Electrical Connector Heat Bridge for Thermal Management
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Solution Overview
Problem
Existing electrical connectors face challenges in efficiently transferring larger powers due to size constraints, as they tend to overheat when transmitting higher currents, limiting their capacity and requiring larger sizes.
Innovation Solution
Incorporating a heat bridge with a thermally connected heat absorption surface to the electrical contact element and an electrically insulated heat transfer surface, allowing for effective heat dissipation, enabling the transfer of higher powers through smaller connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the connector size is reduced, then space utilization is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The patent extends heat dissipation from the traditional lateral direction to the longitudinal direction by incorporating a heat bridge that conducts heat along the connector's length to an external heat sink, utilizing the longitudinal dimension for thermal management while maintaining compact cross-sectional dimensions
Solution Approach 2:
The heat bridge acts as an intermediary thermal conduction path between the contact element and the external heat sink, enabling efficient heat transfer through a dedicated thermal pathway that does not interfere with the electrical connection function
2Volume of moving object
If the connector size is reduced, then space utilization is improved, but power transmission capability deteriorates
Solution Approach 1:
The patent converts the harmful heat generated by high power transmission into a manageable thermal flow by providing a dedicated heat bridge pathway, allowing the connector to transmit higher powers that would otherwise cause overheating, thus turning a limiting factor into a controlled parameter
3Temperature
If thermal connection is improved, then heat dissipation is improved, but electrical insulation deteriorates
Solution Approach 1:
The patent segments the thermal and electrical functions by providing separate pathways: a thermal conduction path through the heat bridge to the heat sink, and an electrical insulation barrier between the heat bridge and external elements, allowing independent optimization of both thermal performance and electrical safety
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 enables the efficient dissipation of heat generated during power transmission, allowing for increased power transfer through smaller connectors, thus addressing the size limitations and overheating issues, while maintaining electrical insulation to prevent unwanted connections.
Implementation Method 1
a heat absorption surface 5 which is thermally connected to the electrical contact element 3
Data Source
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AI summary
The invention relates to an electrical connector (1), comprising a housing (2), an electrical contact element (3) which is received in the housing (2), and a heat bridge (4) which has a heat absorption surface (5) which is thermally connected to the electrical contact element (3), and a heat transfer surface (6) which is accessible from outside the connector (1) and which is electrically insulated from the contact element (3). The invention further relates to an electrical connection arrangement (100), comprising an electrical connector (1) according to any one of Claims 1 to 9 and a heat sink (8) attached thereto.