Composite Conductive Fastener for High-Current Electrical Assemblies
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Solution Overview
Problem
Traditional fasteners for electrical assemblies face limitations in handling large currents and thermal loads due to dimensional and material constraints, compromising their strength and conductivity.
Innovation Solution
A fastener design incorporating a shaft made of a first material, such as steel, and a head made of a second material, like copper or brass, which is more electrically and thermally conductive, along with a conductive spring element and a thermal interface module to manage heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fasteners use high-strength materials like steel, then mechanical strength is improved, but electrical and thermal conductivity deteriorates
Solution Approach 1:
The fastener combines two different materials: a steel shaft for mechanical strength and a copper or brass head for electrical and thermal conductivity. This composite structure allows each material to perform its optimal function, resolving the contradiction between strength and conductivity requirements.
Solution Approach 2:
Different parts of the fastener are made from different materials optimized for their specific functions: the shaft (requiring strength) is made of steel, while the head (requiring conductivity) is made of copper or brass. This local differentiation of material properties resolves the contradiction by matching material characteristics to functional requirements.
2Reliability
If fastener dimensions are increased to handle larger currents and thermal loads, then electrical and thermal conductivity is improved, but mechanical strength and compactness deteriorates
Solution Approach 1:
The copper or brass head material provides superior electrical and thermal conductivity without requiring increased dimensions, while the steel shaft maintains mechanical strength. This material composition allows the fastener to handle large currents and thermal loads effectively without compromising strength or compactness.
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
Enhances electrical conductivity and thermal management while maintaining mechanical strength, allowing for efficient heat transfer and secure electrical connections.
Implementation Method 1
the second material is more electrically conductive and/or thermally conductive than the first material
Implementation Method 2
the second material is more electrically conductive and/or thermally conductive than the first material
Implementation Method 3
The head can include a trough defined in a top surface thereof configured to receive a conductive spring element
Implementation Method 4
a thermal interface module in thermal communication with the head for drawing heat away from the fastener
Data Source
AI summary
In accordance with at least one aspect of this disclosure, a fastener can include a shaft comprising a first material. The fastener can include a head attached to the shaft comprising a second material, wherein the second material is more electrically conductive and/or thermally conductive than the first material.