Connector Assembly With Flexible Heat Path for Compact Cooling
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Solution Overview
Problem
Existing connectors face challenges in dissipating heat generated at the connection points between terminal fittings and conductive components due to limited space and the need for miniaturization, leading to potential component deterioration.
Innovation Solution
A connector unit design featuring a flexible heat transfer member sandwiched between a fixing fitting and a metal frame member, allowing heat to be transferred efficiently while maintaining a compact size, utilizing the frame member's high thermal conductivity and large heat capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a dedicated heat dissipation member (e.g., heat dissipation fin) is attached to the outside of the connector, then heat dissipation performance is improved, but the connector size increases and available space is consumed
Solution Approach 1:
The heat transfer member is integrated into the existing connector structure by being sandwiched between the fixing fitting and frame member, merging the heat dissipation function with the structural components rather than adding a separate external heat dissipation member
Solution Approach 2:
The fixing fitting serves dual purposes: mechanically fastening the terminal fitting and conductive component while also acting as a heat transfer path to the frame member, eliminating the need for dedicated heat dissipation structures
2Reliability
If the connection portion is isolated from the outside by the housing, then electrical connection is protected, but heat dissipation becomes difficult
Solution Approach 1:
The heat transfer member acts as an intermediary that conducts heat from the enclosed connection portion (through the fixing fitting) to the external frame member, which then dissipates heat to the surrounding air, bridging the thermal gap created by the protective housing
Solution Approach 2:
The heat transfer path is extracted from the enclosed housing space and routed through the external frame member, allowing heat to be removed from the protected connection area without compromising the housing's protective function
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 effectively dissipates heat generated at connection points without increasing the connector's size, ensuring reliable operation under external forces and prolonged use.
Implementation Method 1
a heat transfer member configured to thermally connect the frame member and a part of the fixing fitting exposed from the housing
Data Source
AI summary
A connector unit includes: a terminal fitting; a housing configured to accommodate the terminal fitting; a fixing fitting embedded in the housing and configured to fasten and fix the terminal fitting and an external conductive component; a metal frame member on which the housing is mounted; and a heat transfer member configured to thermally connect the frame member and a part of the fixing fitting exposed from the housing. The heat transfer member is sandwiched between the part of the fixing fitting and the frame member, and is flexible enough to deform to fit a shape of a gap between the part of the fixing fitting and the frame member.