm.
In an example embodiment, the at least one surface discontinuity is a chamfer on a surface of the conductive component.
At least one embodiment relates to a heater. In an example embodiment, the heater includes a first end section, an intermediate section, and a second end section. The first end section and the second end section each have at least one surface discontinuity configured to enhance an electrical connection therewith.
In an example embodiment, the at least one surface discontinuity includes one or more structurally-vulnerable portions configured to serve as focused points of contact during an establishment of the electrical connection.
At least one embodiment relates to a power-receiving unit. In an example embodiment, the power-receiving unit includes a pair of electrical contact pads each having at least one surface discontinuity configured to enhance an electrical connection therewith.
In an example embodiment, the pair of electrical contact pads are part of an exterior surface of the power-receiving unit.
At least one embodiment relates to an electronic device. In an example embodiment, the electronic device includes a power-receiving unit and a power-supplying unit. The power-receiving unit includes a pair of electrical contact pads each having at least one surface discontinuity. The power-supplying unit includes connector pins configured to engage with the at least one surface discontinuity of each of the pair of electrical contact pads so as to establish an electrical connection with the power-receiving unit.
In an example embodiment, the connector pins include voltage pins configured to engage with the at least one surface discontinuity of each of the pair of electrical contact pads.
The various features and advantages of the non-limiting embodiments herein may become more apparent upon review of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are merely provided for illustrative purposes and should not be interpreted to limit the scope of the claims. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. For purposes of clarity, various dimensions of the drawings may have been exaggerated.
Some detailed example embodiments are disclosed herein. However, specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.
Accordingly, while example embodiments are capable of various modifications and alternative forms, example embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed, but to the contrary, example embodiments are to cover all modifications, equivalents, and alternatives falling within the scope of example embodiments. Like numbers refer to like elements throughout the description of the figures.
It should be understood that when an element or layer is referred to as being “on,” “connected to,” “coupled to,” or “covering” another element or layer, it may be directly on, connected to, coupled to, or covering the other element or layer or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout the specification. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
It should be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, regions, layers and/or sections, these elements, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, region, layer, or section without departing from the teachings of example embodiments.
Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper,” and the like) may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the term “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
The terminology used herein is for the purpose of describing various example embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” specify the presence of stated features, integers, steps, operations, and/or elements, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and/or groups thereof.
When the terms “about” or “substantially” are used in this specification in connection with a numerical value, it is intended that the associated numerical value includes a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical value. Moreover, when the terms “generally” or “substantially” are used in connection with geometric shapes, it is intended that precision of the geometric shape is not required but that latitude for the shape is within the scope of the disclosure. Furthermore, regardless of whether numerical values or shapes are modified as “about,” “generally,” or “substantially,” it will be understood that these values and shapes should be construed as including a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical values or shapes.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
As used herein, “coupled” includes both removably coupled and permanently coupled. For example, when an elastic layer and a support layer are removably coupled to one another, the elastic layer and the support layer can be separated upon the application of sufficient force.
In some example embodiments, the electrical contact pads of a power-receiving unit may become coated with an oxide layer. Such an oxide layer may occur naturally when certain metals are exposed to oxygen in the atmosphere. For instance, aluminum is reactive with the oxygen in the atmosphere and, as a result, has a naturally-occurring aluminum oxide layer on all oxygen-exposed surfaces of the aluminum. In another instance, stainless steel (e.g., 316 stainless steel) contains, inter alia, chromium, which is reactive with the oxygen in the atmosphere and, as a result, has a naturally-occurring chromium oxide layer on all oxygen-exposed surfaces of the stainless steel.
While a metal oxide layer may serve as a protective layer (e.g., corrosion resistance) for the underlying metal, the metal oxide layer is also an electrical insulator and, thus, may hinder the transmission of an electrical current. In particular, the presence of a metal oxide layer on the electrical contact pads of a power-receiving unit may interfere with the quality and consistency of an electrical connection with the connector elements (e.g., connector pins) of the power-supplying unit.
