Vehicle Electric Box Layout for Compact High-Voltage Isolation
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Solution Overview
Problem
Existing electric junction boxes for vehicles are bulky and lack safety features, such as physical separation between cables, which increases encumbrance and safety risks, particularly in high-voltage applications like electric vehicles.
Innovation Solution
A compact electric box with a support structure and conductive disposition that includes staggered sockets and a safety mechanism to prevent unintended electrical connections, utilizing a conductive path with metallic elements and a safety pin to ensure safe electrical communication only when the cover is closed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical separation between cables is implemented to prevent undesired contacts, then safety is improved, but device volume increases
Solution Approach 1:
The patent transitions from planar cable arrangement to a three-dimensional stacked configuration with multiple levels. Cables are arranged in different vertical planes and connected through vertical insulating structures, effectively using the vertical dimension to achieve physical separation while maintaining a compact footprint. This dimensional change allows safety isolation without proportionally increasing overall device volume.
Solution Approach 2:
The patent employs a nested arrangement where multiple cable connections are stacked vertically within the same horizontal footprint. Each cable pair is isolated in its own vertical plane, with insulating barriers between levels. This nesting approach allows multiple isolated connections to coexist in a compact space, achieving both safety separation and space efficiency.
2Volume of stationary object
If compact design is implemented to reduce encumbrance, then device volume decreases, but safety against undesired contacts deteriorates
Solution Approach 1:
The patent uses thin insulating films and barriers to achieve cable isolation. These thin film structures provide effective electrical insulation between adjacent cable connections while occupying minimal space. The insulating barriers are integrated into the compact structure, ensuring safety without adding significant volume.
Solution Approach 2:
By utilizing vertical stacking and multi-level arrangement, the patent achieves compact horizontal footprint while maintaining adequate isolation distances through the vertical dimension. This allows safe cable separation within a reduced overall device volume.
3Power
If high voltage cable connections are implemented, then power transfer capability is improved, but risk of electrical bridges increases
Solution Approach 1:
The patent introduces insulating barriers and isolation structures as intermediary elements between high voltage cable connections. These intermediaries prevent direct contact between adjacent cables, eliminating the risk of electrical bridges while allowing high power transfer capability. The insulating structures are strategically positioned at critical isolation points.
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 provides a compact, safe, and efficient means to distribute high-voltage electrical energy, supporting up to 800 A at 1000V with integrated safety features that prevent electrical injuries by decoupling sockets when the cover is removed, maintaining operational safety and reducing encumbrance.
Implementation Method 1
a conductive disposition (8) configured to establish an electrical connection between the at least one first electric socket and the at least one second electric socket
Implementation Method 2
a safety mechanism to prevent unintended electrical connections, utilizing a conductive path with metallic elements and a safety pin to ensure safe electrical communication only when the cover is closed
Data Source
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AI summary
Electric box (1) for connecting at least one first electric cable to at least a second electric cable, and comprising a structure (2) delimiting a space (3) isolated, in use, from the environment, and at least one first electric socket (I') configured to allow connection of the at least one first electric cable and at least one second electric socket (O') configured to allow connection of the at least one second electric cable, the electric box comprising a conductive disposition (8) housed within space and configured to electrically connect the at least one first electric socket (I') to the at least one second electric socket (O').