Electric Junction Box with Straddling Connector Housing
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Solution Overview
Problem
Conventional electric junction boxes face challenges in space efficiency and cost due to the large size of high-voltage relays and the need for extensive bus bar wiring, with existing configurations either increasing component count or failing to adequately downsize the junction box.
Innovation Solution
The electric junction box integrates relay housings with a shared partition wall and a connector housing that straddles adjacent relay housings, reducing the length of the bus bar and enhancing space efficiency by consolidating components, while also improving rigidity and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If relays are mounted alternately in opposite directions with bus bars partitioned by insulating plates in layers, then space efficiency is improved, but component count increases and height increases
Solution Approach 1:
The patent merges the connector housing with the relay housings by providing the connector housing on the external peripheral surface of adjacent relay housings. This integration eliminates the need for separate insulating plates and layered bus bar arrangements, reducing component count while maintaining space efficiency. The bus bar is disposed to straddle the relay housings and connector housing, creating a simplified conductive path structure.
2Ease of manufacture
If connector housing is provided separately away from relay mounting portion, then relay mounting is simplified, but distance to coil power supply terminal increases and space is wasted
Solution Approach 1:
The connector housing is merged with the relay housings by providing it on the external peripheral surface of adjacent relay housings. This integration reduces the distance between the connector and relay coil power supply terminals, eliminating wasted space while maintaining ease of manufacture through the integrated structure.
3Reliability
If bus bar is wired from connector housing to relay coil power supply terminals, then power conduction is achieved, but bus bar length increases and space is required
Solution Approach 1:
The bus bar is disposed to straddle the relay housings and connector housing in a three-dimensional arrangement that optimizes the conductive path. This spatial optimization reduces the bus bar length while maintaining reliable power conduction, utilizing the available space efficiently rather than following a linear wiring path.
Data Source
AI summary
A connector housing conducting power to a coil is integrated straddling adjacent relay housings on external peripheral surfaces thereof and utilizing a peripheral wall of the adjacent relay housings, the adjacent relay housings being separated by and sharing a partition wall as a portion of a wall portion. A bus bar straddling the connector housing and the adjacent relay housings forms a conductive path from an external power supply terminal provided in the connector housing to a relay coil power supply terminal provided in each of the adjacent relay housings.