Relay Connection Box Layout for Terminal Heat Dissipation
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Solution Overview
Problem
Existing electrical connection boxes generate excessive Joule heat at contact points between terminals and busbars, which is not efficiently dissipated, leading to potential operational issues due to high thermal stress on electronic components.
Innovation Solution
The electrical connection box design includes a pair of relays with a gap between them, featuring protruding portions near terminals to dissipate heat through air flow, and optionally uses a heat transfer member to further enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If electronic components are operated in a compact electrical connection box, then space utilization is improved, but heat dissipation deteriorates due to confined space and accumulated Joule heat
Solution Approach 1:
The patent extracts the heat dissipation function from the relay housing and implements it as a separate heat transfer member. This member is positioned to contact the terminal where Joule heat is generated and extends toward the gap between relays to efficiently conduct heat away from the heat source, resolving the contradiction between compact size and heat dissipation.
Solution Approach 2:
The heat transfer member acts as an intermediary between the terminal (heat source) and the surrounding environment. It conducts heat from the terminal through its structure and dissipates it toward the gap between relays, providing an efficient thermal pathway that enables compact packaging while maintaining adequate heat dissipation.
2Reliability
If relay housing is made of resin for insulation, then electrical insulation is improved, but heat dissipation deteriorates due to resin's low thermal conductivity
Solution Approach 1:
The patent applies different material properties to different locations: the relay housing remains resin for electrical insulation, while the heat transfer member uses high thermal conductivity material (aluminum or copper) specifically at the heat dissipation location. This local differentiation resolves the contradiction by maintaining insulation where needed while enabling heat transfer where required.
Solution Approach 2:
The patent creates a composite thermal management system combining resin (for insulation) and metal heat transfer member (for heat conduction). This composite approach allows the housing to maintain its insulating properties while the integrated heat transfer member provides efficient thermal pathways, resolving the contradiction between insulation and heat dissipation.
3Loss of energy
If contact resistance at terminal connections is reduced, then energy loss is improved, but manufacturing complexity increases due to precision requirements
Solution Approach 1:
The patent extracts the heat management function from the terminal connection structure itself and implements it through a separate heat transfer member. This allows the terminal connections to focus on electrical conductivity while the heat transfer member handles thermal management, reducing the need for extremely precise terminal contact surfaces and thereby reducing manufacturing complexity while maintaining low energy loss.
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 design promotes effective heat dissipation from relays, reducing thermal stress and allowing for a compact box size while maintaining efficient operation.
Implementation Method 1
the heat transfer member absorbs heat released from the at least one terminal and transfers the heat in a direction away from the at least one terminal
Implementation Method 2
Joule heat is usually generated in electrified portions such as the input and output terminals of the electronic components due to the flow of a current
Data Source
AI summary
An electrical connection box (1) includes a pair of relays (20A, 20B) disposed with a gap (S) in between, a case (10), and a heat transfer member (70). Each of the pair of relays (20A, 20B) includes a plurality of terminals (51 to 54), and a protruding portion (23) having a shape protruding toward the gap (S) in a vicinity of at least one (51, 52) of the plurality of terminals. The heat transfer member (70) absorbs heat released from the terminal and transfers the heat in a direction away from the terminal.