Low Profile Power Connector with Split Blade Contacts and Ventilation
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Solution Overview
Problem
Conventional electrical connectors face challenges in achieving high current capacity, reduced contact resistance, and efficient heat dissipation while maintaining a compact design, which limits their performance and manufacturing efficiency.
Innovation Solution
The design incorporates a right-angle electrical connector with front-end loaded power contacts that feature split blades and angled panels, along with ventilation windows for heat dissipation and retention, allowing for increased contact thickness and dielectric material between rows, resulting in higher current capacity and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional electrical connectors use individually installed contacts with standard pitch spacing, then manufacturing is simple, but current capacity is limited and heat dissipation is inefficient
Solution Approach 1:
The patent combines multiple contacts into integrated contact assemblies where contacts are pre-positioned in a molded housing with precise spacing. This merging approach increases current capacity through closer contact spacing while the pre-assembly simplifies installation, resolving the contradiction between higher power capability and device complexity.
Solution Approach 2:
The patent arranges contacts in multiple rows and columns within a compact footprint, utilizing three-dimensional space efficiently. This dimensional arrangement allows higher contact density and current capacity without proportionally increasing the connector's overall size, addressing the power-to-complexity tradeoff.
2Power
If contact thickness is increased to handle higher current, then current capacity improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent pre-assembles contact assemblies with precisely positioned contacts of optimized thickness before installation into the final connector. This preliminary action allows for precise control of contact thickness to achieve required current density while simplifying the final assembly process, reducing overall manufacturing complexity.
Solution Approach 2:
The patent optimizes contact thickness as a specific parameter to achieve the required current density. By carefully selecting and controlling the thickness parameter during manufacturing, the design achieves high current capacity without excessive manufacturing complexity, balancing performance and ease of production.
3Temperature
If contacts are spaced further apart to allow heat dissipation, then thermal management improves, but current capacity decreases due to fewer contacts per area
Solution Approach 1:
The patent incorporates ventilation windows that segment the housing structure to create thermal pathways. These segmented openings allow heat to dissipate from the contact areas while maintaining the close spacing of contacts needed for high current capacity, resolving the contradiction between thermal management and power density.
Solution Approach 2:
The patent provides localized heat dissipation features (ventilation windows) specifically positioned near high-heat-generation areas of the contacts. This local quality approach allows effective thermal management at critical locations without requiring increased spacing between all contacts, preserving high current capacity while improving heat dissipation where needed.
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 configuration enables higher current density, improved heat dissipation, and a more compact design, achieving up to 26% increased current capacity compared to conventional connectors, with enhanced thermal management and manufacturing efficiency.
Implementation Method 1
ventilation windows for heat dissipation and retention
Data Source
AI summary
A receptacle power connector is provided having first and second rows of electrical power contacts retained in a connector housing. The connector housing has a low profile, and the power contacts are arranged in rows that each achieves a current density of about 120 Amps/linear inch (2.54 cm).