Plug Connector U-Shaped Contact Feet Thermal Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connectors face challenges in easy and permanent attachment to devices, especially when dealing with high-temperature carriers, as they often require complex soldering or welding processes and lack efficient mechanical attachment mechanisms.
Innovation Solution
A connector design featuring U-shaped contact feet with parallel legs, a recess between them, and a lower leg that protrudes laterally for mechanical attachment, providing a spring effect and allowing for stable alignment while minimizing installation space, with adjustable spring deflection and optimized material thickness for reduced thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional connectors are used with high-temperature carriers, then thermal conduction occurs causing overheating, but the connector cannot be securely attached to the device
Solution Approach 1:
The contact foot is segmented into multiple functional zones: an upper connection region to the plug-in connection, a U-shaped intermediate section with parallel legs and recess, and a lower attachment leg. This segmentation allows each zone to perform its specific function - electrical connection, mechanical flexibility, and secure attachment - while isolating thermal pathways.
Solution Approach 2:
The contact foot transitions from a simple linear structure to a three-dimensional U-shaped configuration with parallel legs extending in multiple directions. The lower leg protrudes laterally beyond the housing underside, creating a multi-dimensional attachment geometry that enables secure mechanical fastening while directing thermal pathways away from sensitive components.
2Reliability
If complex soldering or welding processes are used for attachment, then secure connection is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The connector performs its own attachment function through the spring effect of the U-shaped contact foot. The elastic deformation and recovery of the contact foot automatically create mechanical pressure and friction against the carrier, enabling self-securing attachment without requiring external soldering or welding operations.
Solution Approach 2:
The invention replaces thermal joining processes (soldering/welding) with a mechanical attachment system based on elastic deformation. The U-shaped contact foot's spring effect provides a purely mechanical means of secure attachment, eliminating the need for complex thermal processing equipment and procedures.
3Adaptability or versatility
If contact feet are made longer to increase spring effect, then elasticity improves, but installation space requirements increase
Solution Approach 1:
Instead of increasing contact foot length in a single direction, the design utilizes three-dimensional U-shaped geometry with parallel legs arranged in multiple directions. The lower leg protrudes laterally beyond the housing, creating elastic flexibility through spatial configuration rather than simple length extension, thereby maintaining compact dimensions while achieving adequate spring effect.
Solution Approach 2:
The contact foot is designed with optimized material properties and cross-sectional geometry in the U-shaped region. By adjusting material thickness and distribution in the parallel leg section, the design achieves maximum elastic flexibility within minimum space constraints, creating a composite structural solution that balances spring effect and compactness.
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
Enables easy and secure attachment to devices with reduced thermal conduction and shorter soldering times, maintaining stability and alignment while accommodating high-temperature carriers.
Implementation Method 1
a certain elasticity and/or spring effect is achieved both through the somewhat elongated shape of the contact feet and, above all, through the design of the foot end with the U-shape
Implementation Method 2
reduced thermal conduction
Data Source
Figure 1~4
Figure 5~7
AI summary
The plug connector (11) has housing (12) in which multiple metallic plug terminals (14a-14c) are provided. Multiple contact feet (16) are projected from bottom of the housing to make electrical contact and mechanically fix the connector to a support of an electrically connected heating device. One contact foot is provided with U-shaped contact foot provided with upper leg (19) and lower leg (20). The upper leg is merged with recess portion (23), and lower leg is provided on the housing. The height of the recess portion is between 50-150% of height of contact foot. An independent claim is included for a plug connector device.