Stacked Power Terminal Assembly With Airflow Cooling
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Solution Overview
Problem
Existing high current power connectors face challenges in balancing high current transmission with low temperature rise, due to increased impedance and thermal energy generation, which can exceed the connector's temperature range.
Innovation Solution
The power connector employs a stacked power terminal assembly with a design that includes multiple conductive sheets arranged in parallel, forming airflow passages to reduce thermal effects, thereby achieving a balance between high current transmission and low temperature rise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple narrow contacting portions are arranged alternately and cyclically to improve heating situation, then thermal effect is reduced, but impedance of the power terminal increases
Solution Approach 1:
The contacting portion is divided into multiple segments (first contacting portion and second contacting portion) arranged alternately and cyclically along the power terminal. This segmentation reduces the heating situation by distributing the current flow across multiple contact points, thereby reducing the thermal effect while maintaining acceptable impedance levels through the alternating arrangement pattern.
2Device complexity
If fixed space between spring assembly and plastic base is limited, then structural compactness is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The high elastic part acts as an intermediary between the high conductive part and the external environment. Although the fixed space is limited, the high elastic part provides a thermal conduction pathway that facilitates heat dissipation from the high conductive part through the spring assembly structure, enabling heat transfer despite the compact constraints.
3Power
If stacked power terminal assembly is used to improve current-carrying capacity, then current transmission is improved, but device complexity increases
Solution Approach 1:
The power terminal assembly employs a stacked configuration where multiple power terminals are arranged vertically one above another, forming a nested-like structure. This stacking approach increases the current-carrying capacity by providing multiple parallel conduction paths while maintaining a compact overall form factor, as the terminals are arranged in a vertical column rather than spreading horizontally.
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 stacked power terminal assembly enhances current-carrying capacity and reduces thermal effects, ensuring optimal balance between high current transmission and low temperature rise, thus improving the safety and reliability of the power connector.
Implementation Method 1
a head end of the second conductive sheet presses onto the first back surface of the first conductive sheet, and the first conductive sheet and the second conductive sheet form an electrical conduction for commonly transmitting the power
Implementation Method 2
a first airflow passage is defined between the first fixed plate and the second fixed plate... a second airflow passage is defined between the first conductive sheet and the second conductive sheet... the second airflow passage is communicated with the first airflow passage
Data Source
AI summary
A power connector and a power terminal assembly are disclosed in this application. The power connector includes an insulating body and at least one pair of power terminal assemblies. In the pair of power terminal assemblies, each power terminal assembly includes a first power terminal and a second power terminal that form a stacked structure to ensure high current transmission. A first airflow passage is formed between a first fixed plate of the first power terminal and a second fixed plate of the second power terminal. A second airflow passage is formed between a first conductive sheet of the first power terminal and a second conductive sheet of the second power terminal. The second airflow passage is connected to the first airflow passage. The power terminal assembly of the present application can achieve the better balance between high current transmission and low temperature rise.