Contactor Heat Transfer Assembly for Higher Current Capacity

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Solution Overview

Problem

Existing contactors face challenges in increasing current carrying capacity due to overheating issues, which limits their performance in applications requiring high current transmission.

Innovation Solution

The contactor design incorporates a heat transfer device, such as a cold plate with coolant channels or a peltier device, thermally coupled to fixed contacts to dissipate heat, and a thermally conductive isolator to prevent short circuits, enhancing thermal management and allowing higher current capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If current carrying capacity is increased, then power transmission capability is improved, but temperature of contactor components increases

Engineering Contradiction:

Improvecurrent carrying capacityVSAvoidtemperature of fixed contacts

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The harmful heat generated by high current flow is extracted from the contactor system by introducing a heat transfer device with coolant channels. The coolant circulates through these channels to remove heat from the fixed contacts, allowing the contactor to maintain high current carrying capacity without excessive temperature rise.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A heat transfer device acts as an intermediary between the fixed contacts and the cooling system. This device includes coolant channels that facilitate heat removal, and a thermally conductive isolator that provides both thermal management and electrical isolation, enabling high power transmission while controlling temperature.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If heat transfer device is added to dissipate heat, then temperature control is improved, but device complexity increases

Engineering Contradiction:

Improveoperating temperatureVSAvoidstructure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heat transfer device combines multiple functions into a single integrated structure. The coolant channels are integrated directly into the housing, and the thermally conductive isolator simultaneously provides electrical isolation and thermal conduction to the heat sink, reducing the need for separate components and simplifying the overall system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermally conductive isolator serves dual purposes: it provides electrical isolation between the movable contact and housing, and simultaneously conducts heat from the fixed contacts to the heat sink. This multi-functionality reduces component count and simplifies the thermal management system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If thermally conductive isolator is used, then electrical isolation is prevented, but thermal conduction is improved

Engineering Contradiction:

Improveprevention of short circuitsVSAvoidheat dissipation efficiency

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The isolator material exhibits different properties in different directions or contexts: it provides electrical isolation to prevent short circuits, while simultaneously providing thermal conduction to transfer heat from the fixed contacts to the heat sink. This local quality differentiation allows the same component to address both electrical and thermal requirements.

Inventive Principle:

Principle #3Local quality

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 implementation of a heat transfer device reduces operating temperatures, thereby increasing the contactor's current carrying capacity and improving its performance in high-current applications.

Implementation Method 1

The heat transfer device is thermally coupled to the first fixed contact and the second fixed contact to dissipate heat from the first fixed contact and the second fixed contact

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The cold plate includes a thermal interface thermally coupled to the first fixed contact and the second fixed contact to dissipate heat from the first fixed contact and the second fixed contact with aid of coolant fluid flowing through the coolant channel

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

The peltier device uses thermoelectric cooling to dissipate heat from the first fixed contact and the second fixed contact

Methodology Applied

Scientific EffectPeltier effect: Peltier Effect

Data Source

PatentUS12456593B2Contactor with heat transfer device

Publication Date: 2025.10.28 TE CONNECTIVITY BRASIL IND DE ELECTRONICSOS LTDA

AI summary

A contactor includes a housing defining a cavity. The contactor includes a switch assembly received in the cavity. The switch assembly includes first and second fixed contacts received in the cavity and a movable contact movable within the cavity between a mated position and an unmated position. The movable contact engages the first and second fixed contacts to electrically connect the first and second fixed contacts in the mated position. The switch assembly includes a coil assembly in the cavity operated to move the movable contact between the unmated position and the mating position. The contactor includes a heat transfer device coupled to the housing. The heat transfer device is thermally coupled to the first fixed contact and the second fixed contact to dissipate heat from the first fixed contact and the second fixed contact.