Ridged Electrical Connector for High Current Stability
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Solution Overview
Problem
Existing electrical connector assemblies for high current transmission are complex in structure and suffer from instability in maintaining multiple-point contact and poor heat dissipation, despite using precious metals and additional plating to reduce contact resistance and temperature.
Innovation Solution
The electrical connector assembly features a simple configuration with angled or zigzag ridges on the connectors that contact at multiple points, combined with ventilation holes for enhanced heat dissipation, allowing for stable and efficient high current transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple spring contacts are used to achieve stable electrical contact at multiple points, then contact reliability is improved, but device complexity increases
Solution Approach 1:
The single contact surface is segmented into multiple ridges (first ridge and second ridge) that extend in different directions. Each ridge creates multiple contact points with the mating connector, achieving multi-point contact without requiring multiple separate spring contacts. This segmentation of the contact surface resolves the contradiction by providing reliable multi-point contact through a simplified single-piece structure.
Solution Approach 2:
The ridges extend in different spatial dimensions (one ridge extending in a first direction, another ridge extending in a second direction different from the first). This multi-dimensional arrangement of ridges allows the single engagement portion to achieve contact at multiple points across different spatial locations, resolving the contradiction between contact reliability and structural complexity.
2Power
If precious metals with large thickness are used for high current transmission, then current carrying capacity is improved, but device complexity and cost increase
Solution Approach 1:
The engagement portion is segmented into multiple ridges that create multiple contact points. This segmentation increases the effective contact area and distributes the high current across multiple parallel contact paths, enabling high current transmission without requiring excessively thick single-piece conductors, thus reducing complexity while maintaining power capacity.
Solution Approach 2:
The connector uses a composite structure combining the ridged engagement portion with a housing, creating a multi-component assembly that achieves high current transmission through distributed contact paths rather than relying on a single thick precious metal piece, thereby reducing overall complexity and material costs.
3Reliability
If multiple spring contacts are used to decrease contact resistance, then electrical performance is improved, but heat dissipation performance deteriorates
Solution Approach 1:
The contact surface is segmented into multiple ridges creating multiple contact points, which distributes the electrical current and reduces contact resistance. Simultaneously, the segmented ridge structure creates channels and surfaces that facilitate heat dissipation, resolving the contradiction by improving both electrical performance and thermal management through the same geometric feature.
4Ease of manufacture
If a simple connector structure is used, then ease of manufacture is improved, but electrical contact stability deteriorates
Solution Approach 1:
The engagement portion is designed with integrated ridges that are formed as a single piece, maintaining manufacturing simplicity. The ridges are segmented in their geometric arrangement (extending in different directions) to create multiple contact points, achieving contact stability without requiring complex assembly processes or multiple separate components.
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 achieves stable multiple-point electrical contact and effective heat dissipation, enabling the transmission of high currents (e.g., 20A or more) while maintaining a low temperature, below 30°C under rated load, through the use of symmetrically arranged ridges and ventilation holes.
Implementation Method 1
one of the at least one ridge of the electrical connector electrically contacts with a respective one ridge of the mating electrical connector at a plurality of points
Implementation Method 2
ventilation holes for enhanced heat dissipation
Data Source
Figure 1~2
Figure 3~4
AI summary
An electrical connector assembly, comprising: a first connector (100) having a first engagement portion (110) at one end thereof; and a second connector (200) having a second engagement portion (210) at one end thereof. The second engagement portion is formed with a chamber into which the first engagement potion of the first connector is inserted to electrically contact with the second engagement portion of the second connector. At least one first ridge (111) is formed on and protruded from an outside surface of the first engagement portion. At least one second ridge (211) is formed on and protruded from an inside surface of the chamber of the second engagement portion. When the first engagement portion is inserted into the chamber of second engagement portion, the first ridge electrically contacts with the second ridge.