Electrical Junction Box Heat Dissipation Without Busbar Growth
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Solution Overview
Problem
Existing electrical junction boxes for vehicles face challenges in efficiently dissipating heat from relays without increasing the complexity or size of the busbar, particularly in electric and hybrid vehicles where heat generation is higher.
Innovation Solution
The electrical junction box incorporates a case with a relay, a busbar connected to the relay's terminal, and a first heat dissipation member that transfers heat from the relay to both the busbar and a separate heat dissipation member, allowing for efficient heat dissipation without enlarging the busbar structure. This configuration includes a first heat dissipation member made of metal and a second heat dissipation member made of synthetic resin, which are brought into close contact to enhance heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a busbar is used for heat dissipation by bringing an intermediate portion close to the lower cover member, then heat dissipation is improved, but the busbar structure becomes complex and large
Solution Approach 1:
The heat dissipation function is segmented from the busbar by introducing a dedicated heat dissipation member. The busbar focuses on electrical connection while the separate heat dissipation member handles thermal management, reducing the busbar's structural complexity and size while maintaining effective heat dissipation through the dedicated component.
2Temperature
If the busbar intermediate portion is brought close to the lower cover member for heat dissipation, then heat transfer to the battery case is improved, but the overall device size increases
Solution Approach 1:
The heat dissipation path is extended into the vertical dimension by stacking the heat dissipation member between the busbar and the lower cover member. This layered arrangement allows efficient heat transfer through the thickness direction without requiring lateral expansion, thereby maintaining compact device dimensions while achieving effective thermal management.
3Power
If electric vehicles and hybrid vehicles are used, then more power is available, but more heat is generated from relays requiring improved heat dissipation
Solution Approach 1:
The heat dissipation member acts as an intermediary between the relay and the lower cover member, providing a dedicated thermal conduction path. This intermediary component efficiently transfers heat from the relay to the heat dissipation member and then to the lower cover member and battery case, enabling effective thermal management for high-power electric and hybrid vehicles.
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 enables efficient heat dissipation from the relay without increasing the busbar's size or complexity, effectively managing heat transfer through the use of multiple heat dissipation members and a structured case to separate power supply and heat dissipation paths.
Implementation Method 1
a first heat dissipation member that is connected to the relay so as to be able to transfer heat
Data Source
AI summary
An electrical junction box includes: a case that is insulative; a relay that is attached to the case; a busbar that is connected to a terminal of the relay; and a first heat dissipation member that is connected to the relay so as to be able to transfer heat. The case includes a first case member and a second case member that is coupled to the first case member and that provides a housing space between the first case member and the second case member, the first heat dissipation member includes a first layer portion that is stacked on the first case member within the housing space, and the busbar includes a second layer portion that is stacked on the first case member and the first layer portion outside the case.