Vehicle Junction Box Lead Frame Communication Bus
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Solution Overview
Problem
Existing electrical connection boxes for vehicles are complex and costly due to the use of multiple connectors, copper traces, and printed circuit boards for relay control, which complicates manufacturing and increases production costs.
Innovation Solution
An electrical connection box with relays featuring a communication bus interface and a lead frame connection grid, eliminating the need for a printed circuit board by using the lead frame as a communication bus for common control of multiple relays, and incorporating a communication bus section that can be electrically coupled with the ground to form a capacitor for interference filtering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a printed circuit board with copper traces and multiple connectors is used for relay control, then reliable electrical connections are achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the control box and electrical junction box into a single integrated unit, merging previously separate assemblies. The lead frame serves dual purposes as both structural support and electrical connection medium, replacing the traditional printed circuit board. This integration eliminates multiple connectors and copper traces while maintaining reliable electrical connections between relays and control circuits.
Solution Approach 2:
The lead frame performs multiple functions simultaneously: it provides mechanical support for relay mounting, establishes electrical connections between relay terminals, and serves as the communication bus for control signals. This multi-functional design eliminates the need for separate printed circuit boards and connector assemblies, reducing overall system complexity while maintaining connection reliability.
2Adaptability or versatility
If multiple independent control sections are used for each relay, then individual relay control is achieved, but the number of control wires and manufacturing complexity increase
Solution Approach 1:
The lead frame acts as a universal communication bus that serves all relays simultaneously. Control signals are transmitted through this shared bus structure, allowing individual relay control without requiring separate control wires for each relay. The lead frame's distributed connection points enable addressable control of multiple relays through a common communication channel.
Solution Approach 2:
The patent merges multiple independent control pathways into a single integrated communication bus formed by the lead frame. Instead of having separate control wires for each relay, the system uses one shared communication infrastructure that can selectively address and control individual relays, significantly reducing the total number of control wires required.
3Reliability
If standard wiring harnesses and connectors are used to connect control box and junction box, then electrical communication is established, but production cost and assembly complexity increase
Solution Approach 1:
The patent merges the control box and electrical junction box into a single integrated assembly, eliminating the need for external wiring harnesses and connectors between these components. The lead frame provides direct electrical pathways within the unified structure, removing the interface complexity and cost associated with connecting separate assemblies through standard wiring harnesses.
Solution Approach 2:
The invention extracts and eliminates the wiring harness and connector components from the system by integrating their electrical connection functions directly into the lead frame structure. This extraction removes unnecessary intermediate components while maintaining the essential electrical communication functionality, thereby simplifying manufacturing and reducing production costs.
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 solution simplifies manufacturing, reduces production costs, optimizes electrical architecture, and minimizes the number of control wires needed, while also enabling efficient data transmission and fault diagnosis in vehicle electrical systems.
Implementation Method 1
The communication bus section may be electrically coupled to an electrical ground section of the leadframe to form an electrical capacitor
Data Source
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AI summary
An electrical junction box includes a plurality of relays, a relay carrier, and a lead frame including connecting sections. Each relay includes electrical connection pins enabling the relay to be plugged into the relay carrier, thereby enabling electrical connection to the lead frame. Each relay includes a communication bus interface that is connected to a control pin of the relay. The lead frame includes a section forming a communication bus. The control pins of the relays are electrically connected to the section forming the communication bus when the relays are plugged into the relay carrier.