Electrical Assembly Bracket Cooling and Flexible Circuit Integration
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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 contactor, a bus bar, a bracket, a flexible circuit, and a cooling member, where the flexible circuit is disposed on or in the bracket, the bus bar is connected to the contactor and bracket, the cooling member is attached to the bracket, and the components are assembled through a method that facilitates electrical connections and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional electrical assemblies are used, then the assembly process is simple, but they do not provide sufficient functionality for large electrical currents and inadequate cooling
Solution Approach 1:
The electrical assembly is divided into modular components including contactors, bus bars, brackets, flexible circuits, and cooling members. Each component can be independently manufactured and assembled, enabling the system to handle large electrical currents while maintaining manageable assembly complexity through standardized interfaces and procedures.
2Temperature
If traditional electrical assemblies without cooling members are used, then the device complexity is reduced, but they provide insufficient cooling for large electrical currents
Solution Approach 1:
The cooling members are integrated with the bracket structure that already supports the contactors and bus bars. This merging of cooling functionality with the existing mechanical support structure provides effective cooling for large electrical currents while minimizing the increase in overall device complexity.
3Ease of manufacture
If complex assembly processes are avoided, then ease of manufacture is improved, but sufficient functionality for large electrical currents and adequate cooling cannot be achieved
Solution Approach 1:
The flexible circuits are pre-attached to the brackets during bracket manufacturing, and the cooling members are pre-integrated with the bracket structure. This preliminary action eliminates complex assembly steps during final assembly, maintaining ease of manufacture while ensuring the complete assembly provides sufficient functionality and reliability for large electrical currents.
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 handling of high electrical currents by providing effective cooling and simplifying the assembly process, ensuring reliable operation and ease of use in applications such as vehicles.
Implementation Method 1
a cooling member connected to the bracket
Implementation Method 2
The cooling member is attached to the bracket
Data Source
AI summary
An electrical assembly may include a contactor, a bus bar connected to the contactor, a bracket connected to the bus bar, a flexible circuit electrically connected to the contactor, and/or a cooling member connected to the bracket. A method of assembling an electrical assembly may include disposing a flexible circuit at least partially on and/or in the bracket, connecting a bus bar with the one or more contactors, connecting the bus bar with the bracket, electrically connecting the flexible circuit to the one or more contactors, disposing a cooling member on or about the bracket, and/or connecting the cooling member with the bracket.