High-Voltage Connector Thermal Interface Layer
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Solution Overview
Problem
Conventional mechanical connectors for high-voltage circuit breakers face challenges in heat transfer due to a small contact area, which disrupts thermal conductivity and can be exacerbated by the use of electrical sliding contacts, leading to inefficient heat dissipation.
Innovation Solution
Incorporating a thermal conductive, electrically insulating layer between the connector parts, which can be compressible and arranged as a sleeve or between end faces, ensures effective heat transfer without compromising electrical conductivity, utilizing materials like Therm-a-gap for optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical connector with circumferential contact is used to minimize transition resistance, then electrical connection is optimized, but heat transfer area is limited
Solution Approach 1:
The connector is divided into two distinct contact zones: a circumferential contact zone for optimal electrical connection and an end-face contact zone for heat transfer. This segmentation allows each zone to perform its specialized function without compromising the other.
Solution Approach 2:
Different regions of the connector are given different functional qualities: the circumferential surface is optimized for electrical conductivity while the end face is optimized for thermal conduction. This local differentiation resolves the contradiction between electrical and thermal performance requirements.
2Ease of operation
If the connector parts are designed for easy disconnection, then operational flexibility is improved, but thermal contact reliability may deteriorate
Solution Approach 1:
A compression element is pre-installed in the connector to automatically apply compressive force when parts are assembled. This preliminary action ensures thermal contact reliability is established before operation begins, maintaining reliable thermal connection even during disconnection cycles.
3Ease of operation
If electrical sliding contacts are used to enable disconnection, then operational flexibility is improved, but heat dissipation efficiency deteriorates
Solution Approach 1:
The heat transfer path is extended from the traditional circumferential contact (one-dimensional) to include the end-face contact area (adding a second dimension). This dimensional expansion significantly increases the heat transfer surface area and improves heat dissipation efficiency.
Solution Approach 2:
A compression element acts as an intermediary mechanism that applies force to ensure intimate contact between the connector parts. This intermediary ensures reliable thermal and electrical contact while enabling the disconnection functionality through controlled compression and release.
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 solution enables efficient heat transfer across the full cross-sectional area, maintaining optimal electrical current paths and ensuring reliable thermal contact, even during disconnection, thus addressing the limitations of conventional connectors.
Implementation Method 1
a thermal conductive, electrically insulating layer is arranged between and in contact with the end face of the second connector part and the bottom of the cavity of the first connector part
Implementation Method 2
spring means are arranged along the circumference of the first end of the second connector part. The spring means provide a resilient electrical contact surface along the circumference
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A mechanical connector for high and low voltages has a first connector part with a first end having a cavity; a second connector part with a first end having a cross section adapted to the cavity of the first connector part, wherein the inner dimensions of the cavity correspond with the outer dimensions of the cross section to provide a slide fit and an electrical connection between the outer circumference of the cross section and the inner circumference of the cavity; and a thermal conductive, electrically insulating layer is arranged between and in contact with the end face of the second connector part and the bottom of the cavity of the first connector part. A circuit breaker may have such a mechanical connector incorporated in the fixed electrode rod.