Low Profile Modular Power Connector Heat Dissipation
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Solution Overview
Problem
Existing power connectors face challenges in reducing size while maintaining high current density without excessive temperature rise, which can lead to loosened contacts and reduced electrical performance due to heat generation from the Joule effect.
Innovation Solution
The design employs uncoupled contacts with exposed surfaces for heat dissipation and improved airflow through cavities in the housing, eliminating the need for bridging structures that occupy space and hinder airflow, allowing for higher current density with minimal temperature rise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If current density is increased to reduce connector size, then power handling capability is improved, but temperature rise increases causing contact loosening and reduced reliability
Solution Approach 1:
The contact structure is divided into multiple independent contact members (first contact member and second contact member) instead of a single monolithic contact. This segmentation allows each contact member to be independently optimized for electrical performance while managing heat dissipation, enabling higher current density without excessive temperature rise that would cause loosening
Solution Approach 2:
The patent introduces a vertical dimension for heat dissipation by positioning contact members at different heights (first contact member at first height, second contact member at second height). This vertical arrangement creates additional surface area for heat radiation and improves airflow pathways, allowing higher power handling while maintaining contact stability through reduced thermal expansion
2Length of stationary object
If connector profile is reduced to save space, then space requirements are improved, but heat dissipation capability deteriorates
Solution Approach 1:
The patent utilizes the vertical dimension efficiently by arranging contact members at different heights within a low-profile housing. This vertical stratification maximizes heat dissipation surface area within the constrained vertical space, allowing effective heat management without increasing the overall connector profile height
Solution Approach 2:
Different regions of the connector are optimized for different functions: the lower region houses the first contact member for stable electrical connection, while the upper region accommodates the second contact member with enhanced heat dissipation surfaces. This local optimization allows the connector to maintain low profile while providing adequate heat dissipation through strategically placed heat dissipation surfaces
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 approach results in power connectors with a lower profile (typically 30% less than commercial connectors) that can handle about 120 to 275 amps per inch without significant temperature rise, preserving power handling capabilities and reducing space requirements.
Implementation Method 1
heat generated by the Joule effect
Implementation Method 2
exposed surfaces to dissipate heat
Implementation Method 3
improve air flow in one or more of the top, bottom, bottom and/or rear of the connector cavities
Data Source
AI summary
Power connector modules are provided that can be plug connectors, receptacle connectors, or a system of plug and receptacle connector modules and optionally other modules, that mate together. Each connector has an uncoupled contact feature. The uncoupled contacts have exposed surfaces to dissipate heat resulting from Joule effects. The uncoupled contacts for the plug connector converge to form a blade structure at one side. The uncoupled contacts for the receptacle connector form a receiving section that engages the blade structure of the plug connector when the plug connector and receptacle connector are used together.