Busbar Detour Layout for Relay Heat Dissipation in Tight Circuits
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Solution Overview
Problem
Conventional circuit structures face challenges in heat dissipation due to limited space for heat dissipation busbars, as they are positioned directly under heat-generating components, restricting the size and placement of heat dissipation components.
Innovation Solution
A circuit structure design that includes a heat-generating component, a busbar with a detour portion connecting electrical and heat transfer portions, a base member with through holes, an insulating plate, and a metal heat dissipation member, allowing for efficient heat transfer and dissipation even when space is limited, using heat transfer sheets to maintain electrical insulation and prevent thermal gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heat dissipation busbar size is increased to improve heat dissipation, then heat dissipation performance is improved, but the available space for disposing the heat dissipation busbar is insufficient due to circuit components located directly under the relay
Solution Approach 1:
The patent transitions from a direct vertical heat transfer path to a multi-dimensional path by introducing a detour portion that extends laterally along the base member. The heat transfer connection portion is positioned at a location different from directly under the relay, utilizing the lateral dimension to bypass the space constraint caused by circuits located directly under the relay.
Solution Approach 2:
The busbar is segmented into distinct functional portions: an electrical connection portion that connects to the relay terminal, a detour portion that laterally connects to bypass occupied space, and a heat transfer connection portion that transfers heat to the heat dissipation busbar. This segmentation allows each portion to optimize its specific function while working together to resolve the space constraint.
2Temperature
If the heat transfer connection portion is positioned away from the heat generating component to improve heat dissipation, then heat dissipation is improved, but the electrical connection reliability may be affected
Solution Approach 1:
The busbar is divided into separate functional sections: the electrical connection portion maintains direct electrical connection to the relay terminal for reliability, while the heat transfer connection portion is positioned optimally for heat dissipation. The detour portion connects these sections, allowing electrical continuity while enabling spatial separation of functions.
Solution Approach 2:
The busbar serves multiple functions simultaneously: it provides electrical connection between the relay and circuit, acts as a heat transfer path from the relay to the heat dissipation busbar, and maintains structural integrity. This multi-functionality allows a single component to resolve both electrical connection reliability and heat dissipation requirements.
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 enhances heat dissipation efficiency, maintains electrical insulation, and allows for improved circuit design flexibility, effectively addressing the space constraints and thermal conductivity limitations in conventional designs.
Implementation Method 1
Heat generated by the relay when receiving electrical power is transferred from the terminals to the busbars
Implementation Method 2
an insulating plate that is made of an insulating material and is arranged below the heat transfer connection portion
Implementation Method 3
a heat dissipation member that is made of a metal and is arranged below the insulating plate
Implementation Method 4
Heat generated by the relay when receiving electrical power is transferred from the terminals to the busbars
Data Source
AI summary
A first busbar includes a first electrical connection portion that is electrically connected to a main relay, a first heat transfer connection portion that is thermally connected to the insulating plate, and a first detour portion that connects the first electrical connection portion and the first heat transfer connection portion to each other. A second busbar includes a second electrical connection portion that is electrically connected to the main relay, a second heat transfer connection portion that is thermally connected to the insulating plate, and a lateral detour portion and a lower detour portion that connect the second electrical connection portion and the second heat transfer connection portion to each other.