Pluggable Connector Unitary Housing Shell Thermal Dissipation

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Solution Overview

Problem

Existing pluggable connectors face challenges in efficiently managing heat generated by internal electronics, which can degrade performance or cause damage, as the current thermal transfer paths are not optimized for efficient heat dissipation.

Innovation Solution

A pluggable connector design featuring a unitary housing shell with seamless thermal-transfer paths from the bottom wall through the side walls to the top surface, enhancing the conveyance of thermal energy for efficient dissipation, potentially incorporating a circuit board and thermal-transfer modules for improved heat management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a conventional connector housing with separate components is used, then manufacturing and assembly are simpler, but thermal transfer efficiency is insufficient

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidhousing structure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the housing components into a unitary housing shell that integrates the first housing portion, second housing portion, and thermal management features into a single seamless structure. This eliminates thermal barriers at interfaces while maintaining manufacturing simplicity through unified construction.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent introduces a thermal interface material as an intermediary between the internal electronics and the housing shell, and between the housing portions, to enhance thermal transfer across interfaces while maintaining structural integrity and ease of assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If internal electronics are positioned closer to the heat dissipation surface, then thermal transfer path is shorter, but heat dissipation efficiency is reduced due to thermal barriers

Engineering Contradiction:

Improvethermal transfer efficiencyVSAvoidthermal transfer path length

Core Design Contradiction:

TemperatureVSLength of moving object

Solution Approach 1:

The unitary housing shell eliminates thermal barriers at interfaces between housing portions, creating a seamless thermal conduction path from the bottom wall where electronics are mounted to the top wall heat dissipation surface, effectively reducing thermal resistance despite maintaining functional spacing.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If heat sink is pressed against the connector housing, then heat dissipation is improved, but structural integrity may be compromised

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidhousing structural integrity

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The heat sink is integrated into the unitary housing shell as a unified structure, eliminating the need for external pressing forces while maintaining intimate thermal contact. The seamless integration preserves structural integrity by removing interface weaknesses.

Inventive Principle:

Principle #5Merging (Combining)

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 significantly improves heat transfer efficiency, minimizing the risk of damage to internal electronics and allowing for more effective heat dissipation, potentially increasing the throughput and reliability of pluggable connectors.

Implementation Method 1

The bottom wall has an interior surface that is coupled to the internal electronics such that the thermal energy is conveyed from the internal electronics into the bottom wall. The unitary housing shell forms a seamless thermal-transfer path that extends from the bottom wall, through the side wall, and to the output area.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9681582B1Pluggable connector and unitary housing shell configured to transfer thermal energy of the pluggable connector

Publication Date: 2017.06.13 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

Pluggable connector includes a connector housing having a unitary housing shell that includes a top wall, a bottom wall that is spaced apart from the top wall, and a side wall that extends between and joins the top and bottom walls. The pluggable connector also includes a communication assembly positioned within an interior cavity of the pluggable connector. The communication assembly includes internal electronics that generate thermal energy during operation. The top wall has an exterior surface that forms an output area configured to dissipate the thermal energy therefrom. The bottom wall has an interior surface that is coupled to the internal electronics such that the thermal energy is conveyed from the internal electronics into the bottom wall. The unitary housing shell forms a seamless thermal-transfer path that extends from the bottom wall, through the side wall, and to the output area.