High-Current Contact Device Cooling Unit
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Contact devices used for transferring high currents experience significant heating, which limits the current that can be effectively transferred to the bus bar, as existing cooling solutions are inadequate for efficient heat dissipation.
Innovation Solution
A contact device with a cooling unit comprising a heat sink, heat transfer medium, and two heat exchanger sections, where the heat sink is electrically insulated from the contact element, allowing for efficient heat dissipation through a fluidic connection between the heat exchanger sections, ensuring uniform heat removal and higher current transfer capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high current is transferred through the contact element, then the current transfer capability is improved, but the contact element heats up considerably which limits further current increase
Solution Approach 1:
The harmful heat generated in the contact element is extracted by introducing a cooling unit with heat exchanger sections that remove heat from the contact element through a heat transfer medium, allowing higher current transfer without excessive temperature increase
Solution Approach 2:
A heat transfer medium acts as an intermediary between the contact element and the cooling unit, absorbing heat from the contact element through the heat exchanger sections and transporting it to the heat sink for dissipation
2Temperature
If a cooling unit is added to the contact device, then heat dissipation capability is improved, but the device complexity increases
Solution Approach 1:
The contact element serves multiple functions: electrical current conduction and heat transfer to the cooling unit. The heat exchanger sections integrated into the contact element utilize the same structural component for both electrical and thermal functions, reducing overall device complexity
Solution Approach 2:
The heat exchanger sections are integrated within the contact element structure itself, with the cooling unit nested around portions of the contact element. This nested arrangement allows efficient heat removal while maintaining a compact design without adding significant external complexity
3Temperature
If the heat sink is positioned close to the contact element, then heat transfer efficiency is improved, but electrical insulation becomes difficult to maintain
Solution Approach 1:
The heat transfer medium and heat exchanger sections act as intermediaries between the contact element and heat sink, enabling efficient thermal coupling while maintaining electrical insulation through the fluid medium and isolated heat exchanger pathways
4Power
If the contact element cross-section is increased to improve current capacity, then the current transfer capability is improved, but the compactness and compatibility with existing devices is reduced
Solution Approach 1:
The heat removal function is extracted and handled by a separate cooling unit with integrated heat exchangers, allowing the contact element to maintain its original compact dimensions while achieving higher current capacity through improved thermal management rather than increased size
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 design enables effective heat removal from the contact element, allowing for higher current transfer without structural changes and preventing local overheating, while maintaining compactness and compatibility with previous contact devices.
Implementation Method 1
the heat transfer medium circulates between the first heat exchanger section and the second heat exchanger section
Implementation Method 2
the cooling unit comprises a heat sink, a heat transfer medium, a first heat exchanger section and a second heat exchanger section
Implementation Method 3
The heat sink is arranged at a distance from the contact element. The heat sink is connected to the second heat exchanger section
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a contact device for high-current transfer, comprising a contact element and a cooling unit, the cooling unit comprising a heat transfer medium, a heat sink, a first heat exchanger section and a second heat exchanger section, wherein the first heat exchanger section is connected to the second heat exchanger section in a fluidic manner, wherein the heat sink is arranged at a distance from the contact element, wherein the heat sink is connected to the second heat exchanger section, wherein the first heat exchanger section is arranged with the contact element, wherein the heat transfer medium circulates in a circuit between the first heat exchanger section and the second heat exchanger section, wherein the first heat exchanger section is electrically insulated from the second heat exchanger section.