Electrical Connection Box Bus Bar Layout to Suppress Housing Warping
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Solution Overview
Problem
Conventional electrical connection boxes for electronic components in vehicles face issues with warping of the housing casing due to heat concentration, leading to degraded contact between the chassis and heat transfer sheets, which impairs heat dissipation.
Innovation Solution
An electrical connection box design featuring a bus bar between opposing surfaces of the housing casing, with holding portions on each surface to secure the bus bar via a heat transfer sheet, ensuring even heat transfer and preventing warping by distributing restraining forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat is transferred via the bus bar to the chassis, then heat dissipation is improved, but warping occurs in the chassis due to temperature difference
Solution Approach 1:
A heat transfer sheet is introduced as an intermediary between the bus bar and the chassis. The heat transfer sheet has lower thermal conductivity than the bus bar, which allows it to distribute heat more evenly across the chassis surface, preventing localized temperature differences that cause warping while still enabling effective heat dissipation.
Solution Approach 2:
The heat transfer sheet is designed with specific local properties - it has lower thermal conductivity compared to the bus bar material. This local quality difference allows the sheet to act as a heat distribution interface, spreading heat over a larger area of the chassis rather than concentrating it at a single point, thereby preventing thermal warping.
2Stability of the object's composition
If the chassis warps due to heat concentration, then contact between the chassis and heat transfer sheet is degraded, but heat dissipation ceases to be proper
Solution Approach 1:
The heat transfer sheet is designed to prevent warping before it occurs by distributing heat evenly across the chassis surface. By preventing the temperature differences that cause thermal expansion and warping, the sheet maintains stable contact between the chassis and itself, ensuring continuous effective heat dissipation throughout the operational life of the device.
3Temperature
If a bus bar is used for heat transfer, then heat dissipation efficiency is improved, but the bus bar causes localized heat concentration that leads to warping
Solution Approach 1:
The heat transfer sheet serves as a mediator between the high-conductivity bus bar and the chassis. It receives heat efficiently from the bus bar and distributes it evenly across the chassis surface, combining the heat transfer efficiency of metal conductors with the heat distribution capabilities of a lower-conductivity material to prevent localized overheating and warping.
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 effectively suppresses warping of the housing casing and maintains contact between the heat transfer sheet and the casing, ensuring efficient heat dissipation from electronic components.
Implementation Method 1
heat generated by the electronic component is transferred to the chassis via the bus bar and the heat transfer sheet and dissipated
Implementation Method 2
heat generated by the electronic component is transferred to the chassis via the bus bar and the heat transfer sheet and dissipated
Data Source
AI summary
Provided is an electrical connection box including a housing casing for housing a relay, and a heat transfer sheet for transferring heat from the relay to the housing casing, the electrical connection box including: a bus bar provided between a top surface and an inside surface that correspond to each other in the housing casing so as to oppose the top surface and the inside surface; a first holding portion protruding from the inside surface and holding the bus bar via the heat transfer sheet; and a second holding portion protruding from the top surface and holding the bus bar.