Planar Beam Power Connector for High Current Density
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Solution Overview
Problem
Conventional electrical power connectors face challenges in achieving low electrical resistance and high current density while maintaining a compact design, leading to increased heat generation and reduced efficiency.
Innovation Solution
The electrical power connector features a dielectric housing with planar electrical power contacts that include first and second beams, spaced to form contacts with pads on opposing surfaces of a substrate, allowing for efficient electrical communication and reduced resistance, and alternating groups of contacts with different geometries to optimize mounting and mating interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional electrical power connectors are designed to achieve high current density, then current carrying capacity is improved, but electrical resistance increases leading to heat generation
Solution Approach 1:
The electrical power connector is divided into multiple individual electrical power contacts (first power contact, second power contact, etc.) that are spaced apart from each other. Each contact can be independently configured with specific beam geometries, allowing optimization of current distribution across multiple contact points, thereby reducing overall electrical resistance while maintaining high current carrying capacity
Solution Approach 2:
The first and second beams of each electrical power contact are configured with specific local geometries and spacing arrangements. The beams extend from opposite sides of the slot to contact pads on opposing surfaces of the substrate, creating localized high-density contact regions that reduce electrical resistance at critical interfaces while maintaining overall connector compactness
2Loss of energy
If electrical power contacts are configured with beams spaced to form contacts with pads on opposing surfaces of substrate, then electrical resistance is reduced, but connector complexity increases
Solution Approach 1:
The electrical power connector is configured to simultaneously achieve multiple functions: the first and second beams of each contact serve both as structural support elements and as electrical conduction paths. The slot configuration serves both as a mounting feature for the substrate and as a means to position the beams for optimal electrical contact, reducing the need for additional components
Solution Approach 2:
The mounting interface and mating interface are integrated into a unified connector structure. The slot that receives the substrate is formed directly in the connector housing, and the beams are positioned to simultaneously engage with substrate pads during the mating process, combining mounting and electrical connection functions into a single operational step
Data Source
AI summary
An electrical power interconnection system is described. The electrical interconnection system may comprise an electrical power connector and a substrate, such as a printed circuit board. The electrical power connector may comprise a housing and a plurality of electrical power contacts supported by the housing. The electrical power contacts may comprise a mounting end, a mating end, and a contact body disposed between the mounting end and the mating end. The electrical power contacts may have planar portions. The mating ends may comprise opposing first second beams defining a slot. The slot may be configured to receive the substrate therein, such that the first beam contacts the first side of the substrate and the second beam contacts the second side of the substrate.