Junction Block Cable Routing and Stress Management
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Solution Overview
Problem
Existing junction blocks in vehicles face challenges in properly connecting high-voltage cables without disrupting the arrangement of electronic components like relays, and in effectively managing cable stress.
Innovation Solution
A junction block design featuring a rectangular flat plate attached to the side of an assembled battery, with a control device positioned near one end, a cable-connecting portion in a corner, and a cable-clamping portion along the side, allowing cables to be laid along the plate without affecting component arrangement and providing stress restraint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the control device is disposed at the center of the flat plate portion, then the electronic component parts can be properly arranged, but the cable-connecting portion cannot be provided at the corner portion effectively
Solution Approach 1:
The flat plate portion is divided into distinct functional zones: the control device is positioned in one region while the cable-connecting portion is provided at a corner portion, allowing independent optimization of electronic component arrangement and cable connection without mutual interference
Solution Approach 2:
The cable-connecting portion is positioned at the corner portion of the flat plate, utilizing the two-dimensional space efficiently. This corner positioning allows cables to be routed along the side surfaces of the battery in multiple directions, solving the spatial conflict between component arrangement and cable connection
2Ease of manufacture
If the electric power cable is connected directly without laying along the side surface, then the connection is simpler, but the cable stress cannot be properly restrained
Solution Approach 1:
The cable-connecting portion is designed to receive and preliminarily position the electric power cable before final connection. The cable is guided to be laid along the side surface of the battery in advance, preparing the cable route to reduce stress on the connector during operation
Solution Approach 2:
The flat plate portion acts as an intermediary structure between the battery and the cable. The cable is laid along the side surface and guided by the flat plate structure, which mediates the stress distribution and protects the cable connection point from direct mechanical stress
3Reliability
If additional protective components are added for cable stress management, then cable security is improved, but the number of components increases
Solution Approach 1:
The flat plate portion serves multiple functions: it provides a mounting surface for the control device, a connection point for the cable at the corner, and a guiding structure for cable routing. This multi-functionality eliminates the need for separate protective components while maintaining cable security
Solution Approach 2:
The cable-connecting portion and the flat plate structure are merged into a single integrated component. The flat plate itself provides the structural support and routing guidance that would otherwise require separate protective elements, reducing the total component count while maintaining cable security
Data Source
AI summary
A junction block (40) includes a generally rectangular flat plate portion (42) attached to a side surface of an assembled battery. A control device (50) is disposed over a portion of the flat plate portion (42) which includes a middle of the flat plate portion (42) and which is positionally biased toward a lower side end of the flat plate portion (42). A connector-connecting portion (47) is provided in one of the four corners of the flat plate portion (42) that is a rear end corner of an upper side end opposite the lower side end of the flat plate portion (42). A rib (48) and a connector-connecting portion (49) are provided at a location on the flat plate portion (42) at which the rib (4) and the connector-connecting portion (49) clamp the electric power cable (28) that is connected to the connector-connecting portion (47) and that is laid along the upper side of the flat plate portion (42).