Electrical Junction Box Cable Routing for Narrow Wiring Space

Solution Overview

Problem

In electrical junction boxes for hybrid and electric vehicles, vibrations cause cables to contact surrounding components, leading to damage due to the narrow wiring space resulting from miniaturization, complicating wiring operations.

Innovation Solution

An electrical junction box with a path restricting wall that guides cables into a preset path, preventing interference with electronic components and allowing easier wiring by restricting the wiring direction within a narrow space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the electrical junction box is miniaturized to save space, then the volume of the electrical junction box is reduced, but the wiring space becomes narrower causing cables to contact surrounding components

Engineering Contradiction:

Improvevolume of electrical junction boxVSAvoidwiring workability

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The housing is divided into multiple chambers by partition walls, with each chamber dedicated to specific components (battery connection terminal chamber, load connection terminal chamber, fuse chamber). This segmentation isolates cables within defined spaces, preventing them from contacting surrounding components while maintaining a compact overall structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Guiding walls are introduced as intermediary structures that direct cables along predetermined paths from the cable introduction portion to their respective terminals. These guiding walls act as mediators between the cable and surrounding components, ensuring cables follow safe routing paths and preventing contact with other components in the narrow space.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the wiring space is narrowed for space saving, then the volume is reduced, but cables are likely to come into contact with surrounding components due to vibration

Engineering Contradiction:

Improvewiring space volumeVSAvoidcable contact prevention

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The housing is divided into multiple chambers by partition walls, with each chamber dedicated to specific components (battery connection terminal chamber, load connection terminal chamber, fuse chamber). This segmentation isolates cables within defined spaces, preventing them from contacting surrounding components while maintaining a compact overall structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Guiding walls are introduced as intermediary structures that direct cables along predetermined paths from the cable introduction portion to their respective terminals. These guiding walls act as mediators between the cable and surrounding components, ensuring cables follow safe routing paths and preventing contact with other components in the narrow space.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If cables are fastened to bus bar fastening portions, then electrical connection is established, but cables may be bitten at fastening positions in narrow spaces

Engineering Contradiction:

Improveelectrical connection establishmentVSAvoidwiring workability

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

Guiding walls are introduced as intermediary structures that direct cables along predetermined paths from the cable introduction portion to their respective terminals. These guiding walls act as mediators between the cable and surrounding components, ensuring cables follow safe routing paths and preventing contact with other components in the narrow space.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The guiding walls are pre-formed as integral parts of the housing structure, establishing predetermined cable paths before cables are installed. This preliminary structuring of the wiring path simplifies the cable installation process and ensures proper cable routing without requiring complex manual positioning during assembly.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11804701B2Electrical junction box

Publication Date: 2023.10.31 YAZAKI CORP

AI summary

An electrical junction box is configured such that an electric or electronic component is mounted thereon. The electrical junction box includes a case having an accommodation recess, a housing configured such that the electric or electronic component is held therein and configured to be attached in the accommodation recess, and a cable configured to be drawn into the accommodation recess. The housing includes a path restricting wall configured to restrict a wiring direction of the cable.