Low-Profile Pass-Through Connector for High-Current Wing Surfaces
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Solution Overview
Problem
Existing connectors for passing electrical voltage and current through conductive wing surfaces, such as those made of carbon fiber or aluminum, face challenges in maintaining aerodynamic performance while providing power to thin film heaters or communication antennas, particularly in preventing overheating due to high electrical currents.
Innovation Solution
A low profile pass-thru connector design featuring a conductive pin with an insulating sleeve and a mating socket, which transitions to a thin copper strip conductor, eliminating the need for solder and utilizing airflow for cooling, and includes a floating center assembly with a snap ring for secure and aerodynamic installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional electrical connector is used to pass high current through the wing surface, then sufficient cross-sectional area is provided to prevent overheating, but the profile height increases and aerodynamic performance deteriorates
Solution Approach 1:
The connector is divided into multiple segments: a large cross-sectional area section for current entry from the wing interior, a transition section, and a thin profile section for the heater element connection. This segmentation allows the connector to provide sufficient cooling cross-sectional area internally while maintaining a low external profile height that preserves aerodynamic performance.
2Temperature
If a thick conductor is used to carry high current without overheating, then sufficient cross-sectional area is provided, but the transition to thin film heaters becomes difficult
Solution Approach 1:
The connector employs local quality variation along its length, with a large cross-sectional area at the wing interior end for high current capacity and a thin profile at the heater end for compatibility with thin film heaters. The transition section gradually changes the cross-sectional dimensions, providing both sufficient cooling area and easy transition to thin conductors without complex assembly procedures.
3Length of stationary object
If the connector profile height is reduced to maintain aerodynamic performance, then the wing's aerodynamic performance is maintained, but the cross-sectional area for current transmission decreases
Solution Approach 1:
The connector utilizes three-dimensional space efficiently by orienting the large cross-sectional area internally within the wing structure rather than extending it externally. The low-profile exterior section maintains aerodynamic performance while the internal geometry provides sufficient cross-sectional area for high current transmission and cooling, effectively using different spatial dimensions to satisfy conflicting requirements.
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 solution effectively maintains aerodynamic performance by preventing overheating and ensuring reliable power transmission to thin film heaters and antennas, even at high currents, while allowing for easy installation and maintenance without compromising the wing's surface integrity.
Implementation Method 1
This thin copper strip does not overheat with high current use because the airflow during flight keeps it cool due to forced convection
Data Source
AI summary
A low profile pass-through electrical connector is designed for aerospace applications. The connector allows voltage and current to pass-thru a conductive wing surface, while maintaining a low profile height for aerodynamic performance considerations. Examples of applications of the electrical connector include power for thin film heaters and communication antennae applications.