Electrical connection box
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Solution Overview
Problem
In electrical connection boxes, especially in vehicles, it is challenging to route thick, rigid electric wires in narrow spaces without applying overload to the housing, and there is a risk of other components contacting electrical connection points when assembled or maintained, due to the increased diameter of wires for weight reduction and large current capacity.
Innovation Solution
An electrical connection box design featuring a tubular frame with a circuit branching component outside the frame, where the internal conductive members and circuit branching members are physically and electrically connected, with exposed surfaces interposed between a resin member and a facing wall to prevent contact with other components, and the circuit branching component is embedded in resin to manage overcurrents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If electric wires with larger diameter are used for weight reduction and large current capacity, then current carrying capability and weight reduction are improved, but routing difficulty and space requirements increase
Solution Approach 1:
The circuit branching component is extracted from the housing and disposed outside the housing. This allows the thick, rigid electric wires to be connected to the circuit branching component in an external space, avoiding the routing difficulties associated with narrow internal housing spaces while maintaining the current carrying capability provided by the larger diameter wires
Solution Approach 2:
The electrical connection structure transitions from a two-dimensional planar arrangement within the housing to a three-dimensional external configuration. The circuit branching component is positioned outside the housing with connection points accessible from multiple directions, providing additional spatial dimensions for wire routing and connection
2Power
If electric wires with larger diameter are used for weight reduction and large current capacity, then current carrying capability and weight reduction are improved, but overload risk to housing increases
Solution Approach 1:
The circuit branching component is extracted from the housing and disposed outside the housing. This separation removes the source of potential overload from the housing interior, eliminating the risk that thick, rigid electric wires may apply overload to the housing while still enabling high current carrying capability through the external component
3Ease of operation
If electrical connection points are disposed outside the housing for accessibility, then ease of connection is improved, but contact risk with other components increases
Solution Approach 1:
The resin member serves as an intermediary between the circuit branching component and the external environment. It embeds and supports the conductive circuit branching member while providing electrical insulation and mechanical protection, allowing the connection points to be accessible outside the housing while preventing contact with other components through the insulating resin barrier
Solution Approach 2:
The circuit branching component combines conductive material (for electrical connection) with insulating resin material (for protection and support). This composite structure enables external accessibility of connection points while the insulating resin prevents harmful contact with other components, simultaneously achieving ease of connection and reliability
Data Source
AI summary
An electrical connection box includes a circuit branching component that is disposed outside a frame and outside a tubular portion and includes a conductive circuit branching member embedded in a resin member, a tubular wall of the tubular portion includes a facing wall body that is disposed to face the circuit branching component outside the tubular portion, the resin member includes a holding portion that holds a load connection portion of the circuit branching member in a state where an exposed surface of the load connection portion is exposed, and the circuit branching component is disposed such that the exposed surface of the load connection portion faces the facing wall body, and the exposed surface is interposed between the holding portion and the facing wall body.