Multi-Point Electrical Connector Assembly for Low Contact Impedance
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Solution Overview
Problem
Traditional electrical connection assemblies experience high contact impedance, leading to decreased power density and efficiency, as well as safety issues due to temperature rise and potential structural damage from increased clamping force.
Innovation Solution
An electrical connection assembly design featuring a first connector with contact parts that engage recesses on a second connector, forming multi-point contacts to reduce contact impedance without increasing clamping force, thereby enhancing power density and efficiency while preventing temperature rise and material fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional point-contact connection is used between male and female connectors, then the device complexity is low, but the contact impedance is high leading to power loss and temperature rise
Solution Approach 1:
The contact surface is segmented into multiple contact points (first contact portion, second contact portion, third contact portion) instead of a single point contact. This segmentation increases the total contact area and reduces contact impedance, thereby reducing power loss while maintaining a relatively simple overall structure.
Solution Approach 2:
The contact interface transitions from point-contact (0D) to surface-contact (2D) by creating multiple contact portions on the contact surface. This dimensional change increases the contact area without significantly increasing the overall connector complexity.
2Loss of energy
If clamping force is increased to reduce contact impedance, then the contact area increases, but the stress on contact portions increases leading to structural damage or material fatigue
Solution Approach 1:
The contact surface is divided into multiple contact portions that distribute the clamping force across different locations. This segmentation reduces the stress concentration on any single contact point, preventing structural damage and material fatigue while maintaining low contact impedance.
Solution Approach 2:
Different contact portions (first, second, third contact portions) are positioned at different locations on the contact surface to optimize the distribution of mechanical stress. This local quality approach ensures that the clamping force is evenly distributed, reducing the risk of structural damage while maintaining effective electrical contact.
3Temperature
If traditional single-point contact is used, then the manufacturing is simple, but the temperature rise exceeds material tolerance causing safety issues
Solution Approach 1:
The contact interface is segmented into multiple contact portions that distribute the electrical current and heat generation across multiple points. This segmentation reduces the temperature at any single contact point, preventing temperature from exceeding material tolerance while maintaining manufacturability.
Solution Approach 2:
The potential harm of high temperature generation from contact impedance is converted into a benefit by distributing the heat across multiple contact portions. This approach uses the additional contact surfaces to dissipate heat more effectively, turning the complexity of multiple contacts into a thermal management solution.
Data Source
AI summary
The present disclosure provides an electrical connection assembly including a first electrical connector and a second electrical connector. The first electrical connector includes a first terminal. The first terminal includes a contact part. The second electrical connector is configured to pluggably connect with the first electrical connector, and includes a second terminal. The second terminal includes a recess. The recess is inwardly recessed from a surface of the second terminal and includes a connection section and a bottom. The connection section is in connection between the bottom and the surface of the second terminal, and includes a plurality of contact portions. The contact part of the first terminal is in connection with the recess of the second terminal, and the contact part of the first terminal is in contact with the bottom and the contact portions of the recess of the second terminal to form a multi-points contact.