Non-Planar Electrical Connector Assembly for Power Inverters
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Solution Overview
Problem
In power electronic modules or power inverters, the interface between mating conductors experiences increased electrical and thermal resistance at peak load conditions, hindering efficient heat management and requiring larger contact sizes, which is inefficient in terms of space usage.
Innovation Solution
The electrical connector assembly features non-planar contact surfaces with increased transition area, utilizing magnetic field concentrators and a flexible circuit carrier with a magnetic field sensor to manage current and thermal flow efficiently, while maintaining a compact 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 is reduced, but the space utilization within the inverter becomes inefficient
Solution Approach 1:
The patent transitions from planar contact surfaces to three-dimensional non-planar contact surfaces. The first contact member has a non-planar first contact surface and the second contact member has a non-planar second contact surface that complements the first, creating increased contact area through vertical dimension utilization rather than horizontal expansion. This dimensional change allows reduced electrical resistance without increasing the envelope size.
Solution Approach 2:
The patent applies non-planar surface geometry specifically at the contact interface regions of the contact members. The non-planar surfaces create localized areas of enhanced contact pressure and increased contact area precisely where electrical conduction occurs, while the rest of the contact member envelope remains compact. This localized application of complex geometry resolves the contradiction between contact quality and overall size.
2Temperature
If larger contact sizes are used to manage heat at peak load conditions, then thermal management is improved, but the inverter becomes less space-efficient
Solution Approach 1:
The non-planar contact surfaces extend into the third dimension, creating increased surface area for thermal conduction without increasing the horizontal footprint. The complementary non-planar surfaces of the two contact members interlock to provide enhanced thermal pathways from the contact interface, improving heat dissipation while maintaining a compact inverter form factor.
Solution Approach 2:
The patent concentrates thermal management capabilities at the contact interface through non-planar surface geometry. The increased surface area is localized precisely at the mating surfaces where heat generation occurs due to electrical resistance, providing targeted thermal management where needed most without requiring larger overall contact member dimensions.
3Reliability
If non-planar contact surfaces are implemented to increase contact area, then electrical and thermal resistance are reduced, but the manufacturing complexity increases
Solution Approach 1:
While the non-planar surfaces do increase manufacturing complexity compared to flat surfaces, the patent achieves this through systematic geometric patterns that can be manufactured using standard precision machining or forming processes. The complementary nature of the non-planar surfaces on mating contact members allows for standardized production approaches, mitigating the complexity increase while still achieving the benefits of enhanced contact area.
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 reduces electrical and thermal resistance at the contact interface, enhancing cooling effectiveness and maintaining a compact size, suitable for high-current applications in power electronics without increasing the overall envelope size.
Implementation Method 1
Magnetic field concentrators are spaced apart to concentrate a magnetic field in a zone. The magnetic field is associated with electric current carried by the electrical connector assembly.
Implementation Method 2
A magnetic field sensor is mounted on the flexible circuit carrier in the zone to detect the magnetic field; hence, measure the current carried by the electrical connector assembly.
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 member (14). Both contact members have non-planar interface surfaces (20, 22). The second interface surface (22) is complimentary to the first interface surface (20). Magnetic field concentrators (702) are spaced apart to concentrate a magnetic field in a zone. The magnetic field is associated with electric current carried by the electrical connector assembly. A flexible circuit carrier has openings to receive the magnetic field concentrators. The flexible circuit carrier (704) comprises a flexible dielectric layer and a conductive traces. A magnetic field sensor (706) is mounted on the flexible circuit carrier in the zone.