To mitigate/address the electrically-insulating effect of the metal oxide layer, an electrical contact arrangement may be configured such that an associated force between the engaging structures is focused on a relatively small surface area so as to increase the likelihood of penetrating (e.g., mechanically and/or electrically) the metal oxide layer and thereby improving the quality and consistency of an electrical connection with the underlying metal. In an example embodiment, an electrical contact pad may be fabricated/modified to introduce at least one surface discontinuity which provides for one or more focused points of contact (e.g., edge(s)) with a corresponding connector when electrically engaged. As used herein, a surface discontinuity should be understood to be disruption in an otherwise smooth and continuous surface. The surface discontinuity (or each of the surface discontinuities) may occupy a contiguous area of about 0.2 mm 2-0.80 mm2 (e.g., 0.4 mm 2-0.6 mm2).
Although the connector pins 653 are shown as each set including three pins, it should be understood that example embodiments are not limited thereto. Specifically, in other instances, the connector pins 653 may include more (e.g., 4 pins per set) or less (e.g., 1-2 pins per set) than the set of three pins shown in the drawings. Additionally, while the connector pins 653 are shown as a set including a voltage pin 653′ between two current pins 653″, it should be understood that other quantities and combinations are possible. Furthermore, while the connector pins 653 and the contact pad 646 are shown as being a part of the power-supplying unit 100 and the power-receiving unit 200, respectively, it should be understood that, in some instances, this configuration may be reversed such that the connector pins 653 and the contact pad 646 are part of the power-receiving unit 200 and the power-supplying unit 100, respectively.
The contact pad 646 may be formed of various conductive materials that are suitable for establishing an electrical connection with the connector pins 653. In particular, the contact pad 646 may be formed of a metal with its outer surface coated with a naturally-occurring oxide of the metal. For instance, the contact pad 646 may be formed of stainless steel, and the chromium in the stainless steel may form a natural layer of chromium oxide on the stainless steel. In such an instance, the contact pad 646 may be regarded as having a base layer/material 647 of stainless steel and an outer/surface layer 648 of chromium oxide. In
The contact pad 646 may be provided with a surface discontinuity 650 (or a plurality of surface discontinuities 650) to enhance the electrical connection between at least one of the connector pins 653 and the contact pad 646. In an example embodiment, the surface discontinuity 650 may be in the form of at least one opening in the surface of the contact pad 646. The opening may have a circular shape, although other shapes may also be utilized (e.g., oval, square, rectangle, diamond, slot). The opening may be provided as a recess/indentation (e.g., dimple) in the contact pad 646. Alternatively, the opening may be provided as a through hole that completely penetrates the contact pad 646. With regard to manufacturing, the contact pad 646 may be punched, stamped, drilled, etched, or otherwise machined before the assembly of the power-receiving unit 200 in order to achieve one or more openings as the surface discontinuity 650. Alternatively, techniques such as drilling may be performed after the assembly of the power-receiving unit 200. As a result of the surface discontinuity 650 in the contact pad 646, a mechanically-vulnerable (e.g., structurally-vulnerable) portion is provided via the rim/edge of the opening which increases the likelihood that a corresponding connector pin 653 will physically pierce, compromise, or otherwise break through this relatively weak point/portion in the outer oxide layer so as to establish a secure and consistent electrical connection with the underlying metal of the contact pad 646.
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The electrical current received by the power-receiving unit may be used to energize, activate, run, or otherwise operate an electrically-powered component, arrangement, or system therein to produce a desired result. In an example embodiment, the electrically-powered component, arrangement, or system may include a heater, light-emitting element (e.g., LED), sensor, motor, and/or display. It should be understood that the various examples of electrically-powered component, arrangement, or system within the power-receiving unit are not exhaustive and are intended to encompass further embodiments known by those of ordinary skill in the art.
In an example embodiment, a power-receiving unit may include a heater that generates heat when an electrical current is received from a power-supplying unit. The heater may include a first end section, an intermediate section, and a second end section. The first end section and the second end section may include external segments of the heater configured to establish an electrical connection with the power-supplying unit (e.g., contact pads for receiving an electrical current from the power-supplying unit). The intermediate section may be a segment (e.g., internal segment) of the heater configured to undergo an increase in temperature so as to generate heat.
