Relay Cooling via Liquid Immersion and Circulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Relays in electric automobiles and hybrid vehicles face heat generation issues due to high current flow, leading to insulation layer deterioration and size increase concerns, as heat generated is proportional to the square of the current, making conventional cooling methods impractical.
Innovation Solution
A relay cooling device with a container filled with liquid coolant and a flow generation means, such as a pump, to circulate the coolant and directly cool the relay components, including through-holes in the case for enhanced heat dissipation without increasing the relay's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the cross-sectional area of the conductor is increased to lower resistance, then the resistance decreases, but the size of the relay increases
Solution Approach 1:
The patent extracts the cooling function from the relay's internal structure and implements it as a separate liquid cooling system. The relay is immersed in a liquid coolant that circulates through channels, carrying heat away from the conductor and other components. This allows the conductor to maintain low resistance without requiring increased cross-sectional area, as the heat is actively removed by the cooling system rather than being dissipated passively through larger conductors.
Solution Approach 2:
The liquid coolant acts as an intermediary between the heat-generating conductor and the environment. Instead of directly increasing conductor size to manage heat, the patent introduces a cooling fluid that absorbs heat from the conductor through thermal conduction and convection, effectively mediating the heat transfer process and allowing compact conductor design.
2Reliability
If conventional cooling methods are used, then the relay structure is maintained, but the cooling efficiency is insufficient for high current applications
Solution Approach 1:
The patent merges the cooling system with the relay housing structure. The liquid coolant flows through channels formed within or around the housing, and the relay components are positioned to be in direct thermal contact with the cooling channels. This integration allows efficient heat removal without requiring separate, complex cooling apparatus, thus improving cooling efficiency while controlling device complexity.
3Temperature
If the relay is cooled by increasing conductor size, then the heat dissipation improves, but the manufacturing cost increases
Solution Approach 1:
The patent replaces the mechanical approach of using larger conductors for heat dissipation with a fluid-based cooling system. Instead of relying on the physical dimensions of solid conductors to manage heat, the system uses liquid coolant circulation to actively remove heat. This substitution allows for more efficient heat dissipation in compact designs and can reduce manufacturing costs by using standard-sized conductors with added cooling infrastructure.
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 solution effectively suppresses temperature rise and improves cooling efficiency, allowing for high current flow without enlarging the relay, while using electrically insulating coolant reduces manufacturing costs by avoiding a liquid-tight case.
Implementation Method 1
heat generated by the relay is transmitted to the liquid coolant
Implementation Method 2
a flow generation means that causes the liquid coolant in the container to flow
Data Source
AI summary
A relay cooling device includes a container, a liquid coolant that is stored in the container, and a relay that is immersed in the liquid coolant.