Contactor Lead Angling for Heat Dissipation
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Solution Overview
Problem
Existing electrical contactor mounting assemblies face inefficiencies in heat dissipation due to the use of thermally and electrically resistive materials, leading to heat buildup and increased size and weight requirements for bus bars to manage both current flow and heat dissipation.
Innovation Solution
The use of electrically and thermally conductive posts and leads with non-planar configurations, such as angled portions, to efficiently transfer heat from the contactor to a conductive housing, allowing for enhanced heat dissipation through radiation and convection, potentially reducing the size and weight of the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermally and electrically resistive materials (plastics, FR-4) are used for mounting assemblies, then electrical insulation is improved, but heat dissipation deteriorates leading to heat buildup
Solution Approach 1:
The mounting assembly is divided into multiple segments: an electrically insulating portion (plastic/FR-4) for electrical isolation, and a thermally conductive portion (metal heat sink) for heat dissipation. This segmentation allows each material to perform its optimal function without compromising the other.
Solution Approach 2:
The mounting assembly uses a composite structure combining electrically insulating materials (plastics, FR-4) with thermally conductive materials (metal heat sink, aluminum). This composite approach allows simultaneous achievement of electrical insulation and thermal conduction by leveraging the complementary properties of different materials.
2Temperature
If larger and heavier bus bars are used, then heat dissipation capacity is improved, but device weight and size increase
Solution Approach 1:
A dedicated heat sink component acts as an intermediary between the bus bar and the mounting panel. This heat sink serves as a thermal bridge that efficiently conducts heat away from the bus bar to the panel, enabling effective heat dissipation without requiring oversized bus bars.
Solution Approach 2:
The solution moves heat dissipation to a different dimension by utilizing the mounting panel as a thermal sink. Instead of relying solely on the bus bar's cross-sectional area for heat dissipation, the system leverages the large surface area of the mounting panel in a different spatial dimension to dissipate heat effectively.
3Temperature
If thermally conductive posts and angled leads are used, then heat transfer efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The mounting assembly integrates multiple functions into a single component: mechanical mounting, electrical connection, and thermal management. The metal heat sink serves simultaneously as a thermal conduction path, a mounting structure, and a heat dissipation surface, eliminating the need for separate components.
Solution Approach 2:
The mounting assembly is designed as a multi-functional component that performs electrical insulation, mechanical support, thermal conduction, and heat dissipation simultaneously. This universal design reduces the total number of parts and simplifies manufacturing by consolidating functions.
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 improves heat dissipation efficiency, allowing for smaller and lighter bus bars, reducing the overall size and weight, and cost of the contactor assembly while maintaining effective electrical current transfer.
Implementation Method 1
The at least one lead has a first portion oriented about a first plane and a second portion extending from the first portion and being oriented about a second plane. The second plane is arranged at an angle to the first plane such that one or more surface of the at least one lead are configured to transmit heat to the contactor housing.
Implementation Method 2
allowing for enhanced heat dissipation through radiation and convection
Implementation Method 3
allowing for enhanced heat dissipation through radiation and convection
Data Source
AI summary
An electrical contactor assembly is provided including an electrical contactor positioned within a contactor housing, an electrical bus bar, and a post constructed from an electrically and thermally conductive material connected to the bus bar. At least one lead is coupled to the electrical contact and to the post. The at least one lead has a first portion oriented about a first plane and a second portion extending from the first portion and being oriented about a second plane. The second plane is arranged at an angle to the first plane such that one or more surface of the at least one lead are configured to transmit heat to the contactor housing.