# US 11,909,192 B2 · High-voltage junction box wire tray

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- Number: US 11,909,192 B2
- Document ID: US11909192B2
- Status: Granted
- Kind: B2
- Application number: 17/342,021
- Filed: 2021-06-08
- Published: 2021-12-30
- Granted: 2024-02-20
- Earliest claimed: 2020-06-26
- Assignees: Lear Corporation
- Applicants: Lear Corporation
- Inventors: Parminder Brar; Michael Scott Duco; Rutunj Rai; Jared Pieknik
- Web page: https://patentgrep.com/patent/US11909192B2

## CPC

- H02G 3/086: {Assembled boxes}
- B60L 53/30: Constructional details of charging stations
- H02B 1/20: Bus-bar or other wiring layouts, e.g. in cubicles, in switchyards (installations of bus-bars H02G5/00)
- H02G 3/081: {Bases, casings or covers}
- H02J 7/70: characterised by the mechanical construction
- H05K 7/1427: {Housings}
- H05K 7/14329: {specially adapted for the configuration of power bus bars}
- H02G 3/0437: {Channels}
- H02G 3/0493: {Service poles}
- H02G 3/083: {Inlets}
- Y02T 10/70: Energy storage systems for electromobility, e.g. batteries
- Y02T 10/7072: Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
- Y02T 90/12: Electric charging stations
- Y02T 90/14: Plug-in electric vehicles
- H02G: INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- B60L: PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES (arrangements or mounting of electrical propulsion units or of plural diverse prime-movers for mutual or common propulsion in vehicles B60K1/00, B60K6/20; arrangements or mounting of electrical gearing in vehicles B60K17/12, B60K17/14; preventing wheel slip by reducing power in rail vehicles B61C15/08; dynamo-electric machines H02K; control or regulation of electric motors H02P); SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES (electric coupling devices combined with mechanical couplings of vehicles B60D1/64; electric heating for vehicles B60H1/00); ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL (control or regulation of electric motors H02P); MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- H02B: BOARDS, SUBSTATIONS OR SWITCHING ARRANGEMENTS FOR THE SUPPLY OR DISTRIBUTION OF ELECTRIC POWER
- H02J: ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

An electronic module is provided with a housing with an inlet to conduct alternating current (AC) power and an outlet to conduct direct current (DC) power to charge a vehicle battery, the housing defining a cavity. A circuit board assembly is supported within the cavity to convert the AC power to DC power. At least two power distribution wires are connected between the circuit board assembly and the outlet. A base is supported by the housing and extends between the at least two power distribution wires and the circuit board assembly to shield the DC power from electromagnetic interference generated by the circuit board assembly. A plurality of walls extend transversely from the base and are spaced apart from each other to define at least two channels, each channel is sized to receive one of the at least two power distribution wires.

## Claims

### Claim 1

An electronic module comprising:
a housing with an inlet to conduct alternating current (AC) power and an outlet to conduct direct current (DC) power to charge a vehicle battery, the housing defining a cavity;
a circuit board assembly supported within the cavity to convert the AC power to DC power;
at least two power distribution wires connected between the circuit board assembly and the outlet;
a base supported by the housing and extending between the at least two power distribution wires and the circuit board assembly to shield the DC power from electromagnetic interference generated by the circuit board assembly; and
a plurality of walls extending transversely from the base and spaced apart from each other to define at least two channels, each channel sized to receive one of the at least two power distribution wires.

### Claim 2 (depends on 1)

The electronic module of claim 1, further comprising a conductor disposed in the base and adapted to connect to a vehicle chassis to provide a ground path for the electromagnetic interference generated by the circuit board assembly.

### Claim 3 (depends on 2)

The electronic module of claim 2, wherein the base further comprises electrically insulative material disposed over the conductor.

### Claim 4 (depends on 1)

The electronic module of claim 1, wherein the at least two channels further define a first channel and a second channel, and wherein the plurality of walls further define:
a first receptacle coupled to the first channel to receive a first connector, and
a second receptacle coupled to the second channel to receive a second connector, and not receive the first connector, to limit incorrect assembly.

### Claim 5 (depends on 1)

The electronic module of claim 1, wherein the plurality of walls further define a terminal cavity, and wherein an opening is formed through the base and aligned with the terminal cavity, the electronic module further comprising a terminal mounted to the base and extending into the terminal cavity.

