Power distribution panel having contactor with thermal management feature

Patent metadata

Field	Value
Publication number	US-10150433-B2
Application number	US-201514752217-A
Country	US
Kind code	B2
Filing date	Jun 26, 2015
Priority date	Jun 26, 2015
Publication date	Dec 11, 2018
Grant date	Dec 11, 2018

Abstract

An aircraft power distribution system according to an exemplary aspect of the present disclosure includes, among other things, a power source, a load, and a power distribution panel receiving power from the power source and selectively providing power to the load. The power distribution panel includes a contactor having a housing. A heat sink provides a portion of the housing.

First claim

The invention claimed is:

1. An aircraft power distribution system, comprising:
a power source;
a load; and
a power distribution panel receiving power from the power source and selectively providing power to the load, wherein the power distribution panel includes a contactor having a housing, wherein a heat sink provides a portion of the housing;
wherein the contactor includes a switch having a moveable arm, the moveable arm having a contact portion configured to close an electrical connection between the power source and the load by contacting an input contactor lead and an output contactor lead;
wherein the moveable arm includes at least one heat sink post projecting from the contact portion;
wherein the contactor includes a flexible spreader having a post connection section connected to the at least one heat sink post, and a base section adjacent a base of the heat sink; and
wherein the flexible spreader includes a flexible arm between the base section and the post connection section.

2. The system as recited in claim 1 , wherein the flexible arm is inclined an angle greater than zero and less than one-hundred-and-eighty degrees relative to the base section.

3. The system as recited in claim 1 , wherein the flexible spreader is provided by a plurality of layers of anodized aluminum (Al).

4. The system as recited in claim 3 , wherein the layers of anodized aluminum (Al) include an interior layer of aluminum (Al) and opposed exterior layers of oxide.

5. The system as recited in claim 4 , wherein the interior layer has a thickness at least 30 times greater than the thickness of the exterior layers.

6. The system as recited in claim 5 , wherein the flexible spreader is provided by between 25 and 75 of the layers of anodized aluminum (Al).

7. The system as recited in claim 1 , wherein the heat sink includes fins projecting outward relative to the housing.

8. The system as recited in claim 1 , wherein:
the power source includes one of a generator of a gas turbine engine, a battery, an auxiliary power unit (APU), a ground power module, and a RAM air turbine; and
the load includes one of aircraft cabin lighting, a hydraulic motor, a cabin air compressor, and an engine electric start motor controller.

9. A contactor for a power distribution panel, comprising:
an exterior housing; and
a heat sink providing a portion of the exterior housing;
the contactor includes a switch having a moveable arm, the moveable arm having a horizontal portion configured to close an electrical connection between a power source and a load by contacting an input contactor lead and an output contactor lead;
the moveable arm includes at least one heat sink post projecting from the horizontal portion; and
the contactor includes a flexible spreader having a post connection section connected to the at least one heat sink post, and a base section adjacent a base of the heat sink; and
wherein the flexible spreader includes a flexible arm between the base section and the post connection section.

10. The contactor as recited in claim 9 , wherein the heat sink includes fins projecting outward relative to the housing.

11. A contactor for a power distribution panel, comprising:
a housing provided in part by a heat sink;
an input contactor lead;
an output contactor lead;
a switch selectively moveable to open and close an electrical connection between the input and output contactor leads;
a flexible spreader provided adjacent the heat sink, wherein a shape of the flexible spreader is manipulated as the switch moves to open and close the electrical connection;
wherein the switch has a moveable arm, and wherein the moveable arm includes at least one heat sink post projecting from a contact portion; and
wherein the flexible spreader has a post connection section connected to the at least one heat sink post, and a base section adjacent a base of the heat sink.

12. The contactor as recited in claim 11 , wherein the flexible spreader includes a flexible arm between the base section and the post connection section.

13. The contactor as recited in claim 12 , wherein the flexible arm is inclined an angle greater than zero and less than one-hundred-and-eighty degrees relative to the base section.

14. The contactor as recited in claim 9 , wherein the heat sink includes a base and fins projecting from the base, and wherein the exterior housing includes a top and sides, the top and sides integrally formed with one another, and wherein the base of the heat sink is attached to the sides to provide a bottom of the exterior housing.

15. The contactor as recited in claim 11 , wherein the flexible spreader is configured to transfer heat to the heat exchanger when the switch is in both the open position and the closed position.

Assignees

• Hamilton Sundstrand Corp

Inventors

• Pal Debabrata

Classifications

• H01H50/12

  Ventilating; Cooling; Heating (for operating electrothermal relays H01H61/013) · CPC title

• H02B1/56

  Cooling; Ventilation · CPC title

• B60R16/005

  Electro-mechanical devices, e.g. switched (electric switches in general H01H) · CPC title

• H01H50/546

  for contactors having bridging contacts · CPC title

• H02J2105/32

  for aircrafts · CPC title