Composite Fastener Head 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 for enhanced heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fasteners use dimensional and material limitations to maintain strength, then mechanical strength is preserved, but electrical and thermal conductivity deteriorate
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 have different material properties optimized for their specific functions. The shaft region requires high strength for mechanical fastening, while the head region requires high conductivity for electrical and thermal performance. This localized material differentiation resolves the contradiction by matching material properties to functional requirements.
2Reliability
If traditional fasteners increase dimensional size to handle large currents and thermal loads, then electrical and thermal conductivity is improved, but mechanical strength and compactness deteriorate
Solution Approach 1:
The copper or brass head material provides superior electrical and thermal conductivity without requiring increased dimensions. The high conductivity of these materials allows the fastener to handle large currents and thermal loads while maintaining a compact size, resolving the contradiction between load handling capability and dimensional constraints.
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 provides improved electrical conductivity and thermal management while maintaining mechanical strength, allowing for efficient heat transfer and secure connections in electrical assemblies.
Implementation Method 1
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
Implementation Method 2
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
Implementation Method 3
The trough can be annular and configured to receive an annular conductive spring element
Implementation Method 4
configured to receive a conductive spring element... receive an annular conductive spring element
Implementation Method 5
a thermal interface module in thermal communication with the head for drawing heat away from the fastener
Implementation Method 6
a thermal interface module in thermal communication with the head for drawing heat away from the fastener
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E
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.