Contactor Heat Sink Coupling for Open-Position Cooling

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Solution Overview

Problem

Existing contactor apparatuses face challenges in effectively removing heat when the moveable contactor is in the open position, due to the creation of an air-gap that limits heat dissipation.

Innovation Solution

Incorporating a heat sink that thermally couples with the moveable contactor in the open position, allowing for the transfer and dissipation of heat to surrounding components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the moveable contactor is in the open position, then the contactor can prevent electrical current flow, but heat dissipation is limited due to air-gap formation

Engineering Contradiction:

Improveelectrical isolationVSAvoidheat dissipation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

A thermal interface material is introduced as an intermediary between the moveable contactor and the heat sink. This material maintains thermal coupling when the contactor is in the open position, overcoming the air-gap problem while preserving electrical isolation. The thermal interface material conducts heat from the moveable contactor to the heat sink without compromising the electrical circuit interruption.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If the moveable contactor thermally couples with the heat sink in the open position, then heat removal is improved, but the structure becomes more complex

Engineering Contradiction:

Improveheat removalVSAvoidstructural complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heat sink is integrated directly into the housing structure of the contactor, merging two previously separate components into one unified structure. This integration reduces the number of parts and simplifies assembly while maintaining effective heat removal from the moveable contactor through the thermal interface material.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If a thermal interface material is used to maintain thermal coupling, then heat transfer is improved, but the device complexity increases

Engineering Contradiction:

Improveheat transferVSAvoidcomponent count

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The housing structure is designed to serve multiple functions: it provides mechanical support, electrical isolation, and integrates the heat sink for thermal management. By making the housing multi-functional, the need for additional separate components is reduced, offsetting the addition of the thermal interface material and overall simplifying the device architecture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Facilitates efficient heat removal from the contactor even when it is in the open position, preventing heat buildup and ensuring optimal performance.

Implementation Method 1

The heat sink can thermally couple with the moveable contactor when the moveable contactor is in an open position. The heat sink can remove heat from the moveable contactor.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12328852B2Contactor apparatus

Publication Date: 2025.06.10 RIVIAN HOLDINGS LLC

AI summary

An apparatus can include a housing, a first contactor portion, a heat sink, and a second contactor portion. The first contactor portion can be coupled with the housing. The heat sink can be coupled with the housing. The second contactor portion can contact the first contactor portion in a first position. The second contact or portion can thermally couple with a heatsink in a second position.