Block-Type Junction Box for Vehicle Electrical Systems

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Solution Overview

Problem

Existing junction box structures for vehicles are not adaptable to various models, leading to increased manufacturing costs, weight, and complexity due to their non-standard design and requirement for specific circuit boards, which complicates production and increases costs.

Innovation Solution

A block-type junction box with standardized busbar, relay, and fuse blocks, coupled via block grooves and clips, allowing for simpler assembly and application across different vehicle models, reducing the need for retainer structures and simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional junction box structure with circuit boards and multiple coupled components is used, then the electrical connection function is achieved, but the weight and manufacturing cost increase

Engineering Contradiction:

Improveelectrical connection functionVSAvoidjunction box weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The junction box is divided into an upper case and a lower case that are separably coupled together. The circuit board is positioned in the upper case while the busbar is positioned in the lower case, allowing independent manufacturing and assembly of these components. This segmentation reduces overall complexity and enables lighter construction compared to monolithic designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal connected to the circuit board and the circuit board itself are integrated as a single assembly. Similarly, the terminal connected to the busbar and the busbar are merged into one unit. This merging eliminates the need for separate retainers to fix terminals, thereby reducing weight and simplifying the structure.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a conventional junction box structure with circuit boards and retainers is used, then the electrical connection function is achieved, but the manufacturing cost increases

Engineering Contradiction:

Improveelectrical connection functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a conventional junction box structure with circuit boards is used, then the electrical connection function is achieved, but the structure becomes complicated

Engineering Contradiction:

Improveelectrical connection functionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If a conventional junction box structure is used, then the electrical connection function is achieved, but the structure cannot be applied to various vehicle models

Engineering Contradiction:

Improveelectrical connection functionVSAvoidapplicability to various vehicle models

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The upper case and lower case are designed with standardized coupling mechanisms that can accommodate different circuit board configurations and busbar arrangements. This universal design allows the same basic junction box structure to be adapted to various vehicle models with different electrical system requirements, eliminating the need for completely different designs for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS7614886B2Junction box having block type structure

Publication Date: 2009.11.10 HYUNDAI MOTOR CO LTD

AI summary

A junction box having a block type structure is provided. The junction box having a block type structure includes: a lower cover of a quadrangular shape in which an inner groove having an opened upper part is formed and at one side of which a sliding groove is formed; a main body at one side of which a flat plate having a step surface is coupled to the sliding groove of the lower cover by downwardly sliding and in an upper part of which a plurality of block grooves are formed; a block assembly being received and assembled in the block grooves of the main body; and an upper cover coupled to the main body by wrapping an upper part of the main body so as to protect the block assembly.