Thermally enhanced electrical connector

#The present invention relates generally to the field of electrical connectors and more specifically to the field of heat dissipation within electrical connectors.

#Many modern electronic devices, such as computers, include modular power supply connectors. These modular connectors allow easy connection and disconnection of the power supply conductors without the use of tools. Within these connections, contact resistance may result in heat build up in high current uses. Often the heat is generated at or around the contact itself, in contrast to heat being generated throughout the connector. This localized heating often results in hot spots within the connectors, and if allowed to get too hot, may result in failure of the connector due to melting of the insulating material surrounding the contact. The current carrying capability of modern connectors is often limited by this localized heating at the contact, and the connector's maximum current allowable is determined by how much heating the insulating material can withstand.

#An electrical connector is constructed including heat-spreading devices in order to reduce hotspots within the connector and to efficiently dissipate heat to the surrounding atmosphere, thus increasing the current carrying capability of the connector.

#FIGS. 1A-1D are engineering drawings of an example embodiment of a electrical connector.

#FIGS. 2A-2D are engineering drawings of an example embodiment of a thermally enhanced electrical connector according to the present invention.

#FIGS. 3A-3D are engineering drawings of an example embodiment of a thermally enhanced electrical connector according to the present invention.

#FIGS. 1A-1D are engineering drawings of an example embodiment of an electrical connector. In an example embodiment of a prior art electrical connector as shown in FIGS. 1A-1D, the connector body 100 may be constructed from plastic, ceramic, or other electrically insulating material. Two electrical connections are shown within the connector body 100, a left connection 102 and a right connection 104. Each electrical connection 102, 104 extends through a pin 106, for attachment to another connector, printed circuit board, or other electrical device. FIGS. 1A-1D include a front view, top view, side view, and perspective view of the prior art electrical connector.

#FIGS. 2A-2D are engineering drawings of an example embodiment of a thermally enhanced electrical connector according to the present invention. The example embodiment of the present invention shown in FIGS. 2A-2D is an electrical connector similar to the device of FIGS. 1A-1D with the addition of a heat spreader 200 within the connector body 202. The heat spreader 200 may be made out of metal or other thermally conductive material. In the example embodiment shown in FIG. 2, the heat spreader 200 is exposed to the front and back of the connector body 202. However, in other embodiments of the present invention the connector body 202 may completely encapsulate the heat spreader 200 such that it is not externally visible. In other embodiments of the present invention the single heat spreader 200 may be physically located elsewhere within the connector body 202 such as below the left connection 102 and the right connection 104 or possibly between the two connections.

#In other embodiments of the present invention, it may be desirable to load the body 202 of the connector with a thermally conductive, electrically resistive material, such as aluminum nitride. This provides a reduction in thermal resistance of the heat path from the contacts through the connector body 202, to the heat spreader. With such a thermally conductive path from the contacts to the heat spreader, the connector may handle higher currents than an equivalent connector without the thermally conductive, electrically resistive material. Alternatively, the connector body may be made completely out of a thermally conductive, electrically resistive material.