Battery Disconnect Unit Cooling for Solid-State Relay Heat
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Solution Overview
Problem
Conventional battery disconnect units using electro-mechanical relays suffer from issues such as contact welding, high power consumption, heat generation, large size, weight, and high failure rates, while electronic relays face damage due to inadequate heat management.
Innovation Solution
A battery disconnect unit incorporating an electronic relay module with a heat dissipation cover and cooling plate, utilizing a refrigerant system to manage heat effectively, thereby preventing contact welding and reducing size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electro-mechanical relays are used in the battery disconnect unit, then the relays can effectively control high current, but contact welding and high failure rates occur
Solution Approach 1:
The patent replaces electro-mechanical relays with solid-state electronic relays that use semiconductor devices (MOSFETs or IGBTs) instead of mechanical moving parts and contacts. This substitution eliminates contact welding issues while maintaining the ability to control high current, directly resolving the contradiction between reliability and contact welding prevention.
2Device complexity
If electro-mechanical relays are used, then the relay structure is simple, but the size and weight are large
Solution Approach 1:
By replacing heavy mechanical components with lightweight semiconductor devices, the patent achieves significant weight reduction while simplifying the overall structure. The solid-state electronic relays eliminate the need for heavy magnetic coils, springs, and contact mechanisms, directly addressing the weight and complexity contradiction.
3Power
If electro-mechanical relays are used, then the relay can handle high current, but power consumption and heat generation are high
Solution Approach 1:
The patent replaces energy-intensive electro-mechanical relays with efficient solid-state switches that consume minimal power during operation. The semiconductor devices maintain high current handling capability while dramatically reducing power consumption and heat generation, resolving the contradiction between power handling and energy efficiency.
4Weight of moving object
If electronic relays are used to reduce size and weight, then the disconnect unit becomes more compact, but heat management becomes critical
Solution Approach 1:
The patent introduces a heat dissipation cover as an intermediary component between the electronic relay module and the cooling system. This cover efficiently transfers heat from the electronic relays to the cooling plate, enabling effective thermal management in the compact design and resolving the temperature management challenge.
5Temperature
If a cooling device is added to manage electronic relay heat, then temperature control is achieved, but device complexity increases
Solution Approach 1:
The patent merges the cooling function with the housing structure by integrating the cooling plate and heat dissipation cover into the existing disconnect unit design. This consolidation achieves effective temperature control while minimizing additional complexity, as the cooling components share space and structural elements with the housing rather than adding separate systems.
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 solution ensures reliable operation of electronic relays by managing heat effectively, preventing contact welding, and reducing the size and weight of the disconnect unit compared to conventional units.
Implementation Method 1
a cooling plate disposed in contact with the heat dissipation cover and configured to allow a refrigerant to flow in the cooling plate
Implementation Method 2
allow a refrigerant to flow in the cooling plate
Implementation Method 3
a heat dissipation cover surrounding at least a portion of the electronic relay module and formed of a material capable of heat exchange with the electronic relay module
Data Source
AI summary
A battery disconnect unit including a housing, an electronic relay module installed on a charge/discharge line of a battery within the housing and including electronic switch devices capable of a switching operation of selectively blocking the flow of a current in the charge/discharge line, a heat dissipation cover provided with a structure surrounding at least a portion of the electronic relay module and formed of a material capable of heat exchange with the electronic relay module, and a cooling plate disposed in contact with the heat dissipation cover and provided to allow a refrigerant to flow in the cooling plate.