Oil-Cooled Rectifier Bus Bar Assembly for Aircraft Thermal Margin
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Solution Overview
Problem
Aircraft generator rectifier assemblies face inefficiencies in cooling, leading to low thermal margins under high power loads, particularly with hot cooling oil conditions, which can result in increased weight and reduced performance.
Innovation Solution
A liquid-cooled rectifier assembly design featuring bus bars with integrated cooling channels and diode arrays, optimized by bolts and springs for electrical and thermal contact, utilizing turbine sump oil for enhanced cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fins are added to the cooling path to improve cooling performance, then cooling efficiency is improved, but overall weight increases
Solution Approach 1:
The patent merges the cooling function directly into the bus bar structure by forming cooling channels within the bus bar itself. This integration eliminates the need for separate fin structures, achieving effective cooling while maintaining low weight. The bus bar serves dual purposes: electrical conduction and thermal management.
Solution Approach 2:
The bus bar is designed to perform multiple functions simultaneously: it provides electrical connection, structural support, and active cooling through integrated channels. This multi-functionality removes the need for additional dedicated cooling components that would increase weight.
2Temperature
If a die is mounted to a substrate and the substrate is mounted to a cold plate, then cooling is provided, but thermal margin is very low or even negative under high power load with hot cooling oil condition
Solution Approach 1:
The patent introduces cooling channels within the bus bar structure as an intermediary thermal path. This intermediary structure provides direct thermal contact between the diode array and the cooling fluid circulation path, significantly improving heat transfer efficiency and thermal margin under high power conditions.
Solution Approach 2:
The patent utilizes fluid (cooling oil) circulation through integrated channels to remove heat from the diode array. This hydraulic cooling system provides efficient heat transfer directly at the heat source, improving thermal margin and reliability under high power load conditions.
3Temperature
If modifications are made to the cooling path, then cooling performance may be improved, but device complexity increases
Solution Approach 1:
By merging the cooling channels directly into the bus bar structure, the patent simplifies the overall device architecture. Instead of adding separate cooling components and complex mounting arrangements, the cooling function is integrated into an existing structural element, reducing overall device complexity.
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 achieves reduced volume and weight with improved cooling efficiency, maintaining thermal and electrical contact, suitable for aeronautical applications.
Implementation Method 1
Heat is transferred from the diodes 110, through a substrate 120 to the cold plate 130 and ultimately to the fluid 190
Implementation Method 2
optimized by bolts and springs for electrical and thermal contact
Data Source
AI summary
A liquid-cooled rectifier assembly includes first and second bus bars, each having at least one cooling channel formed therein, which are adapted and configured to carry a cooling fluid therethrough, and a first power diode array arranged between and in contact with the first and second bus bars. A third bus bar can be provided, along with a second power diode array.