Relay Bus Bar Layout for Wire Access and Heat Dissipation
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Solution Overview
Problem
Conventional circuit assemblies with relays face challenges in securing a sufficient working space for connecting excitation wires due to the lateral opening of the excitation connector part, leading to increased component count and cost, and potential reduction in heat dissipation when the relay is raised to create space.
Innovation Solution
The circuit assembly design includes a relay with an excitation connector part on a side surface, a bus bar with a fastening part protruding upward and inclined at an angle greater than 90°, allowing the excitation connector to be obliquely upward, and a heat transfer part in thermally conductive contact with an external target, maintaining a direct connection path for wires and minimizing heat dissipation distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the relay is raised to create working space for wire connections, then the working space is secured, but the heat dissipation efficiency is reduced due to increased distance from the connection part to the heat transfer part
Solution Approach 1:
The excitation connector part is configured to open obliquely upward, utilizing the vertical dimension to create working space for wire connections without increasing the horizontal distance between the connection part and heat transfer part. This dimensional reorientation allows adequate space for connecting excitation wires while preserving the compact heat dissipation path.
Solution Approach 2:
The bus bar's fastening part is designed with an asymmetric inclination angle greater than 90 degrees relative to the heat transfer part, creating an oblique upward orientation. This asymmetric configuration provides the necessary working space for wire connections while maintaining optimal thermal contact between the connection part and heat transfer part.
2Ease of operation
If additional relay wire is provided to connect to the excitation connector part, then the working space problem is solved, but the number of components and cost increase
Solution Approach 1:
By reorienting the excitation connector part to open obliquely upward, the design creates adequate working space directly at the connector location, eliminating the need for additional relay wires to reach distant connection points. This dimensional reorientation provides direct access for wire connections without adding components.
3Ease of operation
If the excitation connector part is disposed above the lower case by raising the relay position, then the working space is secured, but the heat dissipation distance increases
Solution Approach 1:
The bus bar is designed with an asymmetric inclination where the fastening part protrudes obliquely upward at an angle greater than 90 degrees from the heat transfer part. This asymmetric geometry creates vertical working space while keeping the horizontal distance between the connection part and heat transfer part minimal, preserving heat dissipation efficiency.
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 design reduces the number of components and costs while preserving heat dissipation efficiency by securing a working space for wire connections without increasing the distance to the heat transfer part, thus optimizing the circuit assembly's structure and functionality.
Implementation Method 1
a heat transfer part configured to be in thermally conductive contact with an external heat dissipation target
Data Source
AI summary
A circuit assembly includes: a relay; a case that houses the relay; and a bus bar including a fastening part configured to be fastened to a connection part of the relay, and a heat transfer part configured to be in thermally conductive contact with an external heat dissipation target, wherein the relay includes an excitation connector part that is provided on a side surface of the relay, and that is open in a direction opposite to a direction in which the connection part is open, the fastening part of the bus bar protrudes upward from the heat transfer part disposed on a bottom wall side of the case so as to be inclined at an angle larger than 90°, and the excitation connector part of the relay in which the connection part connected to the fastening part of the bus bar is open obliquely upward.