Insulated Connector Heat Dissipation for High-Current Terminals
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Solution Overview
Problem
Conventional connectors face challenges in suppressing temperature increases due to heat generation from high currents, as increasing the size of terminal fittings or wire diameters is not preferable due to size constraints.
Innovation Solution
A connector design incorporating an insulating heat dissipation member with a heat absorbing portion and a heat transfer portion to effectively dissipate heat from terminal fittings, utilizing materials with higher thermal conductivity, such as fine ceramics, to enhance heat absorption and transfer outside the terminal accommodation chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the size of the terminal fitting is increased to suppress temperature increase, then the heat dissipation performance is improved, but the connector size is significantly increased
Solution Approach 1:
The heat dissipation function is segmented from the terminal fitting structure. A separate heat dissipation member is introduced that specifically handles thermal management, allowing the terminal fitting to maintain its compact size while the heat dissipation member provides the necessary thermal relief through its extended heat radiation surface area.
Solution Approach 2:
The heat dissipation member acts as an intermediary between the terminal fitting and the surrounding environment. It absorbs heat from the terminal fitting through thermal conduction and dissipates it to the ambient air through convection and radiation, thereby protecting the terminal fitting from overheating without requiring the terminal fitting itself to be enlarged.
2Temperature
If the wire diameter is increased to suppress temperature increase, then the heat dissipation performance is improved, but the connector size is significantly increased
Solution Approach 1:
The thermal management function is separated from the electrical conduction function. Instead of increasing wire diameter for heat dissipation, a dedicated heat dissipation member is introduced that handles thermal relief independently, allowing the wire to maintain its original diameter while still achieving effective temperature control.
Solution Approach 2:
The heat dissipation member serves as a thermal intermediary that couples with the terminal fitting to transfer heat away from the high-current carrying components. This mediator approach enables effective heat dissipation without requiring the electrical conductors to be oversized.
3Temperature
If a heat dissipation member is added to enhance heat dissipation performance, then the temperature increase is suppressed, but the device complexity is increased
Solution Approach 1:
The heat dissipation member is integrated with the existing connector assembly rather than being a completely separate component. It is positioned to work in conjunction with the terminal fitting and housing, combining thermal management functionality with the existing electrical connection structure, thereby minimizing the increase in overall device complexity.
Solution Approach 2:
The heat dissipation member is designed to serve multiple functions: it provides thermal management for the terminal fitting, maintains structural integrity of the connector assembly, and can be configured to work with different terminal fitting arrangements. This multi-functionality reduces the need for additional specialized components.
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 enhanced heat dissipation performance of the connector effectively manages temperature increases without enlarging the connector size, maintaining waterproof and shielding performance while coping with higher currents.
Implementation Method 1
a heat absorbing portion that comes into contact with the terminal fitting in the terminal accommodation chamber and takes heat from the terminal fitting
Implementation Method 2
dissipates the heat
Implementation Method 3
dissipates the heat
Data Source
AI summary
A connector includes a terminal fitting, an insulating housing having a terminal accommodation chamber in which the terminal fitting is accommodated, and attached to a casing of an installation target device, and an insulating heat dissipation member that takes heat from the terminal fitting and dissipates the heat are included, and the heat dissipation member includes a heat absorbing portion that comes into contact with the terminal fitting in the terminal accommodation chamber and takes heat from the terminal fitting, and a heat transfer portion that transfers the heat taken by the heat absorbing portion to a heat transfer target portion outside the terminal accommodation chamber.