Electrical Junction Box Shield Retention for EMC and Water Tightness
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Solution Overview
Problem
Existing electrical junction boxes for high voltage harnesses in vehicles require multiple parts and components, increasing costs and labor time while compromising on robustness, EMC protection, and water tightness.
Innovation Solution
A method of manufacturing an electrical junction box that uses an everted braided shield of the cable end, integrated with a conductive housing and adhesive for secure fixation and electrical contact, eliminating the need for additional components like ferrules and reducing part count, while ensuring mechanical and EMC protection and water tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional components like ferrules are used to secure cable ends, then reliable electrical contact and mechanical fixation are achieved, but the number of parts increases and manufacturing cost rises
Solution Approach 1:
The patent combines the electrical contact function and mechanical fixation function into a single integrated retainer section of the housing. The retainer section directly contacts the everted braided shield to provide both electrical connection and mechanical securing, eliminating the need for separate ferrules or connectors. This merging of functions reduces part count while maintaining reliability.
Solution Approach 2:
The retainer section serves multiple functions simultaneously: it provides electrical contact with the braided shield, mechanical fixation of the cable end, and structural support within the housing. This multi-functionality approach allows a single component to replace what would traditionally require multiple specialized parts.
2Reliability
If multiple components are used to ensure water tightness and mechanical protection, then protection reliability is improved, but manufacturing labor time and cost increase
Solution Approach 1:
The sealing function is integrated into the retainer section and housing structure itself, rather than using separate sealing components. The retainer section works in conjunction with the housing to provide water tightness through their combined geometry and material properties, eliminating the need for additional sealing parts and reducing assembly steps.
3Strength
If traditional cable end securing methods are used, then mechanical fixation is achieved, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The mechanical fixation function is merged into the retainer section that is already present in the housing structure. The retainer section directly engages with the everted braided shield through its geometry, providing secure mechanical fixation without requiring separate fastening components or complex assembly procedures.
Solution Approach 2:
The everted braided shield itself serves as the fixation element by being inserted into the retainer section. The braided shield's own structure and geometry enable it to be retained and fixed by the retainer section without requiring additional fixation components. The system uses the cable's own features to achieve its own securing.
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
The method reduces the number of parts and labor time required, achieving robust construction, improved water tightness, and effective electromagnetic shielding with reduced costs, without additional components for securing the cable end.
Implementation Method 1
an electrically conductive adhesive is applied to the retainer section and/or to the everted braided shield section of the cable end
Implementation Method 2
Such high voltage harnesses need to be shielded to prevent electromagnetic radiation to escape that could disturb other components of vehicles or the environment
Implementation Method 3
said retainer section having at least one protrusion for urging against the inverted braided shield section
Data Source
AI summary
An electrical junction box comprises an electrically conductive housing and at least one cable end wherein an everted braided shield section of the cable end is received in a retainer section of the housing and an electrically conductive adhesive is provided.