Electrical Junction Box Thermal Isolation via Partitioning
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Solution Overview
Problem
In electrical junction boxes, heat generated by switching elements can be conducted to circuit boards through bus bars, posing a risk of high-temperature heat transfer when the heat dissipation member becomes saturated, potentially damaging the control elements.
Innovation Solution
The design includes a first and second conductive plate with a switching element connected to each, where the circuit board is spaced apart from both plates, and a cover with partitioning plates forming separate chambers to prevent direct heat conduction to the circuit board, allowing heat to be dissipated through air convection and using a heat dissipation member with recessed portions to manage heat effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the circuit board is placed adjacent to the bus bars for compact layout, then the device size is reduced, but heat from the bus bars is conducted to the circuit board causing potential damage
Solution Approach 1:
The device is divided into separate chambers: a first chamber housing the bus bars and switching elements, and a second chamber housing the circuit board. The partitioning plate creates physical separation between heat-generating components and heat-sensitive components, preventing thermal conduction while maintaining compact overall structure.
Solution Approach 2:
A partitioning plate is introduced as an intermediary thermal barrier between the bus bars and the circuit board. This partitioning plate has lower thermal conductivity than the bus bars, interrupting the heat conduction path and protecting the circuit board from excessive heat while allowing the device to maintain a compact form factor.
2Device complexity
If the circuit board contacts the bus bars directly for electrical connection, then the connection is simplified, but heat conduction to the circuit board increases
Solution Approach 1:
The electrical connection path is segmented from the thermal conduction path. The circuit board connects electrically to the bus bars through controlled connection points while being thermally isolated by the partitioning plate, achieving both simplified electrical connection and thermal protection.
Solution Approach 2:
The partitioning plate provides localized thermal insulation at critical interfaces where the circuit board approaches the bus bars. This allows electrical connections to be made at specific locations while maintaining thermal barrier properties in adjacent areas, optimizing both connectivity and heat management.
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 effectively suppresses heat transfer to the circuit board, preventing damage and allowing for efficient heat dissipation, while also reducing the size of the electrical junction box by utilizing the conductive plates as partitioning elements.
Implementation Method 1
The heat generated from the FET is conducted to the bus bars, and then to a heat dissipation member, and dissipated from the heat dissipation member to the outside of the electrical junction box
Implementation Method 2
allowing heat to be dissipated through air convection
Data Source
AI summary
An electrical junction box includes a first conductive plate, a second conductive plate adjacent to the first conductive plate without contacting the first conductive plate, a switching element including a first terminal connected to the first conductive plate, a second terminal connected to the second conductive plate, and an element body on which the first terminal and the second terminal. A circuit board opposes and is spaced apart from the second conductive plate. A cover has an open side and covers the switching element and the circuit board. The cover includes a partitioning plate that partitions an inside of the cover so as to form a first chamber. The element body of the switching element is arranged in the first chamber, a second chamber is formed inside the cover by the partitioning plate and the second conductive plate, and the circuit board is arranged in the second chamber. An electrical junction box includes a first conductive plate, a second conductive plate adjacent to the first conductive plate without contacting the first conductive plate, a switching element including a first terminal connected to the first conductive plate, a second terminal connected to the second conductive plate, and an element body on which the first terminal and the second terminal. A circuit board opposes and is spaced apart from the second conductive plate. A cover has an open side and covers the switching element and the circuit board. The cover includes a partitioning plate that partitions an inside of the cover so as to form a first chamber. The element body of the switching element is arranged in the first chamber, a second chamber is formed inside the cover by the partitioning plate and the second conductive plate, and the circuit board is arranged in the second chamber.