Pre-Charge Relay Circuit Assembly With Integrated Heat Transfer
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Solution Overview
Problem
The existing circuit assembly for electric vehicles faces inefficiencies in heat dissipation for relays due to the need for large bus bars, leading to increased material and processing costs, and inefficient heat dissipation paths.
Innovation Solution
A circuit assembly with a pre-charge circuit connected in parallel to the main relay, utilizing a heat transfer member in contact with the current-carrying portion of the pre-charge circuit to efficiently dissipate heat, eliminating the need for extensive bus bars and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large bus bar is used to ensure sufficient current-carrying capacity, then the relay can withstand large currents, but material and processing costs increase
Solution Approach 1:
The patent combines the heat dissipation function with the existing pre-charge circuit structure. The heat transfer member is integrated into the pre-charge circuit assembly, allowing it to serve both as a structural component and a thermal management solution, thereby avoiding additional material costs
Solution Approach 2:
The pre-charge circuit's current-carrying portion serves dual purposes: it carries pre-charge current and simultaneously acts as a heat transfer path. The system uses its own existing components to provide heat dissipation functionality without requiring separate dedicated heat dissipation structures
2Temperature
If a large bus bar is used to extend the heat dissipation path to an external heat dissipation member, then heat can be dissipated from the relay, but the distance between the relay connection portion and heat dissipation portion increases, reducing heat dissipation efficiency
Solution Approach 1:
The patent extracts the heat dissipation function from the traditional external heat dissipation member approach and relocates it directly to the pre-charge circuit's current-carrying portion. This eliminates the need for long-distance thermal conduction paths and external heat sinks
Solution Approach 2:
The heat transfer member acts as an intermediary between the relay and the external environment, utilizing the existing pre-charge circuit structure as a thermal conduit. This intermediary approach provides efficient heat transfer without requiring direct connection to distant heat dissipation members
3Productivity
If the pre-charge circuit is used for heat dissipation, then heat dissipation efficiency increases and material costs are reduced, but the structure becomes novel and different from conventional designs
Solution Approach 1:
The pre-charge circuit's current-carrying portion is designed to perform multiple functions: electrical conduction during pre-charge operation and thermal conduction during heat dissipation. This multi-functionality approach allows the same component to serve different purposes without increasing structural complexity
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 heat dissipation efficiency while maintaining cost-effectiveness by using existing components and minimizing material usage, providing a simple and efficient heat transfer path.
Implementation Method 1
dissipating the heat generated in the relay to the chassis or the casing through thermal conduction
Data Source
AI summary
Provided is a circuit assembly including: a main relay that is to be electrically connected between a load and a battery; a pre-charge circuit connected in parallel with the main relay; and a heat transfer member, wherein the pre-charge circuit includes current-carrying portions that are to be connected to the main relay, and the heat transfer member and the current-carrying portions are in contact with each other.