Movable Contact Support Structure for Thermal Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional contactor assemblies in electrified vehicles experience deformation and disruption in electric power flow due to flexing of movable contacts under high thermal energy levels, limiting their current rating and efficiency.
Innovation Solution
A support structure, typically made of a material more resistant to thermal relaxation such as stainless steel, is integrated to limit flexing movements of the movable contact, comprising a channel with brackets that secure and stabilize the contact, allowing it to maintain electrical coupling and withstand higher temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the movable contact is made from a highly conductive material to improve electrical performance, then the current rating is improved, but the component heats up more and deforms under high thermal energy levels
Solution Approach 1:
The movable contact is segmented into two distinct parts: a copper contact portion for optimal electrical conductivity and current carrying capability, and a stainless steel support portion for thermal stability and structural support. This segmentation allows each material to perform its specialized function without compromising the other.
Solution Approach 2:
The movable contact utilizes a composite structure combining copper and stainless steel materials. The copper portion provides superior electrical conductivity for high current rating, while the stainless steel portion provides thermal stability and resistance to deformation at elevated temperatures, effectively resolving the contradiction between electrical performance and thermal resistance.
2Power
If the movable contact is designed for high current carrying capacity, then the power handling is improved, but the component deforms under thermal stress disrupting power flow
Solution Approach 1:
The movable contact is divided into functional segments: the copper contact portion handles high current and power transmission, while the stainless steel support portion maintains structural stability and prevents deformation under thermal stress, ensuring reliable power flow.
Solution Approach 2:
The composite structure of copper and stainless steel in the movable contact enables simultaneous optimization of power handling (through copper's high conductivity) and dimensional stability (through stainless steel's thermal stability), preventing deformation that would disrupt power flow.
3Ease of operation
If the movable contact is made more flexible to ensure proper contact engagement, then the ease of operation is improved, but the component flexes excessively under thermal energy levels
Solution Approach 1:
The movable contact is segmented so that the copper contact portion can flex and adapt for proper engagement with stationary contacts, while the stainless steel support portion maintains rigidity to prevent excessive flexing under thermal energy, achieving both ease of operation and thermal stability.
Solution Approach 2:
The composite copper-stainless steel construction allows the copper section to provide necessary flexibility for contact engagement while the stainless steel section provides thermal stability to limit excessive flexing under high thermal energy levels.
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 support structure enhances the current rating of the contactor assembly by preventing flexing, enabling it to handle higher currents and maintain efficient power transfer, with the movable contact remaining stable up to 180°C or higher, effectively matching the increased capability of the contactor system.
Implementation Method 1
A support structure is configured to limit flexing of a movable contact when in the electrically coupled position... the support structure has a second, different material composition that is more resistant to thermal relaxation than the first material composition
Data Source
AI summary
An exemplary contactor assembly includes, among other things, a moveable contact that moves back and forth between an electrically coupled position with a plurality of stationary contacts, and an electrically decoupled position with the stationary contacts. A support structure is configured to limit flexing of the moveable contact when in the electrically coupled position. An exemplary support method includes, among other things, transitioning a moveable contact from an electrically decoupled position to an electrically coupled position with a plurality of stationary contacts. The method further includes limiting a flexing movement of the moveable contact with a support structure.