A sheet material may be cut or otherwise processed (e.g., stamping, electrochemical etching, die cutting, laser cutting) to produce the heater. In such an instance, the heater will have an integral, continuous form. The sheet material may be formed of one or more conductors configured to undergo Joule heating (which is also known as ohmic/resistive heating). Suitable conductors for the sheet material include an iron-based alloy (e.g., stainless steel, iron aluminides), a nickel-based alloy (e.g., nichrome), and/or a ceramic (e.g., ceramic coated with metal). For instance, the stainless steel may be a type known in the art as SS316L, although example embodiments are not limited thereto. The sheet material may have a thickness of about 0.10 mm-0.30 mm (e.g., 0.15 mm-0.25 mm). The heater may have a resistance between 0.5 Ohm-2.5 Ohms (e.g., 1.0 Ohm-2.0 Ohms).
The terminus of each of the first end section 1342 and the second end section 1346 may be oriented orthogonally to the plane of the intermediate section 1344. Each of the first end section 1342 and the second end section 1346 may also include segments having a sideways J-shape. Furthermore, each of the first end section 1342 and the second end section 1346 may include opposing finger/claw-like structures. The finger/claw-like structures may serve as locating features for manufacturing equipment (e.g., overmolding tool). As a result, the first end section 1342 and the second end section 1346 may be embedded relatively securely within a body or housing of a power-receiving unit while providing a pair of electrical contact surfaces.
Regarding the first end section 1342 and the second end section 1346, which may also be referred to as the contact pads, a surface discontinuity 1350 in a form of an opening may be provided in each of the first end section 1342 and the second end section 1346. The surface discontinuity 1350 may be pre-formed in each of the first end section 1342 and the second end section 1346 prior to the assembly of the power-receiving unit, although example embodiments are not limited thereto.
Regarding the first end section 1342′ and the second end section 1346′, which may also be referred to as the contact pads, a surface discontinuity 1350′ in a form of an opening may be provided in each of the first end section 1342′ and the second end section 1346′. The surface discontinuity 1350′ may be pre-formed in each of the first end section 1342′ and the second end section 1346′ prior to the assembly of the power-receiving unit, although example embodiments are not limited thereto.
In at least some example embodiments and as noted supra, the power-supplying unit may include a power source and a processing or control circuitry. The control circuitry may be hardware including logic circuits; a hardware/software combination such as a processor executing software; or a combination thereof. For example, the control circuitry may include, but is not limited to, a central processing unit (CPU), an arithmetic logic unit (ALU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a System-on-Chip (SoC), a programmable logic unit, a microprocessor, application-specific integrated circuit (ASIC), etc.
It should be understood that the shape of the battery (or batteries) for the power source may vary. For example, the battery may be cylindrical, prismatic, disc-shaped, a pouch battery, or any other variation of battery shape known in the art. Additionally, it should be understood that the battery may be any of a variety of types. For example, in one embodiment, the battery may be a rechargeable battery (e.g., lithium-ion). In another embodiment, the battery may be a non-rechargeable battery (e.g., alkaline). In yet another embodiment, the battery may include silver oxide, carbon zinc, cadmium, nickel, or any another material known in the art. Furthermore, the battery may include a primary cell and/or a secondary cell. It will be understood by those of ordinary skill in the art that various changes in form and details of the battery may be made without departing from the spirit and the scope of the invention.
While some example embodiments have been disclosed herein, it should be understood that other variations may be possible. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. For example, while aspects of the invention have been described with respect to providing improved electrical contact in the presence of an oxide layer, it should be understood that the example embodiments are also applicable and provide improved electrical contact regardless of the presence of an oxide layer (e.g., in the absence of an oxide layer).
Although described with reference to specific examples and drawings, modifications, additions and substitutions of example embodiments may be variously made according to the description by those of ordinary skill in the art. For example, the described techniques may be performed in an order different with that of the methods described, and/or elements such as the described system, architecture, devices, circuit, and the like, may be connected or combined to be different from the above-described methods, or results may be appropriately achieved by other elements or equivalents.
This application claims priority under 35 U.S.C. § 119 to U.S. Provisional Application No. 63/407,932, filed on Sep. 19, 2022, the entire contents of which are hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63407932 | Sep 2022 | US |
