Segmented Relay Busbar Layout for Compact Heat Dissipation
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Solution Overview
Problem
Existing electrical devices face challenges in efficiently dissipating heat generated by heat-generating components within a limited space, particularly due to the demand for downsizing.
Innovation Solution
The electrical device incorporates a busbar configuration with multiple busbar strips, each having abutting and separated portions, allowing for increased surface area and efficient heat dissipation while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a single busbar is used for heat dissipation, then the structure is simple, but the heat dissipation efficiency is insufficient and the device size increases
Solution Approach 1:
The busbar is divided into multiple separate busbar strips (first busbar strip, second busbar strip, third busbar strip, fourth busbar strip) instead of using a single solid busbar. These segmented strips are arranged in a specific pattern with alternating connections to the relay terminal, creating multiple heat dissipation pathways that improve thermal efficiency while maintaining a compact structure.
2Temperature
If the busbar surface area is increased for better heat dissipation, then heat dissipation efficiency improves, but the device occupies more space
Solution Approach 1:
The busbar strips are arranged in a multi-dimensional configuration with alternating connections to the relay terminal. The strips extend in different directions and are positioned at different heights, utilizing three-dimensional space rather than simply expanding the two-dimensional footprint. This allows increased surface area for heat dissipation without proportionally increasing the device's overall footprint.
3Temperature
If multiple busbar strips are used to increase surface area, then heat dissipation improves, but the manufacturing complexity increases
Solution Approach 1:
Multiple busbar strips are connected to a common relay terminal, merging their electrical and thermal functions into a single integrated structure. The alternating connection pattern allows the strips to work together as a unified heat dissipation system, simplifying the overall assembly process compared to using completely separate components that would require multiple connection points and alignment steps.
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 configuration achieves both downsizing and improved heat dissipation efficiency, preventing temperature rises during high-current conditions by effectively utilizing adjacent space and enhancing convection.
Implementation Method 1
Heat generated from the relay during the passage of current is transferred from the relay terminal to the busbar, and from the busbar to the case via the thermal conductive sheet
Implementation Method 2
This configuration achieves both downsizing and improved heat dissipation efficiency, preventing temperature rises during high-current conditions by effectively utilizing adjacent space and enhancing convection
Data Source
AI summary
An electrical device 1 includes a relay 30 that has a relay terminal 32 and generates heat in response to passage of a current, and an intermediate busbar 50 connected to the relay terminal 32. The intermediate busbar 50 includes: a first busbar strip 51 having a first inner abutting portion 52 connected to the relay terminal 32 and a first separated portion 53 continuous with the first inner abutting portion 52; and a second busbar strip 61 having a first outer abutting portion 54 abutting the first inner abutting portion 52 and a second separated portion 63 continuous with the first outer abutting portion 54 and separated from the first separated portion 53.