Vehicle Junction Box Heat Shield Wall for Contact Condensation
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Solution Overview
Problem
Conventional electrical junction boxes in vehicles do not effectively prevent condensation and freezing issues that can lead to malfunctions in start electrical components due to heat transfer from operational electrical components, causing poor conduction at contacts.
Innovation Solution
Incorporating a heat shield wall between operational and start electrical components to minimize heat transfer, thereby reducing temperature differences and preventing condensation and freezing on contact points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat is transmitted from operational electrical component to the electrical component case of the start electrical component, then the electrical component case temperature increases, but this causes large temperature difference between the case and terminal portion, leading to condensation and freezing on the contact
Solution Approach 1:
A heat shield wall is introduced as an intermediary component between the operational electrical component and the start electrical component's case. This heat shield wall blocks heat transmission from the operational component to the start component's case, preventing temperature rise in the case while maintaining the necessary temperature difference for reliable contact operation.
2Reliability
If heat shield wall is disposed between operational electrical component and start electrical component, then heat transmission to start electrical component case is reduced, but this increases device complexity
Solution Approach 1:
The heat shield wall is designed to serve multiple functions: it acts as both a thermal barrier to prevent heat transmission and a structural support element within the electrical junction box. By integrating these functions into a single component, the overall device complexity is minimized while maintaining the reliability benefits.
3Temperature
If temperature difference between electrical component case and terminal portion is large, then condensation and freezing occur on the contact, but reducing temperature difference requires preventing heat transmission to the case
Solution Approach 1:
The heat shield wall serves as a thermal intermediary that selectively blocks heat flow to the electrical component case while allowing the terminal portion to maintain its operating temperature. This prevents the formation of large temperature differences that would cause condensation and freezing on the contact surfaces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly reduces the likelihood of malfunctions in start electrical components by minimizing temperature differences and preventing condensation and freezing, ensuring reliable current supply during vehicle operation and startup.
Implementation Method 1
the heat shield wall is disposed between the operational electric component and the start electrical component, the heat generated on the operational electrical component is hardly transmitted to the electrical component case of the start electrical component
Implementation Method 2
the terminal portion housed in the electrical component case and having the contact
Data Source
Figure 1
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Figure 3
AI summary
An electrical junction box 10 includes a casing 11 configured to be mounted in a vehicle, a start relay (a start electrical component) 20A housed in the casing 11 and to which a current is supplied at least at a start of the vehicle, an operational electrical component (an operational relay 20B, a connector 14, and a fuse connector 15) housed in the casing 11 and to which a current is supplied at least during an operation of the vehicle, and a surrounding heat shield wall (a heat shield wall) 24 disposed between the start relay 20A and at least one of the operational relay 20B, the connector 14, and the fuse connector 15 that are the operational electrical components. The start relay 20A includes a relay case (an electrical component case) 20a and a terminal portion 20b. The terminal portion 20b is housed in the relay case 20a and has a fixed contact FC and a movable contact MC.