PCB Connector Assembly With Integrated Cooling for High Current
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Solution Overview
Problem
Existing electrical circuit board connectors fail due to overheating when subjected to high currents, leading to decreased current-carrying capacity and potential failure.
Innovation Solution
Designing the connecting element as a cooling element adjacent to a heat sink, with a cooling surface and air flow path to dissipate heat, allowing for increased current transmission capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the current transmitted through the connector is increased, then the power transmission capability is improved, but the connector overheats and fails
Solution Approach 1:
The invention extracts the heat dissipation function from the traditional connector structure by introducing a separate cooling element with cooling channels. This cooling element is integrated into the connector housing but maintains functional independence, allowing heat to be removed from the high-current connecting elements without interfering with the electrical connection function.
Solution Approach 2:
The cooling element acts as an intermediary between the heat-generating connecting elements and the external cooling medium (air or liquid). The cooling channels provide a thermal pathway that mediates heat transfer from the connecting elements through the connector housing to the external environment, preventing direct heat accumulation at the contact points.
2Reliability
If the spring force is increased to maintain contact pressure, then the electrical contact resistance is reduced, but the connector heats up excessively
Solution Approach 1:
The invention converts the harmful heat generated by high-current transmission into a manageable thermal flow by designing cooling channels that guide this heat away from the connecting elements. The heat that would otherwise cause failure is redirected through the cooling element to the external environment, turning a detrimental effect into a controlled thermal management process.
3Ease of manufacture
If the connector structure is simplified, then the manufacturing cost is reduced, but the cooling capability is insufficient
Solution Approach 1:
The invention merges the structural functions of the connector housing with the thermal management function by integrating the cooling element into the housing. The cooling element is formed as part of the housing structure, allowing simultaneous production of both components through injection molding or other manufacturing processes, thereby adding cooling capability without significantly increasing manufacturing complexity.
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 reduces heating in the connector, thereby enhancing its current-carrying capacity and preventing failure by maintaining optimal contact resistance.
Implementation Method 1
the connecting element is designed as a cooling element for dissipating heat from the printed circuit board connector... a cooling air flow passing through the heat sink also reaches the connecting element provided as a cooling element
Implementation Method 2
the electrical contact element is electrically and/or thermally coupled to the connecting element... the connecting element or several connecting elements can form a cooling area that is located between the electrical connection to a power board and the electrical contact area
Data Source
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AI summary
Electrical circuit board connector with at least one electrical contact element which is at least partially surrounded by a connector housing of the circuit board connector, wherein the circuit board connector has at least one connecting element for electrically and mechanically connecting the circuit board connector to a power board, wherein the connecting element is designed as a cooling element for dissipating heat from the circuit board connector.