Electrical Junction Box Heat Leakage Prevention
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Solution Overview
Problem
Traditional electrical junction boxes allow heat from electronic control units to leak out, causing thermal damage to connected electric wires and components, which can deteriorate insulation coatings and impact vehicle controls.
Innovation Solution
An electrical junction box design featuring a frame with a unit storing room and an upper cover that closes the accommodating port, using a separating wall with reinforcing ribs to prevent heat leakage and maintain a compact size, while enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the accommodating port is left open for installing the electronic control unit, then the installation process is simple and accessible, but heat from the electronic control unit leaks to the outside causing thermal damage to electric wires and connectors
Solution Approach 1:
The accommodating port is segmented into two functional zones: an open installation area that remains accessible for mounting the electronic control unit, and a closed storage area separated by a partition wall that prevents heat leakage. This segmentation allows simultaneous achievement of installation ease and thermal protection.
Solution Approach 2:
A partition wall is introduced as an intermediary structure within the accommodating port. This partition wall acts as a thermal barrier that blocks heat transmission from the electronic control unit to the stored electric wires and connectors, while still permitting installation access through the open side.
2Object-affected harmful factors
If a cover is added to close the accommodating port to prevent heat leakage, then thermal protection is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The partition wall is merged with the existing frame structure of the electrical junction box, integrating the thermal barrier function into the structural framework. This merging eliminates the need for a separate cover component, reducing device complexity while maintaining heat leakage prevention.
Solution Approach 2:
The partition wall serves multiple functions simultaneously: it acts as a thermal barrier to prevent heat leakage, provides structural support for the accommodating port, and maintains the organizational separation between storage and installation areas. This multi-functionality reduces the need for additional components.
3Adaptability or versatility
If the electronic control unit is installed in the unit storing room, then the control function is achieved, but heat generated by the unit damages the insulation coatings of connected electric wires
Solution Approach 1:
The heat generation issue is extracted and isolated from the main storage area by creating a dedicated accommodating port with a partition wall. This extraction separates the thermal hazard zone (where the electronic control unit operates) from the sensitive components zone (where electric wires and connectors are stored), protecting the insulation coatings while maintaining control functionality.
Data Source
AI summary
An electrical junction box of the present invention includes a frame (11) in which a storing box B is formed which has a unit storing room (20) in which an electronic control unit (63) is accommodated, and an upper cover (15) which is assembled to the side of the frame (11) where a accommodating port (20a), which becomes an entrance when the electronic control unit (63) is accommodated in the unit storing room (20), is formed so that the accommodating port (20a) is closed.