Conductive Mounting Posts for Aircraft Contactor Heat Dissipation

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Solution Overview

Problem

Conventional electrical contactor assemblies in aircraft power distribution systems face inefficiencies due to thermally and electrically resistive materials used in mounting assemblies, leading to inconsistent voltage drops and increased waste heat generation.

Innovation Solution

The use of electrically and thermally conductive mounting posts with contactor-foil material, which provides multiple points of contact between the contactor pins and bus bars, reducing resistance and enhancing heat dissipation through improved thermal conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermally and electrically resistive materials (plastics or FR-4) are used in mounting assemblies, then the mounting structure provides electrical isolation and mechanical support, but electrical resistance increases leading to inconsistent voltage drops and increased waste heat generation

Engineering Contradiction:

Improveelectrical isolationVSAvoidwaste heat generation

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The mounting assembly is segmented into distinct functional zones: thermally/electrically resistive mounting structure for support and isolation, and thermally/electrically conductive posts for power transmission. This segmentation allows each component to optimize its specific function without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Mounting posts serve as intermediary elements between the resistive mounting structure and the electrical contacts. These conductive posts bridge the gap by providing dedicated thermal and electrical conduction pathways while the main mounting structure maintains its isolating function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If conventional leads and mounting posts with imperfect contact surfaces are used, then the assembly structure is simple, but electrical resistance increases due to inconsistent voltage drops

Engineering Contradiction:

Improveassembly structureVSAvoidelectrical resistance

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The contact interface is transformed from a simple surface-to-surface contact to a multi-dimensional contact system using foil material that wraps around the contactor pin, creating circumferential contact in multiple directions and maximizing contact area.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Thin foil material is used at the contact interfaces to conform to the contactor pin surface, ensuring maximum contact area and consistent electrical connection. The flexibility of the thin film allows it to adapt to surface imperfections.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If thermally resistive materials are used in mounting assemblies, then electrical isolation is maintained, but heat dissipation capability decreases

Engineering Contradiction:

Improveelectrical isolationVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mounting assembly uses composite construction combining materials with different thermal and electrical properties: resistive materials for structural support and isolation, and conductive materials for power transmission pathways, optimizing both thermal management and electrical performance.

Inventive Principle:

Principle #40Composite materials

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 minimizes voltage drops and effectively dissipates heat, increasing the heat generation tolerance of contactor assemblies and ensuring reliable power distribution.

Implementation Method 1

enhancing heat dissipation through improved thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

electrically and thermally conductive mounting posts

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS9991655B2Contactor in power distribution assembly

Publication Date: 2018.06.05 HAMILTON SUNDSTRAND CORP

AI summary

An electrical contactor assembly includes an electrical contactor having an electrical lead having a contactor pin extending therefrom, an electrical bus bar, and at least one post extending between the electrical contactor and the electrical bus bar. The post is constructed from an electrically and thermally conductive material. The post includes an opening for receiving the contactor pin and the opening includes a contactor-foil material disposed in contact with the pin.