Relay Unit Heat Dissipation via Segmented Cover
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Solution Overview
Problem
The existing configuration of a relay unit housed in a battery case faces challenges in heat dissipation due to a significant distance between the heat generation point and the heat discharge portion, leading to reduced cooling efficiency.
Innovation Solution
A relay unit design featuring a first bus bar connected to a lower member with a high heat conductive resin, and an outer heat conductive sheet, allows for efficient heat transfer through inner heat conductive sheets, reducing the distance for heat discharge and utilizing a battery case with larger thermal capacity for improved cooling, while preventing fracturing from vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the bus bar is connected to the chassis or housing at an outer side of the electric equipment housing, then the structural simplicity is improved, but the distance from the connection point to the heat discharge portion becomes large, reducing cooling efficiency
Solution Approach 1:
The device cover is segmented into an upper member and a lower member with different thermal conductivity properties. The lower member specifically forms a heat discharge path to the battery case, while the upper member provides structural coverage. This segmentation allows optimized thermal management without compromising structural integrity.
Solution Approach 2:
Different portions of the device cover are assigned different thermal conductivity characteristics. The lower member has higher heat conductive properties to efficiently discharge heat from the relay, while the upper member can be formed from standard materials. This local differentiation of material properties enables targeted heat management.
2Temperature
If the lower member is formed from a material with high heat conductive property, then the heat discharge capability is improved, but the material may be easily fractured, reducing reliability
Solution Approach 1:
The lower member is formed from a composite material or resin with enhanced heat conductive properties that maintains adequate fracture resistance. This allows the lower member to effectively discharge heat while retaining sufficient mechanical strength to withstand vibrations and thermal stress without fracturing.
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 enhances the cooling efficiency of the relay unit by shortening the heat discharge path and utilizing a larger thermal capacity, while preventing material fracturing from vibrations and ensuring reliable heat transfer.
Implementation Method 1
the first bus bar is connected to the lower member in a manner to allow transfer of heat, via a first inner heat conductive sheet placed between the first bus bar and the lower member
Implementation Method 2
the lower member is formed from a resin having a higher heat conductive property than the upper member
Implementation Method 3
the battery case has a larger thermal capacity. Because of this, it becomes easier to discharge the heat generated in the relay, over a short distance, to the portion having a large thermal capacity
Data Source
AI summary
This relay unit includes: a first bus bar; a relay electrically connected to the first bus bar; and an apparatus cover for covering the first bus bar and the relay. The apparatus cover includes: an upper member in a box shape having a covered upper end, the upper member having an opening formed in a lower end; and a lower member bonded to the upper member such that the opening of the upper member is covered with the lower member. The lower member is formed of a resin having heat conductivity that is higher than that of the upper member. The first bus bar is connected to the lower member via a first inner heat conductive sheet such that heat can be transferred to the lower member, said first inner heat conductive sheet being disposed between the first bus bar and the lower member.