Electrical Terminal Protrusions for Heat Dissipation
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Solution Overview
Problem
Existing electrical terminals, particularly those in load centers, face high temperatures due to inefficient heat dissipation when mating with stranded conductors, as they have smooth surfaces that result in large portions being engaged with ambient air, leading to elevated temperatures beyond the desired 90° C. rating.
Innovation Solution
The introduction of protrusions on the surface of electrical terminals that engage stranded conductors, such as serrated or corrugated surfaces, increases the mating surface area, reducing electrical resistance and enhancing heat dissipation by allowing more effective engagement of the conductor, thereby lowering terminal temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If smooth surfaces are used on terminals for mating with stranded conductors, then the terminal structure is simple and easy to manufacture, but the surface area for electrical contact is reduced, resulting in high electrical resistance and high temperature
Solution Approach 1:
The patent applies curvature by providing protrusions on the terminal surface that engage with the stranded conductor. These protrusions create a curved, non-smooth surface topology that increases the effective contact area between the terminal and conductor, thereby improving heat dissipation and reducing terminal temperature while maintaining structural simplicity
2Reliability
If smooth surfaces are used on terminals, then manufacturing is easier, but heat dissipation is insufficient causing temperature to exceed 90°C rating
Solution Approach 1:
The protrusions on the terminal surface are formed with curved geometries that increase the mating surface area. This curvature-based design enhances heat dissipation capability, ensuring the terminal maintains its 90°C rating reliability while the protrusion features can be integrated into standard manufacturing processes
3Area of moving object
If protrusions are added to increase surface area, then electrical resistance decreases and heat dissipation improves, but the terminal structure becomes more complex
Solution Approach 1:
The patent applies local quality by adding protrusions only at the specific mating surface area where the terminal contacts the stranded conductor. This localized modification increases the contact area precisely where needed for electrical and thermal performance, while the rest of the terminal structure remains simple and unchanged
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 increased surface area reduces electrical resistance and temperature rise, achieving a 90° C. rating while improving thermal conductivity and heat dissipation, thus addressing the inefficiencies of smooth-surfaced terminals.
Implementation Method 1
The resulting heat dissipation can cause the temperature of the collar of the terminal to be unnecessarily high
Implementation Method 2
The temperature of a terminal is a function of the surface area over which a stranded conductor is electrically mated to the terminal
Data Source
AI summary
A terminal includes a fastener; a conductor member having a plurality of protrusions on a surface thereof facing the fastener; and a collar member. The collar member includes first, second, third and fourth surfaces, a tapped opening on the first surface engaging the fastener, and a conduit between the second and third surfaces. The tapped opening intersects and coincides with the conduit and is normal thereto. The fourth surface is opposite the first surface and contains another opening that intersects and coincides with the conduit. The other opening receives the conductor member. The protrusions and the surface of the conductor member are structured to engage a stranded conductor having a plurality of individual solid conductors. The fastener is structured to engage the stranded conductor.