Single-Barrel Power Connector Cooling for 600 W Delivery
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Solution Overview
Problem
Conventional single-barrel power connectors for information handling systems are limited in power delivery, often leading to overheating and damage when attempting to supply more than 330 W, restricting the performance of these systems.
Innovation Solution
A high-performance single-barrel power connector design featuring a connector body with exposed V- and V+ pin contact areas, a thermally conductive shell, and a cover that allows for improved airflow and heat dissipation, enabling the delivery of up to 600 W without increasing the plug size, using materials like brass and copper for the pins and a high thermal conductivity alloy for the shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional single-barrel power connectors are used to deliver more than 330 W, then power delivery increases, but overheating and damage occur
Solution Approach 1:
The connector is divided into multiple thermal zones with dedicated heat dissipation paths. The shell is segmented into sections that contact different pins (V+, V-, signal) to create independent thermal management channels, allowing heat to be dissipated from each pin separately rather than accumulating in a single mass.
Solution Approach 2:
The shell acts as a thermal intermediary between the pins and the external environment. It provides a controlled thermal pathway that transfers heat from the high-power pins to areas with better heat dissipation, preventing direct heat accumulation at the pin-connector interface while maintaining electrical isolation.
2Power
If power delivery is increased beyond 330 W, then system performance improves, but connector damage risk increases
Solution Approach 1:
Heat dissipation structures and thermal pathways are pre-established in the connector design before power delivery begins. The shell geometry and contact areas are configured in advance to provide optimal heat transfer paths, preventing thermal runaway and ensuring reliable operation at elevated power levels up to 600 W.
Solution Approach 2:
The connector design incorporates thermal cushioning through the shell structure that absorbs and distributes thermal stress before it can cause damage. The segmented shell and exposed pin configurations provide a buffer against thermal expansion and stress concentration, protecting the connector from damage at high power levels.
3Volume of moving object
If a standard 7.4 mm plug is used, then plug size remains standard, but heat dissipation is insufficient for high power
Solution Approach 1:
The solution moves heat dissipation from the plug dimension to the connector dimension. The plug maintains its standard 7.4 mm size, but the connector provides an extended thermal management system with a shell and exposed pin surfaces that dissipate heat in additional spatial dimensions, effectively decoupling plug size from heat dissipation capability.
Solution Approach 2:
Heat dissipation functionality is extracted from the plug and placed in the connector shell and pin structure. The plug remains a simple electrical connector, while the shell and exposed pins provide dedicated thermal management, separating the electrical connection function from the thermal management function.
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
The design effectively manages heat dissipation, allowing for increased power delivery while maintaining a standard 7.4 mm plug size, reducing temperature differentials and preventing overheating, thus enhancing the performance and reliability of information handling systems.
Implementation Method 1
a shell coupled to the connector body... formed from a high thermal conductivity material
Data Source
AI summary
A high-performance single barrel power connector for receiving electric power may be capable of receiving more than 330 W up to approximately 600 W of power. The V+ pin and V− pin may each be configured with a large plurality of contact points for connecting to a power plug. A connector body retaining the V+ pin and V− pin may configured with openings to expose more of the V+ pin and V− pin to air and allow the V+ pin and V− pin to extend out of the power connector for convective and conductive heat transfer. A shell having a high thermal conductivity may be connected to the V− pin and V− pin and further connected to a bracket for increased heat transfer away from the V+ and V− pins.