Contactor Thermal Absorber Using PCM for Fixed Contact Heat
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Solution Overview
Problem
High-power electrical contactors generate excessive heat, leading to component damage over time, particularly in applications like aerospace, where larger components to manage heat increase weight and are impractical.
Innovation Solution
Incorporation of a thermal absorber with a phase change material element in the contactor to absorb heat passively, using a housing with a phase change material element configured to absorb heat from fixed contacts, reducing operating temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If larger contactors with larger components are used to handle higher temperatures, then temperature management is improved, but weight increases
Solution Approach 1:
The patent applies phase change material (PCM) that transitions from solid to liquid phase to absorb heat from the contactor components. The PCM is positioned in thermal contact with the fixed contacts and absorbs excessive heat during high-current operations through its phase transition, thereby reducing operating temperatures without requiring larger contactor components.
Solution Approach 2:
The patent introduces a thermal absorber as an intermediary component between the heat-generating contacts and the surrounding environment. This thermal absorber, containing the phase change material, acts as a heat sink that temporarily stores thermal energy, allowing the contactor to maintain lower operating temperatures without increasing overall size or weight.
2Temperature
If larger contactors are used to manage heat, then temperature management is improved, but device size increases
Solution Approach 1:
The phase change material absorbs heat through its phase transition from solid to liquid, providing efficient thermal management within a compact volume. This allows the contactor to handle high temperatures without requiring proportionally larger components or increased overall device volume.
Solution Approach 2:
The patent changes the thermal parameters of the contactor system by introducing material with high latent heat of fusion. This parameter change allows the same volume to absorb significantly more thermal energy, improving temperature management without increasing device size.
3Temperature
If conventional heat dissipation methods are used, then thermal management is achieved, but weight and size increase
Solution Approach 1:
The phase change material provides passive thermal management by absorbing heat during its phase transition. This eliminates the need for active cooling systems, heavy heat sinks, or complex thermal management components, thereby reducing the overall weight of the contactor assembly while maintaining effective temperature control.
Solution Approach 2:
The thermal absorber system is self-regulating and requires no external power or control systems. The phase change material automatically absorbs heat when temperatures rise and releases it when temperatures fall, providing autonomous thermal management that reduces the need for additional heavy components.
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
The thermal absorber effectively manages transient thermal excursions, maintaining lower operating temperatures and preventing damage, while being lightweight and compact, allowing for improved performance and reliability in high-power applications.
Implementation Method 1
The thermal absorber includes a phase change material element configured to absorb heat from the first fixed contact
Implementation Method 2
a phase change material element configured to absorb heat from the first fixed contact
Data Source
AI summary
A contactor includes a housing having a wall defining a cavity and a cover closing the cavity. The contactor includes a first fixed contact and a second fixed contact received in the cavity. The contactor includes a movable contact movable within the cavity between a mated position and an unmated position. The movable contact engages the first and second fixed contacts to electrically connect the first fixed contact and the second fixed contact in the mated position. The contactor includes a coil assembly in the cavity operated to move the movable contact between the unmated position and the mating position. The contactor includes a thermal absorber thermally coupled to the first fixed contact to reduce an operating temperature of the first fixed contact. The thermal absorber includes a phase change material element configured to absorb heat from the first fixed contact.