Junction Box Placement for EV Charging Harness Routing
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Solution Overview
Problem
In electric vehicles, the long high voltage harness during rapid charging results in power transmission loss and reduced charging efficiency due to the harness passing through a high-voltage module away from the virtual line connecting the battery-side and unit-side connector terminals.
Innovation Solution
A vehicle configuration where a junction box electrically connects the charging port and the battery's power line connection portion, with the junction box disposed on a virtual line connecting the two in a side view, shortening the power transmission path and reducing power loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the high voltage harness passes through a high-voltage module disposed away from the virtual line connecting the battery-side connector terminal and the unit-side connector terminal, then the high voltage harness can be routed through existing structural components, but the power transmission path becomes long and power transmission loss increases
Solution Approach 1:
The patent introduces a junction box as an intermediary component positioned on the virtual line between the battery-side connector terminal and the unit-side connector terminal. This junction box serves as a power transmission path that directly connects these two terminals, eliminating the need for the high voltage harness to detour through the high-voltage module. By using the junction box as a mediator, the patent achieves both short power transmission paths (reducing power loss) and easy manufacturability (utilizing existing junction box structure).
Data Source
AI summary
A vehicle includes a vehicle interior, a battery provided below the vehicle interior with a floor panel in between, a front room provided in front of the vehicle interior with a dashboard in between, a charging port disposed in the front room, and a junction box which electrically connects a first power line extending from the charging port and a second power line extending from a power line connection portion of the battery. The junction box is disposed on a virtual line connecting the charging port and the power line connection portion in a side view.