Flat Conductor Structure for Heat Dissipation and Low Waste
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Solution Overview
Problem
Existing flat conductors face challenges in productivity due to waste material generation and temperature rise during energization, particularly in structures with varying conductivity and those using press punching, and temperature differences lead to inefficient heat management.
Innovation Solution
A flat conductor design with a conductive plate material having lower resistance end portions and a thermally conductive sheet connecting these to a central portion, utilizing a higher thermal conductivity material to reduce temperature differences and improve productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a plate material is press punched into a T-shaped conductor plate to increase cross-sectional area, then the temperature rise is restricted, but waste material is produced and productivity decreases
Solution Approach 1:
The invention changes the cross-sectional area parameter along the longitudinal direction of the conductor plate, creating a variable cross-section design where the central portion has a larger cross-sectional area than the end portions. This is achieved through progressive deformation processes rather than press punching, thereby reducing waste material while effectively restricting temperature rise in high-current regions.
Solution Approach 2:
The conductor plate employs a dynamic cross-sectional area design where the cross-section varies continuously along the longitudinal direction. The central portion is expanded to have a larger cross-sectional area to handle higher current density and heat generation, while the end portions maintain smaller cross-sectional areas, optimizing both thermal management and material utilization.
2Object-generated harmful factors
If metals having different conductivities are joined to restrict heat generation, then heat generation in connecting portions is reduced, but temperature difference between parts increases
Solution Approach 1:
The invention applies local quality by creating regions with different cross-sectional areas along the longitudinal direction of the conductor plate. The central portion has a larger cross-sectional area to reduce resistance and heat generation in high-current regions, while end portions have smaller cross-sectional areas. This gradual variation in local geometry provides continuous heat dissipation paths, preventing large temperature differences between joined portions.
3Temperature
If the cross-sectional area is increased in the central portion, then heat dissipation is improved, but the manufacturing complexity increases
Solution Approach 1:
The conductor plate features a dynamic cross-sectional area design where the central portion is progressively expanded along the longitudinal direction. This is achieved through sequential deformation processes that gradually increase the cross-sectional area in the central region while maintaining smaller end portions. The progressive deformation approach simplifies manufacturing compared to creating complex T-shaped structures, as it involves controlled plastic deformation rather than multiple punching and joining operations.
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 design effectively restricts temperature rise and heat generation by providing dual heat transfer paths and reducing conductor resistance, enhancing productivity through simplified manufacturing and efficient heat dissipation.
Implementation Method 1
a thermally conductive sheet that connects the end portion and the central portion of the plate material and is made of a material having a higher thermal conductivity than the end portion and the central portion
Implementation Method 2
flat conductors generate heat due to a temperature rise caused by resistance during energization
Data Source
AI summary
A flat conductor includes an elongated conductive plate material having an end portion in a longitudinal direction and a central portion adjacent to the end portion. A conductor resistance per unit length of at least one end portion in the plate material is lower than a conductor resistance per unit length of the central portion. The flat conductor includes a thermally conductive sheet that connects the end portion and the central portion of the plate material and is made of a material having a higher thermal conductivity than the end portion and the central portion.