Electrical Connection Unit Layout for Thermal Stress Relief

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Solution Overview

Problem

Existing electrical connection units face challenges in improving thermal characteristics, particularly in managing thermal stress and heat dissipation in components with different heat generation timings.

Innovation Solution

The electrical connection unit incorporates a support member that fixes circuit constitution bodies with different heat generation timings to a metal plate, reducing thermal stress on synthetic resin portions by curbing expansion and warpage, and enhances heat dissipation through a heat transfer member and insulating cover.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If circuit constitution bodies with different heat generation timings are mounted on a metal plate, then thermal stress on synthetic resin portions is reduced and heat dissipation is enhanced, but device complexity increases due to the need for multiple fixing portions

Engineering Contradiction:

Improvethermal characteristicsVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The base member is divided into multiple fixing portions that are separately disposed to surround the outer side of the facing region. Each fixing portion independently secures the circuit constitution body to the support member, allowing for localized thermal management and reduced thermal stress on synthetic resin portions while maintaining a manageable structural complexity through modular fixation points.

Inventive Principle:

Principle #1Segmentation

2Reliability

If multiple fixing portions are used to secure the base member, then thermal stress on synthetic resin portions is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal stress resistanceVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fixing portions are segmented and separately disposed around the facing region, allowing each portion to be independently manufactured and positioned. This segmentation reduces thermal stress by distributing fixation points while maintaining ease of manufacture through standardized, repeatable fixing portion designs that can be produced using conventional manufacturing techniques.

Inventive Principle:

Principle #1Segmentation

3Temperature

If the base member is fixed at multiple separate locations, then heat dissipation is enhanced, but production time increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidproduction efficiency

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The multiple fixing portions are strategically positioned to maximize heat dissipation efficiency by securing the base member at optimal locations that facilitate thermal management. Despite the increased number of fixing portions, production efficiency is maintained through designs that allow for efficient assembly processes and standardized fixing portion configurations.

Inventive Principle:

Principle #1Segmentation

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 design improves thermal characteristics by reducing thermal stress on resin portions and enhancing heat dissipation, thereby prolonging the life of the synthetic resin portions and maintaining efficient operation.

Implementation Method 1

fixes the circuit constitution bodies with different heat generation timings to a metal plate 80... enhances heat dissipation through a heat transfer member

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

enhances heat dissipation through a heat transfer member and insulating cover

Methodology Applied

Scientific EffectHeat dissipation: Convection

Data Source

PatentUS20250372976A1Electrical connection unit

Publication Date: 2025.12.04 YAZAKI CORP

AI summary

An electrical connection unit includes a plurality of circuit constitution bodies and a support member that supports the plurality of circuit constitution bodies. Each of the circuit constitution bodies includes a plurality of electronic components, a bus bar that electrically connects the plurality of electronic components, and an insulating base member that holds the bus bar. In a case where a direction in which the plurality of electronic components and the base member face each other is a first direction, the base member has a facing region facing the plurality of electronic components when viewed from the first direction, and is fixed to the support member via a plurality of fixing portions that are separately disposed to surround an outer side of the facing region when viewed from the first direction.