Contoured Electrical Connector Contacts for Low-Resistance Interfaces
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Solution Overview
Problem
Existing electrical connector assemblies for power electronic modules face challenges in reducing electrical resistance at the contact interface without increasing the outside envelope size, which is critical for efficient thermal management during peak load conditions.
Innovation Solution
The electrical connector assembly employs non-traditional shapes and increased transition surface area through non-planar interface contours, such as ridges and valleys, to reduce electrical and thermal resistances at the mating surfaces, while maintaining a compact package size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outside envelope size of the contacts is increased to reduce electrical resistance at the contact interface, then electrical resistance decreases, but the space utilization within the inverter becomes inefficient
Solution Approach 1:
The patent transitions from planar contact surfaces to three-dimensional non-planar interfaces with ridges and valleys. This dimensional change increases the effective contact area without increasing the external envelope dimensions, thereby reducing electrical resistance while maintaining compact size. The raised ridges and corresponding valleys create multiple contact points that enhance both electrical and thermal conductivity at the interface.
Solution Approach 2:
The contact surfaces incorporate curved and non-planar geometries through raised ridges and valleys rather than flat surfaces. This curvature creates increased surface area and multiple contact points, improving electrical connection quality without requiring larger overall contact dimensions. The three-dimensional contoured surfaces enable better current distribution and reduced contact resistance.
2Reliability
If the contact interface is designed for low electrical resistance, then electrical current flow improves, but thermal heat flow management becomes more difficult due to heat generation at the interface
Solution Approach 1:
The three-dimensional non-planar contact interface with ridges and valleys increases the effective surface area for both electrical conduction and thermal dissipation. By distributing current across multiple elevated contact points, the design reduces current density and associated heat generation at any single point while maintaining low overall electrical resistance. The increased surface area also provides enhanced thermal management capability.
Solution Approach 2:
The contact interface features localized raised ridges and valleys that concentrate electrical contact at specific high-quality points while distributing thermal load across a larger three-dimensional surface. This local quality variation optimizes electrical conductivity at the ridge contact points while the extended valley structures provide thermal pathways for heat dissipation, addressing both electrical and thermal requirements simultaneously.
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 design effectively manages peak overloading in electronic power modules by decreasing interface thermal resistance, enhancing cooling efficiency, and maintaining a compact size, suitable for installation on vehicles.
Implementation Method 1
increased transition surface area through non-planar interface contours, such as ridges and valleys, to reduce electrical and thermal resistances
Implementation Method 2
the interface between two mating conductors or contacts becomes more critical because this interface can be a bottleneck for electrical current and thermal heat flow
Implementation Method 3
There is an inherent resistance at the interface which generates heat
Implementation Method 4
This also hinders thermal flow used for cooling, which makes heat management difficult
Data Source
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AI summary
An electrical connector assembly (10) includes a first electrically conductive contact member (12) and a second electrically conductive contact (14) member. Both contact members have non-planar interface surfaces (20, 22). The second interface surface (22) is complimentary to the first interface surface (20). The first interface surface may include a plurality of elongated first ridges (30) and a plurality of elongated first valleys (32), and the second interface surface may include a plurality of elongated second ridges (34) and a plurality of elongated second valleys (36). A first ridge is received by a second valley and a second ridge is received by a first valley.