Electrical Junction Box Cooling Structure for Insulated Heat Transfer

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Solution Overview

Problem

Existing electrical junction boxes and wire harnesses face challenges in improving cooling performance without increasing weight and size, as conventional methods to enhance cooling components result in bulkier and heavier designs.

Innovation Solution

The design incorporates a cooling unit with a metal plate shaped to conform to heat-generating components, a metal pipe for coolant flow, and an insulating heat transfer member between the components, maintaining insulation and facilitating efficient heat transfer while reducing size and weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the volume of the cooling member and heat transfer member is increased to improve cooling performance, then cooling performance is improved, but weight and size increase

Engineering Contradiction:

Improvecooling performanceVSAvoidweight

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The metal plate is formed in a shape that conforms to the shape of the heat generating component, creating localized high-quality heat transfer paths where needed. This allows efficient cooling without increasing overall component volume, as the cooling structure is precisely tailored to match the heat generation pattern rather than using uniform bulk cooling components.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cooling unit components are nested within each other: the heat transfer member is positioned between the heat generating component and the metal plate, while the metal pipe is disposed along and in contact with the metal plate. This nested arrangement maximizes heat transfer efficiency within a compact volume, avoiding weight and size increases.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Temperature

If the volume of the cooling member and heat transfer member is increased to improve cooling performance, then cooling performance is improved, but size increases

Engineering Contradiction:

Improvecooling performanceVSAvoidsize

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cooling structure utilizes three-dimensional conformal geometry where the metal plate follows the contours of the heat generating component. This dimensional adaptation allows the cooling system to effectively cover heat generation surfaces without requiring increased linear dimensions or overall volume of the electrical junction box.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Temperature

If a metal plate is used for heat transfer, then heat transfer efficiency is improved, but electrical insulation is compromised

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidelectrical insulation

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The heat transfer member with insulating properties serves as an intermediary component positioned between the heat generating component and the metal plate. This mediator enables thermal coupling for efficient heat transfer while simultaneously providing electrical insulation, thus resolving the contradiction between heat transfer efficiency and electrical insulation reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The heat transfer member is made of a material that combines thermal conductivity with electrical insulation properties. This composite material approach allows the single component to fulfill both thermal and electrical requirements, enabling efficient heat transfer from the heat generating component while maintaining necessary electrical insulation.

Inventive Principle:

Principle #40Composite materials

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 configuration enhances cooling performance by effectively transferring heat to the metal plate for coolant dissipation, maintaining insulation, and reducing overall size and weight, thus optimizing the electrical junction box and wire harness.

Implementation Method 1

a metal plate being formed in a shape conforming to a shape of the heat generating component, a metal pipe through which a coolant flows, the metal pipe being disposed along and in contact with the metal plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a heat transfer member having insulating properties and intervening between the heat generating component and the metal plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a metal pipe through which a coolant flows

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12407153B2Electrical junction box and wire harness

Publication Date: 2025.09.02 YAZAKI CORP

AI summary

An electrical junction box includes a heat generating component, a cooling unit that cools the heat generating component, and a resin case that holds the heat generating component and the cooling unit. The cooling unit includes: a metal plate being formed in a shape conforming to a shape of a bus bar of the heat generating component; a metal pipe being disposed along and in contact with the metal plate and through which a coolant flows; and a heat transfer member having insulating properties and intervening between the heat generating component and the metal plate.