Molded Heat Spreader Electrical Assembly for HV Contactor Cooling
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Solution Overview
Problem
Existing electrical assemblies in high voltage systems, such as those used in vehicles, face challenges in efficiently dissipating heat generated by contactors and bus bars, leading to potential performance issues and inefficiencies.
Innovation Solution
An electrical assembly design that includes a heat spreader molded onto contactors and bus bars, utilizing a thermosetting polymer for thermal conductivity and electrical insulation, with reduced fasteners and consistent spacing, allowing for effective heat dissipation through fins and optional connection to a cold plate for further cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional electrical assemblies are used without integrated heat spreaders, then manufacturing complexity is reduced, but heat dissipation efficiency deteriorates leading to thermal issues
Solution Approach 1:
The heat spreader is molded directly onto the contactor and bus bar assembly, merging thermal management functionality with the electrical components. This integration eliminates the need for separate heat dissipation devices and complex assembly procedures, while effectively conducting heat away from critical components through the molded heat spreader structure
2Strength
If fasteners are used to attach heat spreaders, then assembly strength is improved, but the number of parts and assembly complexity increases
Solution Approach 1:
The heat spreader is molded directly onto the contactor and bus bar assembly as an integrated structure, eliminating the need for separate fasteners and attachment hardware. This direct molding approach maintains strong thermal and mechanical coupling between components while significantly reducing the total part count and simplifying the assembly process
Solution Approach 2:
The mechanical fastening system (fasteners, bolts, clips) is replaced with a molded attachment system where the heat spreader is formed directly onto the electrical components. This substitution maintains the necessary mechanical strength for thermal conduction and structural support while eliminating the complexity of multiple fastening elements
3Temperature
If thermaly conductive materials are used, then heat dissipation is improved, but electrical insulation may be compromised
Solution Approach 1:
The heat spreader is constructed from composite materials that simultaneously provide high thermal conductivity for effective heat dissipation and sufficient electrical insulation properties. This composite material approach allows the heat spreader to conduct heat away from the contactor and bus bar while maintaining the necessary electrical isolation between different voltage components
Solution Approach 2:
The heat spreader design incorporates varying material properties or structural characteristics in different regions to optimize both thermal conduction and electrical insulation. Critical areas requiring electrical isolation may have different material composition or geometric features compared to regions prioritized for thermal conduction, allowing simultaneous optimization of both functions
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 provides improved heat dissipation, consistent electrical isolation, and adaptability to various configurations, enhancing the performance and reliability of high voltage systems by minimizing thermal stresses and maintaining electrical integrity.
Implementation Method 1
a heat spreader molded onto contactors and bus bars. The heat spreader can include a set of cooling fins
Implementation Method 2
The heat spreader can include a set of cooling fins
Implementation Method 3
effective heat dissipation through fins
Data Source
AI summary
An electrical assembly, comprising an electrical contactor including a first terminal; a bus bar connected to the first terminal; and a heat spreader molded onto the electrical contactor and the bus bar. The heat spreader can comprise a thermoset material that is electrically insulating and thermally conductive. The bus bar can be welded with the first terminal.