Vehicle Electrical Connection Box Reducing Voltage Loss
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Solution Overview
Problem
Conventional electrical connection boxes in vehicles experience significant power loss due to high contact resistance, especially when handling high currents, which is not effectively minimized by existing connector designs.
Innovation Solution
The electrical connection box incorporates a connector assembly with square cross-section connectors and sockets, featuring rounded corners to increase contact area and reduce resistivity, along with a lock member and living hinge mechanism for secure plug retention, and a combined voltage regulator and rectifier circuit to manage current efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional male and female connectors are used in electrical connection boxes, then the connection structure is simple and easy to manufacture, but the contact resistance is high causing significant power loss when handling high currents
Solution Approach 1:
The connector is divided into multiple contact points arranged in parallel, where each contact point contributes to the total current flow. This segmentation reduces the current density at each individual contact point, thereby reducing contact resistance and power loss according to the formula P=I²R
Solution Approach 2:
Multiple contact points are merged into a single connector assembly, creating a multi-contact connector that combines several parallel current paths. This merging of multiple contact interfaces reduces the overall contact resistance compared to a single contact point, minimizing power loss while maintaining a integrated connector structure
2Loss of energy
If conventional round or rectangular connectors are used, then the manufacturing process is simple, but the contact area is limited resulting in higher electrical resistivity
Solution Approach 1:
The contact surfaces of the connector are designed with curved or rounded features instead of sharp edges, increasing the effective contact area between mating connectors. This curvature principle ensures better surface contact and reduces electrical resistivity, thereby minimizing voltage loss while the curved geometry can be achieved through standard forming processes
3Reliability
If simple connector designs are used, then the device is easy to manufacture, but the connections are not secure and susceptible to vibration and loosening in vehicle environments
Solution Approach 1:
The connector incorporates a dynamic locking mechanism that can transition between locked and unlocked states, providing secure retention during vibration while allowing for controlled connection and disconnection. This dynamic feature enhances reliability without requiring overly complex assembly structures
Solution Approach 2:
A locking mechanism acts as an intermediary element between the connector components, providing additional retention force to secure the electrical connection against vibration and loosening forces in vehicle environments
Data Source
AI summary
An electrical connection box includes a housing and a connector assembly coupled to the housing. The connector assembly includes sockets for receiving plugs from a motor vehicle. The housing is formed to include a cavity that is designed to house electronic circuitry. The connector assembly includes at least one socket and at least one connector positioned within the socket. The connector is configured to create an electrical connection with an electrical plug that is received in the socket to electrically couple components of the vehicle with the electronic circuitry and minimize a voltage loss across the electrical connection.