Electrical power connectors with cooling features

• US 7,476,108 B2
• Filed: 10/20/2005
• Issued: 01/13/2009
• Est. Priority Date: 12/22/2004
• Status: Active Grant

• Current Assignee: FCI Americas Technology Incorporated (FCI)
• Original Assignee: FCI Americas Technology Incorporated (FCI)
• Inventors: Kolivoski, Christopher J., Daily, Christopher G., Swain, Wilfred James
• Primary Examiner(s): Patel; Tulsidas C.
• Assistant Examiner(s): Patel; Harshad C
• Application Number:
  US11/255,295
• Publication Number:
  US 20060228948A1
• Time in Patent Office: 1,181 Days
• Field of Search: 439/70, 439/79, 439/947, 439/487, 439/196, 439/485, 439/347, 361/712, 361/703, 361/704, 361/730, 361/705
• US Class Current: 439/79
• CPC Class Codes: G06F 1/20 Cooling means
• CPC Class Codes: H01R 12/7088 Arrangements for power supply
• CPC Class Codes: H01R 13/514 composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them
• CPC Class Codes: H01R 13/533 Bases, cases made for use in extreme conditions, e.g. high temperature, radiation, vibration, corrosive environment, pressure H01R13/52 takes precedence
• CPC Class Codes: Y10S 439/947 PCB mounted connector with ground terminal

Abstract

Electrical connectors can include thermally conductive material in regions proximate contacts residing therein to sink heat away from the contacts. The thermally-conductive materials can be provided in the housing structure of the connectors. The thermally-conductive material can also be provided as a thermally-conductive member distinct from the housing.

Claims

1. An electrical connector, comprising:

a housing comprising a thermally-insulative material;

a power contact positioned in the housing; and

a thermally-conductive clip formed from a thermally-conductive thermoplastic and engaging the power contact so that the thermally-conductive clip transfers heat from the power contact.

2. The electrical connector of claim 1, wherein the thermally-conductive clip comprises a first portion exposed to the environment around the electrical connector, and a first panel adjoining the first portion and positioned adjacent a first major surface of the power contact.

3. The electrical connector of claim 2, wherein the thermally-conductive clip further comprises a second panel adjoining the first portion, the second panel being positioned adjacent a second major surface of the power contact.

4. The electrical connector of claim 2, wherein the electrical connector comprises two power contacts and the first panel is positioned between the power contacts.

5. The electrical connector of claim 2, wherein the first panel and the housing define a channel in fluid communication with the environment around the electrical connector whereby heat can be transferred from the power contact to the environment around the electrical connector by conduction and convection.

6. The electrical connector of claim 2, wherein the first portion comprises a plurality of fins.

7. The electrical connector of claim 2, wherein the first portion comprises a plurality of studs.

8. The electrical connector of claim 1, wherein the power contact comprises two plates that define, in combination, both a female mating contact and a male mating contact.

9. The electrical connector of claim 1, wherein the thermally-conductive thermoplastic comprises a polymeric material selected from the group consisting of:

nylons;

liquid crystal polymers; and

polyesters; and

a material selected from the group consisting of;

graphite carbon fibers;

carbon powder;

metallic fillers; and

ceramic fillers.

10. The electrical connector of claim 2, wherein the electrical connector comprises two power contacts;

the thermally-conductive clip further comprises a second panel adjoining the first portion;

the first panel contacts a first of the power contacts; and

the second panel contacts a second of the power contacts.

11. The electrical connector of claim 2, wherein the first panel transfers heat from the power contact to the first portion by conductive heat transfer, and the first portion transfers heat to the environment around the electrical connector by convective heat transfer.

12. An electrical connector, comprising:

a housing comprising a thermally-insulative material;

a power contact positioned in the housing;

a thermally-conductive member formed from a thermally-conductive thermoplastic and disposed proximal to the power contact so that the thermally-conductive member transfers heat from the power contact; and

at least one of a thermally-conductive gasket and a thermally-conductive compound disposed between the power contact and the thermally-conductive member.

13. The electrical connector of claim 12, wherein the thermally-conductive member comprises a first portion exposed to the environment around the electrical connector, and a first panel adjoining the first portion and positioned adjacent a first surface of the power contact.

14. The electrical connector of claim 13, wherein the electrical connector comprises two power contacts and the first panel is positioned between the power contacts.

15. The electrical connector of claim 13, wherein the electrical connector comprises two power contacts and the first panel is positioned between the power contacts.

16. The electrical connector of claim 13, wherein the first panel and the housing define a channel in fluid communication with the environment around the electrical connector whereby heat can be transferred from the power contact to the environment around the electrical connector by conduction and convection.

17. The electrical connector of claim 13, wherein the first portion comprises a plurality of fins.

18. The electrical connector of claim 13, wherein the first portion comprises a plurality of studs.

19. The electrical connector of claim 13, wherein the power contact comprises two plates that define, in combination, both a female mating contact and a male mating contact.

20. The electrical connector of claim 12, wherein the thermally-conductive thermoplastic comprises a polymeric material selected from the group consisting of:

nylons;

liquid crystal polymers; and

polyesters; and

a material selected from the group consisting of;

graphite carbon fibers;

carbon powder;

metallic fillers; and

ceramic fillers.

21. The electrical connector of claim 13, wherein the electrical connector comprises two power contacts;

the thermally-conductive member further comprises a second panel adjoining the first portion;

the first panel contacts a first of the power contacts; and

the second panel contacts a second of the power contacts.

22. The electrical connector of claim 13, wherein the first panel transfers heat from the power contact to the first portion by conductive heat transfer, and the first portion transfers heat to the environment around the electrical connector by convective heat transfer.

23. An electrical connector, comprising:

a housing comprising a thermally-insulative material;

a power contact positioned in the housing; and

a thermally-conductive member formed from a thermally-conductive thermoplastic and touching the power contact so that the thermally-conductive member transfers heat from the power contact , wherein the thermally-conductive member includes a first portion exposed to the environment around the electrical connector, and a first panel adjoining the first portion and positioned adjacent a first major surface of the power contact, wherein the first panel and the housing define a channel in fluid communication with the environment around the electrical connector whereby heat can be transferred from the power contact to the environment around the electrical connector by conduction and convection.

24. An electrical connector, comprising:

a housing comprising a thermally-insulative material;

a power contact positioned in the housing; and

a thermally-conductive member formed from a thermally-conductive thermoplastic and comprising a first portion exposed to the environment around the electrical connector, and a first panel adjoining the first portion and positioned adjacent a first major surface of the power contact, wherein the first portion comprises at least one of a fin or a stud.

25. An electrical connector, comprising:

a housing comprising a thermally-insulative material;

a power contact positioned in the housing, the power contact comprising a first body portion and a second body portion, the first body portion having a first internal surface and a first external surface, and the second body portion having a second internal surface facing the first internal surface and a second external surface; and

a thermally-conductive member formed from a thermally-conductive thermoplastic, the thermally-conductive member touching at least one of the first and second external surfaces of the power contact so that the thermally-conductive member transfers heat away from the power contact.