Integrated Junction Box for Electric Vehicle High and Low Voltage Systems
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Solution Overview
Problem
The integration of high-voltage and low-voltage systems in electric vehicles poses challenges due to increased wire size, weight, and manufacturing costs when using lower voltage, and requires new components for high voltage compatibility, while also risking electric shock and component interference.
Innovation Solution
A low-voltage and high-voltage integrated junction box is designed with a high-voltage distribution part and a low-voltage control board, including a high-voltage relay, bus bar, pre-charging relay, current sensor, and brake switch, which are accommodated in a control box to manage and control high voltage distribution, prevent electromagnetic interference, and ensure safety by cutting power when the cover is removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If lower voltage is used to maintain certain power level, then compatibility with existing low-voltage electric components is improved, but wire size, weight, and manufacturing cost increase
Solution Approach 1:
The junction box is divided into separate high-voltage and low-voltage compartments with physical barriers. The high-voltage distribution part and low-voltage control board are spatially segmented to prevent interference while maintaining各自 functionality. This segmentation allows the system to use high voltage for power efficiency while keeping low-voltage control components compatible with existing systems.
Solution Approach 2:
A pre-charging relay and resistor are introduced as intermediary components between the high-voltage battery and the output terminals. These intermediaries gradually charge the capacitance of wiring and components, preventing sudden current surges that could damage low-voltage components. This intermediary mechanism enables safe integration of high-voltage power distribution with existing low-voltage electric components.
2Weight of moving object
If high voltage is used to reduce current amount, then wire size and weight are reduced, but compatibility with existing low-voltage electric components is lost and new high-voltage components are required
Solution Approach 1:
The patent merges high-voltage distribution functionality with low-voltage control functionality into a single integrated junction box. The control box accommodates both the high-voltage distribution part and low-voltage control board, allowing high-voltage power transmission with reduced current while maintaining control compatibility with existing low-voltage components through the integrated architecture.
Solution Approach 2:
The pre-charging relay and resistor act as intermediaries that enable high-voltage operation while protecting low-voltage components. They gradually charge the system capacitance before full high-voltage power is applied, preventing damage to existing low-voltage electric components and enabling the use of thinner, lighter wires.
3Reliability
If high-voltage and low-voltage circuits are provided separately, then functionality is ensured, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines separate high-voltage and low-voltage circuits into a single integrated junction box with unified housing. The control box accommodates both the high-voltage distribution part and low-voltage control board in close proximity with appropriate isolation. This merging reduces the number of separate components and simplifies installation while maintaining functional reliability through proper spatial arrangement and electromagnetic shielding.
4Volume of moving object
If high-voltage distribution part and low-voltage control board are integrated in same space, then device size is reduced, but electromagnetic interference between components may occur
Solution Approach 1:
The control box interior is divided into distinct high-voltage and low-voltage zones with different electromagnetic shielding requirements. The high-voltage distribution part and low-voltage control board are positioned in separate local areas with appropriate shielding materials between them. This local quality differentiation allows compact integration while minimizing electromagnetic interference through targeted shielding at critical interfaces.
Data Source
AI summary
A low-voltage and high-voltage integrated junction box includes a high-voltage distribution part, a low-voltage control board, and a control box. The high voltage distribution part includes a high-voltage relay for applying/cutting high voltage to an output terminal by distributing high voltage applied from a high-voltage battery and a bus bar for transmitting the high voltage applied through the high-voltage relay to the output terminal. The low-voltage control board controls low-voltage load and controls a breakdown of the high-voltage distribution part and operation of electric components of a vehicle. The control box accommodates therein the high-voltage distribution part and the low-voltage control board. With this integrated injunction box, manufacturing costs can be reduced.