Contactor Interconnect Heat Dissipation Segmentation
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Solution Overview
Problem
Conventional power distribution systems in aircraft face inefficiencies in heat dissipation, leading to oversized and heavier bus bars due to heat rejection requirements, which can complicate the system and increase weight.
Innovation Solution
The introduction of an interconnect with electrically conductive heat rejection components arranged in parallel between the contactor lead and bus bar, providing a greater surface area for heat dissipation and allowing current to traverse these components, thereby enhancing passive heat rejection without increasing the size or weight of the bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If bus bars are sized larger or made from heavier materials to dissipate heat, then heat dissipation capability is improved, but system weight and complexity increase
Solution Approach 1:
The heat dissipation function is segmented from the bus bar structure by introducing separate heat rejection components (fins) that are attached to the bus bar. These fins provide additional surface area for heat dissipation without requiring the bus bar itself to be larger or heavier, thus resolving the contradiction between heat dissipation capability and bus bar weight.
2Temperature
If bus bars are sized larger to dissipate heat, then heat dissipation capability is improved, but system complexity increases
Solution Approach 1:
The heat dissipation function is segmented from the bus bar structure by introducing separate heat rejection components (fins) that are attached to the bus bar. These fins provide additional surface area for heat dissipation without requiring the bus bar itself to be larger or heavier, thus resolving the contradiction between heat dissipation capability and bus bar weight.
3Temperature
If heat rejection components are added to the interconnect, then heat dissipation capability is improved, but interconnect complexity increases
Solution Approach 1:
The heat rejection components are merged with the interconnect structure by attaching fins directly to the lead post and bus bar post. This integration allows the interconnect to perform both its primary function of connecting electrical components and its secondary function of dissipating heat, thereby improving heat dissipation capability while minimizing the increase in interconnect complexity.
4Temperature
If heat rejection components are added to the interconnect, then heat dissipation capability is improved, but manufacturing complexity increases
Solution Approach 1:
The heat rejection components are merged with the interconnect structure by attaching fins directly to the lead post and bus bar post. This integration allows the interconnect to perform both its primary function of connecting electrical components and its secondary function of dissipating heat, thereby improving heat dissipation capability while minimizing the increase in interconnect complexity.
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 effectively dissipates heat generated by contactors, reducing the need for oversized bus bars and potentially using lighter materials like aluminum, while maintaining reliable operation without additional cooling components, thus optimizing thermal management in power distribution systems.
Implementation Method 1
passively dissipating heat conveyed from the lead post toward the bus bar post
Implementation Method 2
Heat can be rejected in a flow direction that is angled with respect to current flow through the interconnect
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A contactor interconnect includes a lead post (116), a bus bar post (118) and a plurality of electrically conductive heat rejection components (120). The lead post electrically connects to the bus bar post in series through the plurality of heat rejection components. The heat rejection components in turn connect electrically in parallel with one another between the lead post and the bus bar post for conducting current between the posts and passively dissipating heat conveyed from the lead post toward the bus bar post.