Relay Arrangement Flat Conductor Heat Dissipation
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Solution Overview
Problem
Relay arrangements in converter apparatuses experience thermal overloading due to high power losses during operation, which is exacerbated by compact designs and low current-carrying capacity, leading to inadequate heat dissipation measures.
Innovation Solution
A relay arrangement with at least two series-connected relays mechanically and electrically connected to a main printed circuit board via flat conductors that act as both good electrical and thermal conductors, allowing for efficient heat dissipation through a multilayer printed circuit board design, which integrates electrical connection and isolation, and is supported by convection air streams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If compact relay designs with lightweight construction are used, then cost is reduced, but heat dissipation capability deteriorates
Solution Approach 1:
The patent merges the electrical connection function and thermal conduction function into a single integrated structure. The flat conductor serves dual purposes: conducting electrical current between relays and dissipating heat from the relay contacts. This eliminates the need for separate cooling components, maintaining compact design while improving heat dissipation.
Solution Approach 2:
The flat conductor is designed as a multi-functional component that simultaneously performs electrical connection and thermal management. By making the conductor both electrically conductive and thermally conductive, the invention allows a single component to address multiple requirements (current flow and heat dissipation), resolving the contradiction between compact design and thermal performance.
2Reliability
If series-connected relays are used for single-fault safety, then reliability is improved, but power losses and heat generation increase
Solution Approach 1:
The patent converts the harmful effect of heat generation into a beneficial thermal management solution. The same flat conductor that carries the current and enables the series-connected relay configuration also serves as the heat dissipation path. By utilizing the conductor's thermal conductivity, the invention transforms the heat problem into an integrated solution, allowing series-connected relays to maintain reliability while managing their inherent heat generation.
3Device complexity
If standard relay contact connections are used, then device complexity is minimized, but heat dissipation is insufficient
Solution Approach 1:
The invention combines the electrical connection function and thermal conduction function into a single integrated structure. The flat conductor serves dual purposes: conducting electrical current between relays and dissipating heat from the relay contacts. This eliminates the need for separate cooling components, maintaining compact design while improving heat dissipation.
Solution Approach 2:
The flat conductor is designed as a multi-functional component that simultaneously performs electrical connection and thermal management. By making the conductor both electrically conductive and thermally conductive, the invention allows a single component to address multiple requirements (current flow and heat dissipation), resolving the contradiction between compact design and thermal performance.
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 provides effective and cost-efficient heat dissipation, enabling reliable and robust operation of converter apparatuses by distributing heat away from the relays and maintaining a compact design with minimal additional components.
Implementation Method 1
The flat conductor is mechanically connected to the main printed circuit board and electrically and thermally connected to the first terminals of the relays for dissipating of the heat produced during operation of the relays
Implementation Method 2
The relay arrangement with improved heat dissipation... supported by convection air streams
Data Source
AI summary
A relay arrangement includes at least two series-connected relays, which are mechanically and electrically connected to a main printed circuit board via first terminals and second terminals, and at least one flat conductor for conducting current between the at least two series connected relays. The flat conductor is mechanically connected to the main printed circuit board and electrically and thermally connected to the first terminals of the relays, and the at least one flat conductor is configured to dissipate heat produced during operation of the relays.