Vehicle Junction Box Closed Loop Cooling System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Junction boxes in vehicles face heat-related damage due to retained heat from electrical components, which can be exacerbated by exposure to harsh environmental conditions, necessitating a cooling system that maintains equipment cool without exposing it to external contaminants.
Innovation Solution
A closed loop cooling system utilizing a junction box housing and a storage compartment with cool and warm air ducts, where cool air from the storage compartment absorbs heat from the junction box, and the warmed air returns to the storage compartment, maintaining a stable temperature without introducing outside air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a closed junction box is used to protect electrical equipment from environmental contaminants, then protection against moisture and chemicals is improved, but heat retention increases causing temperature to rise
Solution Approach 1:
The cooling system is segmented into distinct functional components: a cooling element (evaporator) positioned within the junction box, a condensing element positioned externally, and separate ducts for cool air supply and warm air exhaust. This segmentation allows the cooling function to be integrated while the heat rejection function is externalized, resolving the contradiction between protection and heat retention.
Solution Approach 2:
A refrigerant fluid acts as an intermediary carrier between the internal cooling process and external heat rejection. The refrigerant absorbs heat from the electrical equipment through the evaporator, transports it through piping to the condensing element, and releases it externally. This intermediary mechanism enables effective cooling while maintaining the sealed protective environment.
2Temperature
If ventilation is provided to remove heat from the junction box, then cooling is improved, but exposure to environmental contaminants increases
Solution Approach 1:
The ventilation function is segmented into internal cooling air circulation and external heat rejection air flow. Cool air is drawn from the external environment through a filtered intake, circulated through the junction box to absorb heat, and then expelled through a separate exhaust path. This segmentation allows heat removal while minimizing contaminant exposure through filtration and controlled airflow paths.
Solution Approach 2:
The refrigerant-based cooling system acts as an intermediary that enables heat removal without direct ventilation of the junction box interior. The evaporator absorbs heat internally, and the condensing element rejects heat externally, eliminating the need for direct air exchange between the protected environment and external contaminants while maintaining effective cooling.
3Temperature
If a cooling system is added to the junction box, then temperature control is improved, but device complexity increases
Solution Approach 1:
The cooling system components are designed with multi-functionality to reduce overall complexity. The condensing element serves both as a heat rejection device and can be integrated with existing vehicle thermal management systems. The control system incorporates temperature sensors and controllers that can monitor and regulate multiple parameters, making the system adaptable to different operating conditions without requiring entirely separate control mechanisms.
Solution Approach 2:
The cooling system incorporates self-regulating features including temperature sensors that automatically detect when cooling is needed, controllers that modulate cooling capacity based on actual temperature conditions, and thermal expansion devices that automatically regulate refrigerant flow. These self-service characteristics reduce the need for complex manual control systems and enable automatic adaptation to varying thermal loads.
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 system effectively cools electrical equipment within the junction box by utilizing the storage compartment's volume to normalize warm air temperatures, reducing exposure to moisture and contaminants while minimizing energy usage and maintenance costs.
Implementation Method 1
The cool air absorbs heat generated by the electrical equipment in the junction box housing, thereby cooling the electrical equipment and increasing the temperature of the cool air to form the warm air.
Implementation Method 2
Excess heat from the warm air is absorbed into the relatively large volume of source air, and the temperature of the warm air normalizes to the lower temperature of the source air.
Data Source
AI summary
A closed loop cooling system for a junction box in a vehicle includes a junction box housing and a storage compartment for a vehicle. A cool air duct interior volume of a cool air duct and a warm air duct interior volume of a warm air duct are each in fluidic communication with a housing interior volume of the junction box housing and a compartment interior volume of the storage compartment to form a closed loop cooling system. The cool air duct interior volume is sized to convey cool air from a cool air outlet of the storage compartment to a cool air inlet of the junction box housing, and the warm air duct interior volume is sized to convey warm air, which is warmer than the cool air, from a warm air outlet of the junction box housing to a warm air inlet of the storage compartment.