Vehicle Junction Box Layout for Overlapping HV and LV Bus Bars

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Solution Overview

Problem

Existing electrical junction boxes for vehicles face challenges in accommodating both high-voltage and low-voltage bus bars in a compact size while ensuring adequate insulation, leading to complex configurations and increased size due to the use of insulating plates and lid-shaped members.

Innovation Solution

The electrical junction box design features a housing with a low-voltage bus bar attached to the top plate and a high-voltage bus bar attached to the bottom plate, overlapping with a clearance distance in the up-down direction, utilizing a distance maintaining portion to ensure insulation and accommodate both bus bars in a space-efficient manner.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If insulating plates and lid-shaped insulating members are used to insulate between high-voltage and low-voltage bus bars, then insulation is ensured, but the configuration becomes complicated and the size increases

Engineering Contradiction:

Improveinsulation between bus barsVSAvoidconfiguration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The housing integrates both structural support and insulation functions into a single component. The housing includes a first housing portion for the high-voltage bus bar and a second housing portion for the low-voltage bus bar, with an insulating wall between them. This merging eliminates the need for separate insulating plates and lid-shaped members, simplifying the overall configuration while maintaining insulation reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing serves multiple functions simultaneously: it provides mechanical support for both bus bars, maintains spatial separation between them, and provides electrical insulation through the insulating wall. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity while ensuring reliable insulation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If insulating plates and lid-shaped insulating members are used to insulate between high-voltage and low-voltage bus bars, then insulation is ensured, but the size of the electrical junction box increases

Engineering Contradiction:

Improveinsulation between bus barsVSAvoidsize of electrical junction box

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The high-voltage and low-voltage bus bars are nested within the same housing structure, with each bus bar positioned in its own designated portion. The insulating wall is integrated into the housing structure itself, allowing compact arrangement of components without requiring additional external insulating elements, thereby reducing the overall volume.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Volume of stationary object

If high-voltage and low-voltage bus bars are accommodated together, then space efficiency is improved, but short circuiting or leakage may occur

Engineering Contradiction:

Improvesize of electrical junction boxVSAvoidinsulation between bus bars

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

The housing is segmented into distinct portions: a first housing portion for the high-voltage bus bar and a second housing portion for the low-voltage bus bar. An insulating wall separates these portions, creating clear spatial and electrical boundaries. This segmentation allows compact accommodation of both bus bars while preventing short circuiting or leakage through the insulating barrier.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating wall acts as an intermediary element between the high-voltage and low-voltage bus bars. It physically separates the two conductors and provides electrical insulation, enabling them to be accommodated in close proximity without risk of short circuiting or leakage.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12176699B2Electrical junction box

Publication Date: 2024.12.24 SUMITOMO WIRING SYSTEMS LTD

AI summary

Provided is an electrical junction box that can be reduced in size by accommodating a high-voltage bus bar and a low-voltage bus bar in a space-efficient manner. The electrical junction box is an electrical junction box for a vehicle including a housing that accommodates a high-voltage bus bar for high voltages and a low-voltage bus bar for low voltages, in which the low-voltage bus bar is attached to a top plate of the housing, the high-voltage bus bar is attached to a bottom plate facing the top plate, and the high-voltage bus bar and the low-voltage bus bar are disposed overlapping each other with a clearance distance therebetween in an up-down direction.