Electrical Junction Box Heat Dissipation Stack for Relay Cooling
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Solution Overview
Problem
Existing electrical junction boxes in vehicles face inefficiencies in heat dissipation due to air interposition between the busbar and heat dissipation sheets, which hampers effective heat transfer, especially in high-heat applications like electric and hybrid vehicles.
Innovation Solution
The design incorporates a stacked configuration of a case with first and second heat dissipation members, where the first heat dissipation member is made of metal and the second of synthetic resin, sandwiched by case members to ensure close contact and efficient heat transfer, utilizing coupling portions to maintain contact and improve insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air is interposed between the busbar and the heat dissipation sheet, then the structure is simpler to manufacture, but heat transfer efficiency deteriorates
Solution Approach 1:
A heat dissipation sheet is introduced as an intermediary component between the busbar and the lower cover member. This sheet is made of thermally conductive material and is positioned to fill the gap between the busbar and the cover, ensuring continuous thermal contact while maintaining manufacturing simplicity. The heat dissipation sheet acts as a mediator that bridges the thermal path without requiring precision machining or complex assembly procedures.
2Temperature
If electric vehicles and hybrid vehicles generate more heat from relays, then the heat dissipation demand increases, but the existing heat dissipation structure becomes insufficient
Solution Approach 1:
The heat dissipation structure employs composite material construction: the heat dissipation sheet is made of thermally conductive material (such as aluminum or copper alloy), while the lower cover member is made of insulating material (such as resin). This composite structure optimizes thermal conduction from the busbar through the sheet to the cover, while the insulating cover material prevents heat transfer to sensitive components. The busbar itself is made of high-conductivity metal to efficiently conduct heat from the relay contacts.
3Strength
If the first case member and the second case member are coupled together, then the structural integrity is improved, but the heat dissipation path may be interrupted
Solution Approach 1:
The case is divided into two separate members: the lower cover member and the upper cover member. The lower cover member is designed with integrated heat dissipation functionality, including the heat dissipation sheet and the busbar connection structure. The upper cover member houses the relay and provides structural support. This segmentation allows the lower cover to be optimized for heat dissipation while the upper cover focuses on structural integrity and component housing, with the heat dissipation path maintained through the lower cover's design.
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 allows for efficient heat dissipation from the relay without increasing the size or complexity of the busbar, effectively managing heat in high-heat applications like electric vehicles.
Implementation Method 1
a first heat dissipation member that is connected to the relay so as to be able to transfer heat and a second heat dissipation member that is connected to the first heat dissipation member so as to be able to transfer heat
Data Source
AI summary
An electrical junction box includes: a case; a relay; a first heat dissipation member connected to the relay; and a second heat dissipation member connected to the first heat dissipation member. The case includes a first case member, a second case member, a first coupling portion and a second coupling portion coupling the first case member to the second case member. The first case member, the first heat dissipation member, the second heat dissipation member, and the second case member are arranged in a stacked. The first coupling portion and the second coupling portion are arranged at an interval and are orthogonal with respect to the stack, the first heat dissipation member and the second heat dissipation member are interposed therebetween. The first coupling portion is disposed on an outer surface of the case, and the second coupling portion is on an inner surface of the case.