Offset Contact Blades for Electrical Connector Heat Dissipation
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Solution Overview
Problem
Existing electrical connectors with U-shaped power contacts suffer from inadequate heat dissipation due to blocked airflow, which limits their thermal management capabilities.
Innovation Solution
The design incorporates pairs of contact blades with embossments that abut each other for electrical connection while maintaining space for enhanced heat dissipation, utilizing an insulative housing with mating and mounting ports, and strategically placed heat dissipation holes and airflow paths to facilitate airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If U-shaped power contacts are used to link opposite spring fingers, then electrical connection is achieved, but heat dissipation deteriorates due to blocked airflow
Solution Approach 1:
The contact structure is segmented into separate first and second contact blades instead of a unified U-shaped structure. Each blade is independently positioned with embossments that abut to provide electrical connection, while the segmented design creates gaps that allow airflow for heat dissipation.
Solution Approach 2:
The first and second contact blades are positioned asymmetrically with offset embossments. The embossment on the first contact blade abuts against the embossment on the second contact blade at offset positions, creating an asymmetric configuration that maintains electrical connectivity while preserving airflow paths for thermal management.
2Reliability
If contact blades are positioned close together for electrical connection, then electrical conductivity improves, but heat dissipation worsens due to reduced space
Solution Approach 1:
The embossments on the contact blades are designed with localized abutting surfaces that provide electrical connection only at specific points. The main bodies of the contact blades remain separated with gaps between them, allowing airflow for heat dissipation while the localized embossment contact ensures electrical conductivity.
3Strength
If solid contact structure is used for electrical connection, then mechanical strength improves, but heat dissipation deteriorates
Solution Approach 1:
The contact structure is divided into separate first and second contact blades with embossments that abut for electrical connection. This segmentation reduces the continuous solid material that blocks heat dissipation while maintaining mechanical strength through the embossment abutment interface.
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 improves heat dissipation by allowing airflow and reducing thermal resistance, effectively managing heat in electrical connectors.
Implementation Method 1
Each of the main body of the first contact blade and the main body of the second contact blade forms an embossment abutting against each other so as to electrically unify both the first contact blade and the second contact blade
Implementation Method 2
without blocking the space therebetween for enhancing heat dissipation thereof
Data Source
AI summary
An electrical connector includes an insulative housing having opposite mating port and mounting port. Plural pairs of contacts are retained in the housing. Each pair of contacts has a first contact blade and a second contact blade. Each of the first contact blade and the second contact blade includes a main body, a contacting section extending into the mating port, and a mounting leg of the main body disposed in the mounting port. Each of the main body of the first contact blade and the main body of the second contact blade forms an embossment abutting against each other so as to electrically unify both the first contact blade and the second contact blade without blocking the space therebetween for enhancing heat dissipation thereof.