Spring-Loaded Busbar Connector for Stable Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The formation of tiny gaps between the busbar and housing due to dimensional errors and differences in linear expansion coefficients in connectors with ceramic members leads to increased thermal contact resistance, deteriorating heat dissipation.
Innovation Solution
A connector design featuring a metal housing, a flat plate-like busbar, a ceramic member interposed between the busbar and housing, and compression coil springs pressing the busbar against the ceramic member to maintain contact without gaps, utilizing the high thermal conductivity of the ceramic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a ceramic member is merely placed adjacent to the busbar and the housing, then the structure is simple and easy to manufacture, but tiny gaps are formed due to dimensional errors and difference in coefficient of linear expansion, causing thermal contact resistance to increase and heat dissipation to deteriorate
Solution Approach 1:
The pressing member is designed to be elastically deformable, allowing it to dynamically adjust and maintain continuous pressing force on the ceramic member against the busbar. This elastic deformation capability ensures that contact pressure is maintained despite dimensional variations or thermal expansion differences, eliminating gaps while keeping the structure relatively simple
Solution Approach 2:
The pressing member changes its physical state from a rigid fixed position to an elastically deformable state, allowing it to adapt to dimensional errors and thermal expansion. This parameter change in the pressing member's mechanical properties enables it to compensate for manufacturing tolerances and maintain reliable thermal contact
2Reliability
If a pressing member is introduced to press the busbar toward the contact portion, then thermal contact resistance is reduced and heat dissipation is improved, but the device complexity increases
Solution Approach 1:
The pressing member utilizes its own elastic recovery force to automatically maintain contact between the ceramic member and the busbar. This self-service mechanism eliminates the need for external actuation systems, complex control mechanisms, or additional components to maintain pressing force, thereby improving heat dissipation without significantly increasing device complexity
Solution Approach 2:
The pressing member acts as an intermediary element between the housing and the busbar, transferring the pressing force through the ceramic member to ensure thermal contact. This intermediary approach allows the system to achieve reliable thermal contact while maintaining a relatively simple overall structure, as the pressing member is a single component that performs the mediating 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 ensures stable contact between the busbar and housing, enhancing heat dissipation by eliminating gaps and improving thermal conductivity.
Implementation Method 1
a ceramic member to be interposed between one flat surface of the busbar and a contact portion of the housing
Implementation Method 2
a pressing member for pressing another flat surface of the busbar toward the contact portion
Data Source
AI summary
One aspect of the present disclosure is to provide a connector enabling good heat dissipation. A connector 11 according to the one aspect of the present disclosure is provided with a housing 13 made of metal, a flat plate-like busbar 14 to be held in the housing 13, a ceramic member 20 to be interposed between one flat surface 14a of the busbar 14 and a contact portion 19 of the housing 13, and compression coil springs 21 for pressing another flat surface 14b of the busbar 14 toward the contact portion 19.