Composite Electrical Connector Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical connectors in power distribution circuits face challenges with heat generation due to high current flow, leading to increased contact size and cost, as they require large cross-sectional areas to manage resistance heat without overheating.
Innovation Solution
The use of highly conductive non-metal strips mounted on metal contacts to efficiently transfer heat away from the contacts to heat distribution members, which radiate heat into the air for dissipation, combined with high thermal conductivity materials and pyrolytic highly oriented graphite for enhanced heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If large cross sectional areas are used for metal contacts to reduce resistance heat, then contact temperature is controlled, but contact size and cost increase
Solution Approach 1:
The heat management function is segmented from the electrical contact function. The contact remains small for electrical connection, while separate heat transfer strips and heat distribution members handle thermal dissipation. This segmentation allows the contact to be small (reducing area) while still controlling temperature through dedicated thermal pathways.
Solution Approach 2:
Heat transfer strips made of highly conductive non-metal materials serve as intermediaries between the metal contacts and heat distribution members. These strips efficiently conduct heat away from the contacts without requiring the contacts themselves to be large, thus resolving the contradiction between small contact area and temperature control.
2Temperature
If large cross sectional areas are used for metal contacts to reduce resistance heat, then contact temperature is controlled, but device size increases
Solution Approach 1:
The housing is segmented to include dedicated heat distribution members and heat dissipation surfaces that are separate from the contact structure. This allows the housing to efficiently manage heat without requiring larger dimensions, as the thermal management components are integrated into the housing structure itself rather than requiring additional space.
Solution Approach 2:
Heat dissipation is achieved by utilizing the housing's external surfaces and creating three-dimensional heat distribution pathways. Heat dissipation surfaces are positioned on the housing exterior, and air flow paths are established through the housing structure, utilizing spatial dimensions to enhance heat dissipation without increasing overall device volume.
3Device complexity
If conventional metal contacts are used without heat removal, then contact design is simple, but heat dissipation efficiency is insufficient
Solution Approach 1:
Heat transfer strips made of highly conductive non-metal materials serve as intermediaries between the metal contacts and heat distribution members. These strips efficiently conduct heat away from the contacts without requiring the contacts themselves to be large, thus resolving the contradiction between small contact area and temperature control.
Solution Approach 2:
The connector assembly uses composite materials including highly conductive non-metal heat transfer strips (such as pyrolytic graphite) combined with metal contacts and heat distribution members. This composite approach leverages the electrical conductivity of metals and the thermal conductivity of non-metal materials to achieve superior heat dissipation while maintaining electrical functionality.
4Loss of energy
If heat dissipation surfaces are placed inside recesses, then heat is effectively radiated into air flow, but manufacturing complexity increases
Solution Approach 1:
The housing serves multiple functions: it provides structural support for contacts, integrates heat distribution members, creates air flow passages, and provides heat dissipation surfaces. By making the housing multi-functional, the design achieves effective heat dissipation without requiring separate components or complex assembly processes, thus maintaining ease of manufacture while improving thermal performance.
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
This solution effectively reduces contact size and cost by efficiently removing and dissipating heat generated by current flow, improving thermal conductivity and air flow paths within the connector assemblies for effective heat dissipation.
Implementation Method 1
heat which is transmitted away from the contacts by highly conductive non-metal strips mounted on the contacts by heat-transfer pressure connections. The strips rapidly and efficiently flow heat away from the contacts to heat distribution members
Implementation Method 2
The contacts are held in heat transfer pressure connections with the highly conductive strips. Heat flowed from the contacts and through the strips to the heat distribution members heats the members which radiate the heat into adjacent air for flow away from the connectors and dissipation
Implementation Method 3
Air flows into and out of the recess through one or more openings. Alternatively, the heat dissipation surfaces may be outside the contact housings.
Data Source
AI summary
A heat dissipating power electrical connector assembly has a contact housing, a metal contact in the housing, a heat dissipating member with a surface for heating adjacent air and a non-metal heat transmitting member for flowing heat from the contact to the heat dissipating member.