Junction Box Vent Structure for Heat Dissipation and Busbar Protection
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Solution Overview
Problem
Existing electrical junction boxes face challenges in ensuring heat dissipation and protecting busbars from foreign body infiltration, particularly in high-voltage applications where relays and fuses generate heat and there is a risk of foreign objects entering through openings like wire outlets.
Innovation Solution
The electrical junction box incorporates a relay unit with a resin component that includes a heat dissipation hole with a step part on its periphery. This configuration allows for effective heat dissipation by emitting heat through housing holes while preventing foreign bodies from entering the heat dissipation hole and contacting the busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the box body is made of metal housing for durability and heat dissipation, then heat dissipation is improved, but foreign body infiltration risk increases through housing holes
Solution Approach 1:
The housing hole is segmented into two functional zones: an upper communication portion for heat dissipation and a lower infiltration prevention portion with a step structure. This segmentation allows the same opening to simultaneously serve heat dissipation while preventing foreign body entry, resolving the contradiction between heat dissipation efficiency and foreign body protection.
Solution Approach 2:
The step structure acts as an intermediary barrier within the housing hole. It creates a physical obstruction that foreign bodies cannot bypass while maintaining the open channel necessary for heat dissipation. This intermediary structure enables both heat to escape and foreign bodies to be blocked.
2Adaptability or versatility
If wire outlets are provided for electrical wire connection, then electrical connectivity is improved, but busbar protection from foreign bodies deteriorates
Solution Approach 1:
The housing hole is divided into an upper communication portion that allows wire passage and heat dissipation, and a lower infiltration prevention portion with a step structure that blocks foreign bodies. This segmentation enables the opening to fulfill both wire connection adaptability and busbar protection reliability.
Solution Approach 2:
The step structure introduces a vertical dimension barrier within the housing hole. By creating a height difference (step) in the vertical dimension, foreign bodies are prevented from reaching the busbar while maintaining horizontal wire connectivity, thus resolving the contradiction between adaptability and reliability.
3Adaptability or versatility
If relays and fuses are installed for electrical relay functions, then electrical relay capability is improved, but heat generation increases causing overheating risk
Solution Approach 1:
The heat dissipation function is extracted as a separate structural feature (the heat dissipation hole with step structure) from the main housing. This dedicated heat extraction path allows relays and fuses to perform their electrical relay functions while generated heat is actively removed through the specialized hole structure, preventing overheating.
4Adaptability or versatility
If the housing hole is opened for wire passage, then wire connectivity is improved, but heat dissipation efficiency deteriorates if blocked by protection structures
Solution Approach 1:
The housing hole is segmented vertically into a communication portion that remains open for wire passage and heat dissipation, and an infiltration prevention portion with the step structure. This segmentation ensures that the wire passage function and heat dissipation efficiency are maintained in the upper portion while protection is provided in the lower portion, avoiding the trade-off between openness and heat dissipation.
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 solution effectively addresses the issues of heat dissipation and foreign body protection, ensuring that the electrical junction box can handle high-voltage currents without overheating and preventing potential electrical hazards from foreign object infiltration.
Implementation Method 1
the resin component has a heat dissipation hole for dissipating heat of the relay unit generated when current flows through the relay unit
Data Source
AI summary
Provided is an electrical junction box that is able to ensure heat dissipation within the metal housing and protect busbars from infiltration of a foreign body through a housing hole. A relay unit of an electrical junction box has a resin component forming a main body of the relay unit and to which at least a relay is attached, and a busbar attached to a resin component and used as wiring of the resin component. The metal housing has a housing hole for externally leading out a wire attached to the resin component and electrically connected to the busbar. The resin component has a heat dissipation hole for dissipating heat of the relay unit generated when current flows through the relay unit. The heat dissipation hole has, on at least part of the hole periphery, a step part located on the far side thereof as viewed from the housing hole.