Electrical Assembly Bus Bar Heat Dissipation via Indirect Cooling

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Solution Overview

Problem

Existing electrical assemblies often fail to provide sufficient functionality for large electrical currents, inadequate cooling, and require complex assembly processes, which limits their effectiveness and usability.

Innovation Solution

The proposed electrical assembly includes a bus bar assembly, a fuse connected to the bus bar assembly, a contactor connected to the bus bar assembly, a bracket connected to the bus bar assembly, and a cooling member connected to the bracket, allowing for indirect heat dissipation from the fuse through the bus bar assembly to the cooling member, which is facilitated by a method involving the assembly and operation of these components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing electrical assemblies are used, then the assembly structure is simple, but they do not provide sufficient functionality for large electrical currents and inadequate cooling

Engineering Contradiction:

Improvefunctionality for large electrical currentsVSAvoidassembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electrical assembly is divided into separate functional modules: fuse holder assembly, contactor assembly, bus bar assembly, and cooling member assembly. Each module can be independently designed, manufactured, and assembled, allowing the system to handle large currents reliably while maintaining manageable complexity through modular construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bus bar assembly serves multiple functions: it provides electrical connectivity between components, acts as a structural support element, and functions as a heat conduction path to transfer heat from the fuse to the cooling member. This multi-functionality reduces the need for additional dedicated components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If existing electrical assemblies are used, then the assembly process is complicated, but they do not provide sufficient cooling for large electrical currents

Engineering Contradiction:

Improvecooling efficiencyVSAvoidassembly process

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The cooling member is integrated with the bracket structure, and the bracket is connected to the bus bar assembly, creating a combined structural and thermal management system. This merging of functions provides effective cooling through the heat conduction path while simplifying the assembly process by reducing the number of separate components to install

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bus bar assembly acts as an intermediary element that serves as both an electrical conductor and a thermal conduction path. It mediates between the heat-generating fuse and the cooling member, transferring heat efficiently while maintaining electrical connectivity, thus providing sufficient cooling without complicating the assembly

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If existing electrical assemblies are used, then the assembly is compact, but they require complicated assembly processes and do not provide sufficient functionality

Engineering Contradiction:

Improveeffective operation with high currentsVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fuse holder assembly and contactor assembly are pre-configured with their respective connections to the bus bar assembly before final assembly. The bus bar assembly is pre-attached to the bracket with the integrated cooling member. These preliminary actions ensure proper alignment and connectivity, enabling reliable high-current operation while simplifying the final assembly process

Inventive Principle:

Principle #10Preliminary action

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

This configuration enables efficient heat dissipation and effective operation with high currents, improving the assembly's functionality and simplifying the assembly process, allowing for reliable performance in high-current applications.

Implementation Method 1

conducting the heat from the fuse to the bus bar assembly, conducting the heat from the bus bar assembly to the cooling member

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

generating heat via the current flowing through the fuse

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Data Source

PatentUS11735891B2Electrical assembly

Publication Date: 2023.08.22 LEAR CORP

AI summary

An electrical assembly may include a bus bar assembly, a fuse connected to the bus bar assembly, a contactor connected to the bus bar assembly, a bracket connected to the bus bar assembly, and/or a cooling member connected to the bracket such that the fuse is indirectly connected to the cooling member via the bus bar assembly and the bracket. A method of operating an electrical assembly may include controlling the contactor to provide current from a power source to a load, generating heat via the current flowing through the fuse, conducting the heat from the fuse to the bus bar assembly, conducting the heat from the bus bar assembly to the cooling member, and/or dissipating the heat via the cooling member.