Vehicle Junction Box Base Embedding for Busbar Heat Dissipation
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Solution Overview
Problem
Existing junction boxes in electric and hybrid vehicles face challenges with excessive heating of busbars due to high current levels, and existing cooling methods are not sufficiently effective, leading to energy inefficiencies.
Innovation Solution
The junction box design embeds portions of busbars in an electrically insulating base made of materials like resin or polymer, allowing for thermal dissipation through conductive contact, and incorporates a support frame for stiffness, along with a cooling system and common mode filters to manage heat and electrical interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If busbars are provided with high current levels to deliver power, then the power delivery capability is improved, but excessive heating of busbars occurs
Solution Approach 1:
The patent introduces a thermally conductive, electrically insulating base material as an intermediary between the busbar and the external environment. This base acts as a heat sink that conductively absorbs heat from the busbar while maintaining electrical insulation, thereby managing the temperature rise caused by high current levels without compromising power delivery capability.
Solution Approach 2:
The patent replaces active cooling systems (such as fans or liquid cooling circuits) with a passive thermal management approach using a thermally conductive base material. This substitution eliminates complex mechanical cooling systems while effectively managing busbar temperature through conductive heat transfer to the base structure.
2Temperature
If cooling systems are added to reduce busbar temperature, then thermal management is improved, but energy consumption increases
Solution Approach 1:
The patent implements a self-service thermal management system where the base material passively absorbs and dissipates heat from the busbar through its inherent thermal conductivity. No external energy input is required as the system uses the natural heat flow from hot to cold regions, eliminating the need for energy-consuming active cooling mechanisms.
Solution Approach 2:
The patent replaces active cooling systems requiring energy input with a passive thermal management solution using a thermally conductive base. This substitution eliminates energy consumption associated with fans, pumps, or other active cooling components while maintaining effective temperature control.
3Temperature
If busbars are embedded in the base, then thermal dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the thermal management function and the structural support function into a single integrated base component. The base simultaneously provides mechanical support for the busbar and serves as a heat sink through its thermal conductivity, eliminating the need for separate cooling components and simplifying the overall manufacturing process.
Solution Approach 2:
The base material serves multiple functions: it provides mechanical support for the busbar, acts as a thermal management system through conductive heat dissipation, and provides electrical insulation. This multi-functionality reduces the number of separate components needed and simplifies manufacturing while improving thermal dissipation efficiency.
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 effectively reduces busbar heating, enhances thermal dissipation, and maintains electrical insulation while providing structural integrity, thus improving energy efficiency and reducing the need for excessive energy to manage temperatures.
Implementation Method 1
Thermal dissipation can take place through direct conductive contact between the busbar and the base
Implementation Method 2
the use of ferrite cores to reduce common mode currents
Data Source
Figure 1A~1C
Figure 1B
Figure 1D~1E
AI summary
The present disclosure relates to junction boxes for a vehicle comprising a plurality of busbars, and a housing to substantially enclose the plurality of busbars. The housing comprises a base, a cover and one or more sidewalls connecting the base to the cover. The base is made of an electrically insulating material and a portion of at least one of the plurality of busbars is embedded within the base. The present disclosure also relates to suitable methods for producing such junction boxes.