Modular High-Voltage Junction Box Assembly for Vehicle Customization
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Solution Overview
Problem
Existing high-voltage junction boxes are typically custom-designed for specific applications, lacking flexibility and commonality, necessitating separate manufacturing for different vehicle models, which complicates customization and maintenance.
Innovation Solution
A modular design for high-voltage junction boxes comprising interchangeable modules with standardized housings and interfaces, allowing for customizable assemblies that can accommodate various applications by combining different modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If high-voltage junction boxes are custom-designed for specific applications, then the design can meet specific electrical and physical requirements, but the manufacturing complexity increases and flexibility decreases
Solution Approach 1:
The junction box is divided into multiple modular sections (first section, second section, third section, fourth section) that can be independently manufactured and then assembled. Each module contains standardized interfaces that allow flexible configuration for different applications without requiring custom design of the entire system.
Solution Approach 2:
The patent creates universal interface standards that allow the same modular components to be used across multiple applications. The standardized housings and interfaces enable a single module design to serve multiple electrical and physical requirements through different combinations and configurations.
2Adaptability or versatility
If separate manufacturing is performed for different vehicle models, then specific requirements are met, but production time and costs increase
Solution Approach 1:
By segmenting the junction box into standardized modules, the system allows different vehicle models to be configured using the same set of pre-manufactured modules. This eliminates the need for separate manufacturing lines for each vehicle model while still meeting specific requirements through module selection and arrangement.
Solution Approach 2:
The patent enables configuration changes through parameter variations in module assembly rather than physical redesign. Different vehicle models are accommodated by changing which modules are assembled and how they are connected, not by manufacturing different components, thereby maintaining high manufacturing efficiency.
3Stability of the object's composition
If components are fixed in place in preassembled junction boxes, then structural stability is maintained, but maintenance and replacement difficulty increases
Solution Approach 1:
The modular design allows components to be firmly secured within their respective modules for structural stability, while the modules themselves can be easily detached and replaced. This two-level segmentation maintains stability during operation while enabling easy maintenance by allowing entire modules to be swapped without disassembling individual components.
4Adaptability or versatility
If custom designs are used for each application, then specific requirements are met, but cost-effectiveness decreases
Solution Approach 1:
The patent implements universal module designs that can be used across multiple applications. By standardizing housings, interfaces, and connection protocols, the same components serve multiple purposes and can be configured for different vehicle models and applications, significantly reducing per-unit manufacturing costs while maintaining customization capability.
Data Source
AI summary
A high-voltage junction box module includes: a housing; a plurality of electrical ports disposed at the first side of the housing; a plurality of buses contained within the housing and operatively controlling electrical flow and electrical connection between auxiliary electronic devices that are electrically coupled with the junction box module via the electrical ports; and at least one interface having one or more coupling sections disposed at one or more of the second side, the third side, the fourth side, the first section, or the second section of the housing. The interface physically and electrically couples the junction box module directly with an additional junction box module.