Electrical Connection Box Grounding Bracket Design

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Solution Overview

Problem

The existing electrical connection boxes for vehicles require a separate grounding conductor wire or an incorporated grounding circuit, increasing design, manufacturing, and assembly time and costs.

Innovation Solution

An electrical connection box with a belt-like grounding metal plate and a fixing bracket that allows ground connection by attaching the box to the vehicle body with a bolt, eliminating the need for a grounding conductor wire, and featuring a slit and notch design to enhance safety during collisions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate grounding conductor wire or incorporated grounding circuit is used, then the grounding connection is reliable, but the number of man-hours and cost in design, manufacture and assembly increases

Engineering Contradiction:

Improvegrounding connection reliabilityVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The grounding function is merged with the fixing bracket structure. The fixing bracket includes a grounding metal plate that extends from the grounding member to the outside of the box main body, and a bolt through hole that electrically connects the grounding metal plate to the bolt. This integration allows the grounding connection to be achieved simultaneously with the fixing operation, eliminating the need for separate grounding conductor wires and reducing assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bolt serves multiple functions: it acts as both a fixing element to secure the electrical connection box to the vehicle body and as a grounding conductor to establish the electrical ground connection. The fixing bracket is designed to extend integrally from the box main body and includes both the grounding metal plate and bolt through hole, making it a multi-functional component that combines structural support and electrical grounding.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a grounding conductor wire is used, then the grounding connection can be established, but the design and manufacturing complexity increases

Engineering Contradiction:

Improvegrounding connectionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The grounding conductor wire is extracted from the system and replaced by the integrated grounding metal plate and bolt through hole structure. This extraction simplifies the overall system by removing the separate grounding wire component and its associated routing, connection, and fastening requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

3Strength

If the fixing bracket is made strong to prevent breakage, then structural integrity is maintained, but safety during collision is reduced due to potential exposure of grounding components

Engineering Contradiction:

Improvefixing bracket strengthVSAvoidexposure of grounding components during collision

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

A slit is provided in the fixing bracket at a position where it is more likely to break during a collision. This preliminary weakness is intentionally designed to guide the breakage to occur at a specific location that prevents exposure of the grounding metal plate and other grounding components. The slit acts as a stress concentration point that ensures controlled fracture behavior during impact events.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The potential harm of bracket breakage during collision is converted into a benefit by designing the slit to guide the breakage to a safe location. The controlled fracture at the slit position prevents uncontrolled breakage that could expose grounding components, thus converting the harmful effect of structural failure into a protective feature that enhances safety.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 simplifies the design and assembly processes, reduces costs, and enhances safety by preventing unintended breakage and exposure of grounding components during vehicle collisions.

Implementation Method 1

a belt-like grounding metal plate extending from the grounding member to an outside of the box main body

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

a bolt through hole formed through a tip end portion of the fixing bracket to electrically connect the grounding metal plate to a bolt to be inserted

Methodology Applied

Scientific EffectElectrical contact through mechanical fastening: Mechanical Fastener

Data Source

PatentUS10892569B2Electrical connection box and ground connection structure thereof

Publication Date: 2021.01.12 YAZAKI CORP

AI summary

An electrical connection box includes: a box main body; an electric circuit body loaded into the box main body; a grounding member provided in the electric circuit body; a belt-like grounding metal plate extending from the grounding member to the outside of the box main body; a fixing bracket extending integrally with the box main body and including the grounding metal plate; and a bolt through hole formed through a tip end portion of the fixing bracket to electrically connect the grounding metal plate to a bolt to be inserted.