Electrical Junction Box Phase-Change Cooling Unit
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Solution Overview
Problem
Conventional electrical junction boxes using liquid coolants face challenges in maintaining effective cooling performance due to leakage issues caused by vibration and increased weight.
Innovation Solution
An electrical junction box design featuring a resin case with a recess, elastic packing along the peripheral edge, and a heat transfer member that solidifies at low temperatures, liquefies upon heat generation, and is sealed by the packing to prevent leakage, enhancing cooling efficiency while reducing weight and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid coolant is used for cooling heat generating components, then cooling performance is improved, but weight increases and leakage occurs due to vibration
Solution Approach 1:
The patent changes the physical state parameter of the heat transfer medium from liquid to solid/liquid phase-change material. The heat transfer member is filled with phase-change material that melts at a specific temperature range, transitioning from solid to liquid state to absorb heat, thereby maintaining cooling effectiveness while reducing weight and eliminating leakage issues associated with liquid coolants.
Solution Approach 2:
The patent utilizes phase transition of the heat transfer member. The heat transfer member contains phase-change material that transitions from solid to liquid state when exposed to heat from generating components, absorbing latent heat in the process. This phase change mechanism provides efficient cooling without requiring the heat transfer medium to remain in liquid state, thus preventing vibration-induced leakage and reducing overall system weight.
2Temperature
If liquid coolant is used for cooling, then cooling performance is improved, but leakage occurs due to vibration
Solution Approach 1:
The patent changes the operational state parameter of the heat transfer medium from liquid to solid/liquid phase-change material. By utilizing the phase-change property, the heat transfer member remains in solid state at normal temperatures, providing structural integrity and preventing vibration-induced leakage, while transitioning to liquid state only when needed for heat absorption.
Solution Approach 2:
The patent employs phase transition mechanism where the heat transfer member transitions from solid to liquid state only when exposed to heat. During normal operation and vibration conditions, the heat transfer member remains solid, ensuring reliable containment and preventing leakage. The phase change occurs locally and temporarily at the heat generation site, maintaining system reliability.
3Reliability
If packing is provided to prevent leakage, then sealing performance is improved, but device complexity increases
Solution Approach 1:
The patent utilizes phase transition of the heat transfer member to eliminate the need for additional packing structures. The heat transfer member itself, through its phase-change properties, naturally seals the cavity when in solid state, preventing leakage without requiring separate packing components. This self-sealing mechanism reduces device complexity while maintaining reliable sealing performance.
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
The solution effectively moderates temperature rise of heat-generating components, prevents leakage of the heat transfer medium, and improves heat transfer efficiency, making it suitable for applications with high thermal demands like rapid charging systems.
Implementation Method 1
a heat transfer member housed in the recess and an inside surrounded by the packing, solidified and in contact with the heat generating component while the heat generating component does not generate heat, and liquefied following heat generation of the heat generating component
Data Source
AI summary
An electrical junction box includes a heat generating component and a cooling unit that cools the heat generating component. The cooling unit includes: a recess provided at the holding position of the heat generating component in a resin case that holds the heat generating component; packing that is provided along the peripheral edge of the recess, is compressed by the contact with the heat generating component, and seals the recess together with the heat generating component; and a heat transfer member that is housed in the recess and the inside surrounded by the packing, is solidified and is in contact with the heat generating component while the heat generating component does not generate heat, and is liquefied following the heat generation of the heat generating component.