Aircraft Power Switch Busbar Thermal Management

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Solution Overview

Problem

Modern aircraft solid state power controllers face challenges in efficiently dissipating heat from solid state power switches, which can lead to overheating if not adequately managed.

Innovation Solution

A solid state power switch assembly comprising a circuit board, solid state power switches, and a busbar that sandwiches the switches between the busbar and the circuit board, allowing for efficient heat dissipation and electrical current transfer, with the busbar serving multiple functions including energy supply, heat dissipation, and mechanical protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solid state power switches are used to control electric power supply in aircraft, then power control efficiency and reliability are improved, but heat generation increases causing overheating risks

Engineering Contradiction:

Improvepower control reliabilityVSAvoidheat generation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent combines the electrical connection function and thermal dissipation function into a single integrated busbar structure. The busbar simultaneously provides electrical power to the solid state power switches and serves as a heat sink to conduct away generated heat, eliminating the need for separate cooling components and effectively managing thermal loads while maintaining reliable power control

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar is designed to perform multiple functions: it serves as an electrical conductor for power supply, as a thermal conductor for heat dissipation, and as a mechanical support structure. This multi-functional design addresses both the power control reliability requirement and the heat management challenge within a single component

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If separate cooling components are added to dissipate heat from solid state power switches, then heat dissipation efficiency is improved, but device complexity and manufacturing costs increase

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidassembly complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the cooling function into the existing busbar structure used for electrical power delivery. By integrating thermal management capabilities into the already-necessary busbar component, the design achieves effective heat dissipation without adding separate cooling components, thereby reducing assembly complexity and manufacturing costs

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The busbar is designed to simultaneously perform electrical power transmission and thermal dissipation functions. This multi-functional approach eliminates the need for additional dedicated cooling components, simplifying the overall assembly while maintaining effective heat management from the solid state power switches

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If multiple separate components are used for power supply and heat dissipation, then functional performance is improved, but manufacturing costs and assembly efforts increase

Engineering Contradiction:

Improveelectrical connection stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple functions (power supply, heat dissipation, and mechanical support) into a single integrated busbar structure. This reduces the total component count, simplifies assembly procedures, and lowers manufacturing costs while maintaining stable electrical connections and effective thermal management through the unified design

Inventive Principle:

Principle #5Merging (Combining)

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

This configuration effectively reduces heat dissipation efforts and manufacturing costs by using a single busbar to supply energy and dissipate heat from multiple solid state power switches, while maintaining a stable and efficient electrical connection.

Implementation Method 1

The busbar comprises at least one busbar contact portion, which is configured for electrically contacting the power switch electric contact surface in order to allow transferring electricity and heat between the busbar and the at least one solid state power switch

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20240162690A1Solid state power switch assembly of an aircraft solid state power controller and method of providing a solid state power switch assembly for an aircraft solid state power controller

Publication Date: 2024.05.16 HS ELEKTRONIK SYST

AI summary

A solid state power switch assembly of an aircraft solid state power controller includes a circuit board, at least one solid state power switch, and a busbar. The at least one solid state power switch has a first side and an opposing second side. A power switch electric contact surface is formed on the first side and the at least one solid state power switch is arranged on the circuit board with the second side facing the circuit board and the first side facing away from the circuit board. The busbar comprises at least one busbar contact portion configured for electrically contacting the power switch electric contact surface and at least one busbar mounting portion, which is configured for be mounted to the circuit board, so that the at least one solid state power switch is sandwiched between the at least one busbar contact portion and the circuit board.