Thermally Conductive Contactor Panel 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 waste heat generation, which complicates power distribution systems in applications like aircraft power systems.
Innovation Solution
An electrical contactor assembly featuring a panel made of electrically insulating, thermally conductive material with protruding posts that directly contact both the contactor and bus bars, allowing for enhanced heat transfer and dissipation through a larger surface area, potentially incorporating cooling fins for increased efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermally and electrically resistive materials (such as plastics) are used for mounting contactors, then electrical insulation is improved, but heat dissipation deteriorates leading to heat buildup
Solution Approach 1:
The mounting panel is segmented into multiple functional layers: electrically insulating layers for electrical isolation and thermally conductive layers for heat dissipation. This segmentation allows each layer to perform its specialized function without compromise, resolving the contradiction between electrical insulation and heat dissipation.
Solution Approach 2:
The mounting panel uses composite material construction combining electrically insulating materials (such as plastic layers) with thermally conductive materials (such as metal layers or thermally conductive polymers). This composite structure simultaneously provides both electrical insulation and thermal conduction properties, eliminating the need to choose between the two opposing requirements.
2Temperature
If conventional thermally conductive electrical connections are used to transmit heat to bus bars, then heat transmission is improved, but heat dissipation into atmosphere remains limited
Solution Approach 1:
The patent extends heat dissipation from the traditional one-dimensional path through bus bars to a multi-dimensional approach by incorporating cooling fins that increase surface area in three-dimensional space. This dimensional expansion allows heat to dissipate more efficiently into the atmosphere through convection and radiation.
Solution Approach 2:
The patent changes the surface area parameter of the heat dissipation system by adding cooling fins to the bus bars. This increases the effective surface area available for heat transfer to the atmosphere, significantly improving heat dissipation efficiency without changing the fundamental heat transmission mechanism.
3Device complexity
If natural convection and radiation techniques are used for heat dissipation, then simplicity is maintained, but heat dissipation efficiency is insufficient
Solution Approach 1:
The patent improves heat dissipation efficiency by changing the surface area parameter through the addition of cooling fins, while maintaining the simplicity of natural convection and radiation mechanisms. No complex active cooling systems are introduced, preserving design simplicity while achieving better thermal performance.
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, reduces the size and weight of the contactor assembly, and allows for smaller bus bars, resulting in cost savings and enhanced performance in power distribution systems.
Implementation Method 1
The electrical panel and posts are constructed from a thermally conductive material... allow the heat from the contact to be transmitted to the bus bars
Implementation Method 2
The bus bars then dissipate heat into the atmosphere using natural convection and radiation techniques
Implementation Method 3
The bus bars then dissipate heat into the atmosphere using natural convection and radiation techniques
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An electrical contactor assembly, 100, is provided including an electrical contactor, 54, 102, an electrical bus bar, 50, 150, and a single panel, 110, formed of one more layers of an electrically insulating, thermally conductive material. A plurality of posts, 104, 106, protrude through and directly contact the panel, 110. Each of the posts, 104,106, is constructed from an electrically and thermally conductive material. Each post, 104, 106, has a first end configured to electrically and thermally connect to the electrical contactor and a second end configured to electrically and thermally connect to the bus bar, 50, 150.