Vehicle Headliner Electronic Module Phase Change Heat Management

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Solution Overview

Problem

Electronic modules in vehicles generate significant heat due to high energy consumption, exacerbated by solar radiation in the vehicle roof area, posing challenges for efficient heat management within the limited space between the headliner and roof, and existing solutions are either inefficient or compromise the compactness and aesthetics of the assembly.

Innovation Solution

A modular electronic module assembly with a heat-absorbing part containing phase change material and a conductive casing, integrated with a mechanical protection cap, which absorbs and dissipates heat efficiently, and an optional thermal insulating material to reduce solar radiation heat, while maintaining a compact and stable assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the electronic module is placed parallel to the vehicle roof main surface to utilize limited space, then the available space in the vehicle passenger compartment is preserved, but the electronic module receives large amounts of heat from solar radiation

Engineering Contradiction:

Improveavailable space in passenger compartmentVSAvoidheat received from solar radiation

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

A heat-absorbing material is introduced as an intermediary substance between the electronic module and the vehicle roof. This material directly contacts the electronic module's heat-generating components and absorbs heat through phase change (solid to liquid), preventing heat transfer to the electronic module while maintaining the compact parallel arrangement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The heat-absorbing material utilizes phase transition (melting) as the core mechanism to manage heat. The material changes from solid to liquid state when absorbing heat from the electronic module, effectively capturing thermal energy without significantly increasing in volume, thus preserving the limited space between the headliner and vehicle roof.

Inventive Principle:

Principle #36Phase transitions

2Temperature

If heat dissipation devices are added to the electronic module, then heat management is improved, but the device complexity and assembly complexity increase

Engineering Contradiction:

Improveheat managementVSAvoidassembly complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heat-absorbing material is integrated directly into the electronic module's housing or mounting structure, combining the heat management function with the existing module design. This eliminates the need for separate heat dissipation devices and reduces assembly complexity while effectively managing heat generation.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If the electronic module is positioned to face the vehicle roof opening, then heat dissipation is improved, but the available space in the passenger compartment is reduced and aesthetics are compromised

Engineering Contradiction:

Improveheat dissipationVSAvoidavailable space in passenger compartment

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

The invention converts the harmful solar radiation heat into a beneficial cooling mechanism. The heat-absorbing material captures both the heat generated by the electronic module itself and the heat from solar radiation, transforming these thermal challenges into an effective heat management solution that maintains the module's compact parallel positioning.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 manages heat generated by the electronic module and received from solar radiation, maintaining the electronic module within safe operating temperatures, ensuring proper operation and reducing the risk of damage, while maintaining a compact and aesthetically pleasing design.

Implementation Method 1

a heat-absorbing part containing phase change material

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

a heat-absorbing part containing phase change material which absorbs and dissipates heat efficiently

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 3

a conductive casing, integrated with a mechanical protection cap, which absorbs and dissipates heat efficiently

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

an optional thermal insulating material to reduce solar radiation heat

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP3952020B1Roof lining with electronic module assembly for vehicles and vehicle roof assembly comprising the lining

Publication Date: 2023.06.14 GRP ANTOLIN ING SA

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AI summary

Headliner with an electronic module assembly for vehicles wherein the electronic module generates significant amounts of heat due to the high energy consumption during operation. The electronic module assembly comprising a heat absorbing part having a casing which encloses a phase change material in order to manage the heat generated by the electronic module in operation by itself and the heat received by the vehicle roof due to the solar radiation.