Power Contact Plate Beam Design for Heat and Force Management
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Solution Overview
Problem
Electrical connectors face challenges in balancing increased power transmission with dimensional constraints and heat buildup, while high mating forces can cause plastic creep, affecting mechanical and electrical performance.
Innovation Solution
The design incorporates plate-like body members with pinching and deflecting beams to distribute mating forces evenly, reducing stress and heat dissipation through apertures and beam configurations that minimize normal force variation and enhance heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If increased power transmission is implemented, then power transmission capability is improved, but heat buildup increases
Solution Approach 1:
The contact structure is divided into multiple plate-like body members (first body member and second body member) that are stacked against each other. This segmentation allows for distributed current flow paths and improved heat dissipation surface area, enabling higher power transmission without excessive heat buildup in a single contact point.
Solution Approach 2:
The patent applies different properties to different parts of the contact structure. The plate-like body members have specific geometric configurations with varying thicknesses and surface areas at different locations, optimizing both electrical conductivity and thermal management in high-power regions while maintaining structural integrity.
2Strength
If high mating force is applied, then connector connection strength is improved, but plastic creep occurs causing dimensional changes
Solution Approach 1:
The contact design incorporates deflectable beams that can dynamically adjust during mating. The beams are designed to flex and conform to the mating connector, distributing the mating force over time and across multiple contact points rather than applying static high force that would cause plastic creep.
Solution Approach 2:
The plate-like body members with their specific geometric configurations act as intermediaries between the connector housing and the electrical contact. They distribute and transform the mating forces, reducing peak stresses on the plastic housing while maintaining strong electrical connection.
3Power
If power transmission is increased, then power capability is improved, but dimensional constraints are violated
Solution Approach 1:
The patent transitions from a single-plane contact design to a stacked three-dimensional configuration with plate-like body members arranged in layers. This dimensional change allows increased power transmission capability within the same footprint by utilizing vertical space and creating multiple current flow paths without significantly increasing overall connector dimensions.
Data Source
AI summary
Electrical connectors and contacts for transmitting power are provided. One power contact embodiment includes a first plate that defines a first non-deflecting beam and a first deflectable beam, and a second plate that defines a second non-deflecting beam and a second deflectable beam. The first and second plates are positioned beside one another to form the power contact.