Integrated Contactor Post Heat Sink Shunt for Thermal Management
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Solution Overview
Problem
Existing contactor assemblies in electrical applications, such as aircraft power distribution systems, generate excessive heat due to thermally and electrically resistive materials and imperfections in contact surfaces, leading to inefficient heat dissipation.
Innovation Solution
A contactor post with an integrally formed heat sink shunt made of electrically and thermally conductive material, such as aluminum or copper, which extends from the body and is designed to enhance heat transfer to a heat sink, reducing heat generation at joints and improving cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermally and electrically resistive materials (plastics or FR-4) are used for mounting assemblies, then electrical insulation is improved, but heat dissipation deteriorates
Solution Approach 1:
The mounting assembly is divided into two distinct segments: an insulating body (plastic or FR-4) for electrical isolation and a separate heat sink component with high thermal conductivity for heat dissipation. This segmentation allows each material to perform its optimal function without compromise.
Solution Approach 2:
A thermally conductive interface material or bonding mechanism acts as an intermediary between the resistive mounting assembly and the heat-generating electrical contacts. This intermediary transfers heat efficiently while maintaining the electrical insulation properties of the primary mounting structure.
2Ease of manufacture
If contact surfaces have imperfections, then manufacturing ease is improved, but heat generation worsens
Solution Approach 1:
The heat generation problem at imperfect contact surfaces is extracted and isolated from the main mounting structure by introducing a dedicated heat sink component. This heat sink captures and dissipates the waste heat generated at contact interfaces, preventing it from affecting the overall system.
Solution Approach 2:
The imperfections in contact surfaces that generate waste heat are converted into a manageable thermal flow by directing this heat toward the heat sink's dissipation pathways. Rather than allowing heat to accumulate, the design channels it through controlled thermal routes to the heat sink for efficient removal.
3Power
If current flow through contactors is increased, then power distribution capability is improved, but heat generation worsens
Solution Approach 1:
The mounting assembly merges the electrical connection function with the thermal management function by integrating a heat sink directly into the mounting structure. This combination allows high current flow to be supported while simultaneously providing a dedicated thermal pathway for heat removal.
Solution Approach 2:
The mounting assembly serves multiple functions simultaneously: it provides electrical insulation, mechanical support for contacts, and active heat dissipation. This multi-functionality allows the system to handle high power loads without requiring separate thermal management systems.
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 integrally formed heat sink shunt effectively reduces heat generation at electrical contact points and enhances heat transfer, improving the cooling efficiency of the contactor arrangement and preventing heat buildup.
Implementation Method 1
a heat sink shunt extending from the body and comprising the electrically and thermally conductive material... enhance heat transfer to a heat sink
Implementation Method 2
a contactor post extending through the aperture, wherein the contactor post comprises a body comprising an electrically conductive material... allows current to flow through the contactor and the corresponding bus bar
Data Source
AI summary
A contactor post for an electrical contactor may comprise a body comprising an electrically and thermally conductive material, and a heat sink shunt extending from the body and comprising the electrically and thermally conductive material, wherein the body and the heat sink shunt are comprised of a single piece of the electrically and thermally conductive material.