Folded Copper Contact Device for High-Power Contactor Heat Management
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Solution Overview
Problem
Existing contact devices for high-power applications, particularly in AC1 category, face challenges with heat rise and cost due to bulky designs, and require smaller dimensions and reduced costs, while maintaining reliability and ease of connection.
Innovation Solution
A contact device with a flat, rectangular connection terminal strip and folded conductors forming U-shapes, made of copper with silver alloy pads, optimized for heat dissipation and reduced dimensions, featuring multiple pieces superposed to maximize contact surface area and minimize heat rise, and secured with bolts to prevent connection errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional contactor design is used for high-power AC1 applications, then current carrying capacity is achieved, but heat rise increases and dimensions become bulky
Solution Approach 1:
The contact device is divided into multiple separate contact elements (stationary contact areas and movable contacts) that can be individually optimized. Each contact element is designed with specific geometry and material properties to maximize surface area for heat dissipation while maintaining compact overall dimensions. The segmented structure allows for better thermal management compared to conventional monolithic designs.
Solution Approach 2:
The contact elements are designed with three-dimensional configurations that increase surface area without proportionally increasing volume. The stationary contact areas and movable contacts are shaped to utilize spatial arrangement efficiently, creating extended heat dissipation surfaces in multiple dimensions while maintaining a compact footprint suitable for molded case contactors.
2Volume of moving object
If contactor size is reduced for molded case type, then cost and dimensions are improved, but heat dissipation capability deteriorates
Solution Approach 1:
Different regions of the contact device are designed with locally optimized properties. The contact surfaces have enhanced thermal conductivity and surface area, while the overall device maintains reduced dimensions. The connection terminals and contact areas are specifically engineered with local geometric features that maximize heat dissipation efficiency in constrained spaces.
Solution Approach 2:
The contact device utilizes composite construction with materials optimized for different functions. High-conductivity materials are used at critical heat generation points (contact surfaces), while other portions use materials balanced for mechanical strength and thermal management. This composite approach enables effective heat dissipation within reduced overall dimensions.
3Ease of manufacture
If connection terminals are minimized to comply with temperature standards, then cost is reduced, but connection reliability and heat management become challenging
Solution Approach 1:
The connection terminals are pre-designed and pre-positioned during manufacturing with optimized geometry and material selection. The terminals are configured in advance to ensure proper thermal and electrical performance, allowing for reliable connections at reduced sizes. This preliminary optimization during manufacturing ensures that cost reductions do not compromise connection reliability.
Solution Approach 2:
The connection terminals utilize changes in material parameters (such as thermal conductivity, electrical conductivity, and mechanical strength) to achieve reduced dimensions while maintaining reliability. By selecting materials with optimized parameter combinations and adjusting geometric parameters (surface area, thickness, configuration), the terminals achieve cost-effective miniaturization without sacrificing connection reliability or heat management capability.
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 solution reduces heat rise and costs, enhances reliability, and prevents connection errors, making it suitable for high-power applications like wind power generators and resistive heaters, while maintaining compact dimensions and efficient electrical conduction.
Implementation Method 1
The contact device comprises a superposition of a number of pieces equal to the number of conductors. Each piece of the contact device is made from a metal sheet that is then folded into its final shape, and comprises one of the conductors secured to a connection part
Implementation Method 2
The orientation with respect to the contact areas and the size of the connection strip are optimized to minimize heat rise and also to facilitate connection of the bars. Advantageously, the connection surface of the bars is therefore identical to that of the connection strips so as to maximize the assembled copper masses thereby making for better heat dissipation.
Implementation Method 3
the contact areas comprise supports onto which silver alloy pads are brazed
Data Source
AI summary
A contactor comprises, for each phase, a pair of contact devices which comprise a connection strip and at least two conductors provided with a stationary contact, and a movable contact bridge able to close the two stationary contacts or not. According to the invention, the contact device is formed from superposition of a number of pieces equal to the number of conductors, each piece comprising one of the conductors and a connection part corresponding to the connection strip but of smaller thickness. Each of the pieces can be made from folded metal. The connection parts are coupled to one another to form the connection strip by means of holes at the same time as the sets of bars are secured thereto.