Relay Busbar Layout for Compact Electric Junction Boxes
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Solution Overview
Problem
Existing electric junction boxes have a large size due to the arrangement and structure of busbars and electronic components, which limits their compact design.
Innovation Solution
The electric junction box features a pair of relays arranged with a slit between them, with busbars connected to each relay, and a case that accommodates the relays and busbars, where the busbars are positioned within specific ranges defined by the relays' extended side faces, allowing for a compact layout and independent connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a busbar extends over the entire case to connect electronic components, then electrical connectivity is ensured, but the size of the electric junction box increases
Solution Approach 1:
The busbar is divided into multiple independent busbars, each serving specific relays. This segmentation allows the busbars to be positioned within ranges defined by the relays rather than extending across the entire case, reducing the overall volume of the electric junction box while maintaining necessary electrical connectivity.
2Volume of stationary object
If electronic components are arranged closely to reduce size, then compactness is achieved, but heat dissipation becomes insufficient
Solution Approach 1:
The case includes protruding portions that create localized air flow paths between relays. These structural features are specifically designed to enhance heat dissipation in critical areas where relays are positioned closely, allowing compact arrangement while maintaining adequate thermal management through improved local air circulation.
3Manufacturing precision
If independent busbars are used for each relay, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent defines specific positioning parameters for busbars, requiring them to be located within ranges bounded by straight lines extending from relay side faces. This parameter-based approach standardizes the arrangement of independent busbars, improving manufacturing precision while controlling complexity through clear geometric constraints rather than arbitrary complex routing.
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 reduces the overall size of the junction box and enhances heat dissipation through the slit, promoting efficient air flow and reducing manufacturing costs.
Implementation Method 1
enhances heat dissipation through the slit, promoting efficient air flow
Data Source
AI summary
An electric junction box includes a pair of relays arranged with a slit in between, a busbar connected to each of the pair of relays, and a case accommodating the pair of relays and the busbar. Each of the pair of relays has a quadrangular shape that has one side face facing the slit and an opposite side face opposite from the one side face when viewed from an accommodation direction of the relays into the case. The busbar has a shape in which the entire busbar is located within a range sandwiched between a straight line obtained by virtually extending the opposite side face of one of the relays and a straight line obtained by virtually extending the opposite side face of another one of the relays when viewed from the accommodation direction.