Thermoelectric Cooler Controller Integration
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Solution Overview
Problem
Traditional thermal management systems for electronic and electrical components require a separate controller enclosure, leading to increased complexity, space usage, and difficulty in installation and modification due to hardwired connections.
Innovation Solution
A compact thermal management system with a thermoelectric cooling unit and a controller integrated within the enclosure, utilizing quick disconnect connectors for simplified power management and reduced form factor, allowing the controller to be mounted directly to the cooling unit or within the main enclosure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate controller enclosure is used to protect the controller and provide hardwired connections, then the controller is protected and connections are secure, but the system complexity increases, space usage increases, and installation becomes more difficult
Solution Approach 1:
The controller is integrated directly into the thermal management system by mounting it on the heat sink assembly, eliminating the need for a separate controller enclosure. The controller shares the same enclosure space as the cooling unit, and electrical connections are simplified through integrated wiring harnesses that connect directly to the circuit board, reducing overall system complexity while maintaining protection and connection security.
Solution Approach 2:
The controller is nested within the existing thermal management system enclosure by mounting it on the heat sink assembly. This nesting approach allows the controller to occupy space already allocated for cooling components, thereby avoiding the need for additional external enclosure space while maintaining system protection and integration.
2Reliability
If a separate controller enclosure is used, then the controller is protected, but more material is used and space is consumed
Solution Approach 1:
The controller and cooling unit share the same enclosure space by mounting the controller directly on the heat sink assembly. This merging eliminates the need for a separate controller enclosure, reducing the total volume required for the thermal management system while maintaining controller protection within the shared enclosure environment.
Solution Approach 2:
The controller is nested within the thermal management system enclosure by mounting it on the heat sink assembly, utilizing the existing enclosure space already allocated for cooling components. This nesting eliminates the need for additional external enclosure space while maintaining controller protection.
3Reliability
If hardwired connections are used between the controller and cooling units, then connections are secure, but installation and modification become more difficult
Solution Approach 1:
The electrical connection system is segmented into modular components including a circuit board with integrated wiring harnesses and terminal blocks. This segmentation allows for easier installation and modification compared to traditional hardwired connections, as components can be connected and disconnected more easily while maintaining secure electrical connections through the modular terminal block design.
Solution Approach 2:
The connection system incorporates terminal blocks and wiring harnesses that provide dynamic connectivity, allowing for easier installation and modification compared to fixed hardwired connections. The terminal blocks enable quick connection and disconnection of electrical wires while maintaining secure connections during operation, facilitating easier system assembly and maintenance.
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 enables a more compact and easily installable thermal management system, reducing material usage and complexity while maintaining effective cooling capabilities, as the controller can be mounted internally without increasing the enclosure size, and simplifies the connection between input and output power sources.
Implementation Method 1
A thermoelectric cooler controller... thermoelectric cooling unit mounted on the enclosure such that the cooling unit cools an interior space of the enclosure
Implementation Method 2
The cooling unit has a fan for driving air into the interior space
Implementation Method 3
The cooling unit can include a fan and a heat sink for removing heat from the main enclosure
Data Source
AI summary
A thermal management system for an enclosure containing electrical components includes a thermoelectric cooling unit for controlling temperature inside the enclosure and a controller for the cooling unit, the controller being configured so that it can be installed within and protected by the enclosure, rather than requiring its own separate secure enclosure. The controller includes a simplified power management circuit that uses an input quick connector that receives a first cable connector for providing power to the circuit board, and an output quick connector that receives a second cable connector for supplying power from the input quick connector to the fan of the cooling unit. This one-in, one-out arrangement allows for the elimination of multiple hard-wired cable harnesses and the corresponding connectors on the circuit boards of existing controllers. The circuit board size is reduced, and terminal blocks eliminated, so that the controller can be installed inside the enclosure.