Contactor Mounting Post with Integral Fins for Thermal Management
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Solution Overview
Problem
Conventional contactor mounting assemblies in high-power applications, such as aircraft power distribution systems, face inefficiencies in heat dissipation due to reliance on natural convection and radiation, which can lead to heat buildup and reduced reliability.
Innovation Solution
The contactor assembly incorporates a mounting post with integral fins and a design that includes multiple portions connected to both external and internal bus bars, allowing for enhanced heat transfer through both conduction and convection, with optional metallurgical bonding and an insulating outer layer for improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting assemblies made of thermally and electrically resistive materials (plastics, FR-4) are used, then electrical insulation is provided, but heat dissipation efficiency deteriorates leading to heat buildup
Solution Approach 1:
The mounting post is constructed as a composite structure with a thermally conductive core material (such as aluminum or copper) surrounded by an electrically insulating outer layer (such as epoxy or polymer coating). This composite design enables simultaneous thermal conduction and electrical insulation, resolving the contradiction between heat dissipation efficiency and electrical insulation requirements
Solution Approach 2:
The mounting post incorporates extended surfaces in the form of fins protruding from the main body, increasing the heat dissipation surface area by transitioning from a simple cylindrical or rectangular post to a three-dimensional structure with multiple heat transfer surfaces. This dimensional enhancement improves convective and radiative heat dissipation capabilities
2Reliability
If natural convection and radiation cooling methods are used, then no additional cooling components are required, but heat dissipation capacity is insufficient for high power applications
Solution Approach 1:
The mounting post incorporates fin structures that replicate the heat dissipation functionality of dedicated heat sinks, extending the surface area available for convective and radiative heat transfer. These fins act as distributed heat dissipation elements throughout the mounting structure, significantly enhancing the overall heat dissipation capacity without requiring separate cooling components
Solution Approach 2:
The mounting post utilizes materials with high thermal conductivity (such as aluminum or copper) for the core structure, fundamentally changing the thermal parameter of the mounting assembly. This material parameter change enables efficient heat conduction from the contactor terminals through the mounting post to the surrounding environment, increasing power handling capacity
3Temperature
If the mounting post is made of thermally conductive material, then heat dissipation is improved, but electrical insulation capability deteriorates
Solution Approach 1:
The mounting post employs a composite construction with a thermally conductive core material (aluminum, copper, or aluminum alloy) surrounded by an electrically insulating outer layer (epoxy, polymer coating, or ceramic). This layered composite structure enables the core to conduct heat efficiently while the outer layer provides the necessary electrical insulation, simultaneously addressing both thermal and electrical requirements
Solution Approach 2:
The electrically insulating outer layer acts as an intermediary between the thermally conductive core and the surrounding electrical environment. This intermediate layer prevents electrical breakdown and arcing while allowing thermal energy to dissipate through conduction in the core material, mediating between the conflicting thermal and electrical requirements
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 design effectively reduces contactor temperature, enabling increased power handling capacity and improved reliability by efficiently dissipating heat, thus overcoming the limitations of conventional cooling methods.
Implementation Method 1
allowing for enhanced heat transfer through both conduction and convection
Implementation Method 2
dissipating the heat into the atmosphere using natural convection and radiation techniques
Implementation Method 3
dissipating the heat into the atmosphere using natural convection and radiation techniques
Data Source
Figure 1
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Figure 3
AI summary
A contactor assembly post is provided. The contactor assembly post (130) includes a first portion (1301) electrically connected to an external bus bar (120) at an exterior of an electrical contactor housing, a second portion (1302) electrically connected to an internal bus bar (106) at the exterior of the electrical contactor housing, a third portion (1303) and fins (1304). The internal bus bar is configured to extend into an interior (108) of the electrical contactor housing to be electrically coupled to another internal bus bar. The third portion extends transversely between the first and second portions. The fins extend transversely from multiple points defined along a longitudinal axis of the third portion.