Low-Profile Bus Bar Layout With Heat Transfer in Connection Units
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Solution Overview
Problem
The existing electrical connection units have a high height that needs to be reduced to optimize space utilization and efficiency, particularly in vehicle applications.
Innovation Solution
The electrical connection unit incorporates a base member with a flat surface portion, a bus bar, and a heat transfer member, where the bus bar is accommodated in an accommodation portion of the base member, and the heat transfer member is positioned between the bus bar and a metal plate, reducing the overall height by optimizing the layout and integration of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bus bar is attached to the housing in a standing posture, then electrical connection functionality is achieved, but the height of the electrical connection unit becomes large
Solution Approach 1:
The bus bar is repositioned from a vertical standing posture to a horizontal layout within a recessed accommodation portion of the base member. This dimensional change allows the bus bar to be accommodated within the thickness of the base member rather than extending vertically, thereby reducing the overall height of the electrical connection unit while maintaining electrical connection functionality
Solution Approach 2:
The bus bar is nested within the accommodation portion formed in the base member. The accommodation portion is recessed into the base member, allowing the bus bar to be housed within the existing structure rather than adding to the external dimensions. This nesting approach enables the bus bar to be integrated into the base member's thickness, reducing the unit's height
2Volume of moving object
If components are integrated to reduce height, then space efficiency improves, but heat dissipation may be compromised
Solution Approach 1:
A heat transfer member is introduced as an intermediary between the bus bar and the metal plate. This heat transfer member facilitates thermal conduction from the bus bar to the metal plate, which serves as a heat sink. The intermediary ensures efficient heat dissipation even when the bus bar is recessed and integrated within the base member, preventing heat accumulation despite the compact integration
Solution Approach 2:
The heat dissipation function is extracted and separated from the base member structure by introducing a dedicated heat transfer member. This allows the heat management function to be independently optimized and positioned strategically between the heat-generating bus bar and the heat-sinking metal plate, ensuring thermal performance is not compromised by the integrated design
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 allows for a significant reduction in the height of the electrical connection unit, enhancing space efficiency and integration in vehicles such as electric vehicles.
Implementation Method 1
The heat transfer member is disposed between the exposed portion of the bus bar and the metal plate
Data Source
AI summary
An electrical connection unit includes a first electronic component, a base member, a bus bar, a metal plate and a heat transfer member. The base member includes a flat surface portion having a first surface and a second surface, and a first accommodation portion that penetrates the flat surface portion in a first direction. The bus bar is electrically connected to the first electronic component, and includes a plate portion that is accommodated in the first accommodation portion, and an exposed portion exposed to outside of the base member on the second surface side. The metal plate have a gap between the metal plate and the flat surface portion. The heat transfer member disposed between the exposed portion and the metal plate. A contact surface between the heat transfer member and the exposed portion is closer to the metal plate than the second surface in the first direction.