### Claim 6 (depends on 5)

The electronic module of claim 5, further comprising an electrical component with a body and a lead extending from the body and through the opening of the base to engage the terminal.

### Claim 7 (depends on 6)

The electronic module of claim 6, further comprising:
a pair of posts extending from the base and spaced apart from each other to define a pocket sized to receive the body of the electrical component; and
a retention tab extending transversely from a distal end of each of the pair of posts to engage the body of the electrical component during insertion and pivot each post outward to receive the body of the electrical component within the pocket.

### Claim 8 (depends on 7)

The electronic module of claim 7, wherein the electrical component comprises a fuse.

### Claim 9 (depends on 1)

The electronic module of claim 1, further comprising:
a first cover to connect to the housing and enclose the cavity, the first cover having an access opening formed through; and
a second cover to removably mount to the first cover over the access opening to provide external access to a portion of the cavity without disconnecting the first cover from the housing.

### Claim 10 (depends on 9)

The electronic module of claim 9, further comprising:
a first connector mounted to an underside of the base about an opening formed through; and
a second connector mounted to an inside surface of the second cover to mate with the first connector, wherein removal of the second cover from the first cover disconnects the second connector from the first connector to disconnect the power distribution wires from the circuit board assembly.

### Claim 11 (depends on 1)

The electronic module of claim 1, wherein
the base is supported by the housing within a cavity and extends between an inverter, and the at least two power distribution wires, wherein the inverter comprises the circuit board assembly and the at least two power distribution wires comprise first and second power distribution wires;
wherein the at least two channels comprise a first channel and a second channel, wherein the first channel is sized to receive the first power distribution wire and the second channel is sized to receive the second power distribution wire; and
a conductor disposed within the base and adapted to connect to a vehicle chassis to provide a ground path for electromagnetic interference generated by the inverter and shield the first and second power distribution wires.

### Claim 12 (depends on 11)

The electronic module of claim 11, wherein the conductor is formed as a sheet that extends between the first and second power distribution wires and the inverter, and wherein the electronic module further comprises electrically insulative material disposed over the conductor.

### Claim 13 (depends on 11)

The electronic module of claim 11, wherein the plurality of walls further define:
a first receptacle coupled to the first channel to receive a first connector, and
a second receptacle coupled to the second channel to receive a second connector, and not receive the first connector, to limit incorrect assembly.

### Claim 14 (depends on 11)

The electronic module of claim 11, wherein the plurality of walls further define a terminal cavity, and wherein an opening is formed through the base and aligned with the terminal cavity to receive a lead of an electrical component, the electronic module further comprising a terminal mounted to an underside of the base and extending into the terminal cavity to engage the lead.

### Claim 15 (depends on 14)

The electronic module of claim 14, further comprising:
a pair of posts extending from the base and spaced apart from each other to define a pocket sized to receive a body of the electrical component; and
a retention tab extending transversely from a distal end of each of the pair of posts to engage the body of the electrical component during insertion and pivot each post outward to receive the body of the electrical component within the pocket.

### Claim 16 (depends on 11)

The electronic of claim 11,
wherein the housing defines the cavity and is adapted to mount to the vehicle chassis,
the electronic module further comprising:
the inverter, wherein the inverter converts AC power to DC power; and
the first and second power distribution wires, wherein the first and second power distribution wires connect the inverter to the outlet.

### Claim 17 (depends on 16)

The electronic module of claim 16, further comprising:
a first cover to connect to the housing and enclose the base within the cavity, the first cover having an access opening formed through;
a second cover to removably mount to the first cover over the access opening to provide external access to a portion of the cavity without disconnecting the first cover from the housing;
a first connector mounted to the base and connected to the inverter; and
a second connector mounted to an inside surface of the second cover to mate with the first connector to electrically connect the inverter to the first and second power distribution wires.

### Claim 18 (depends on 1)

A method for manufacturing the electronic module of claim 1 comprising:
molding an electrically insulative material over a conductor to form a wire tray;
disposing the wire tray within the housing and between an inverter and the at least two power distribution wires that are connected between the inverter and the outlet of the housing, the inverter comprising the circuit board assembly; and
connecting the conductor to a vehicle chassis to provide a ground path for electromagnetic interference generated by the inverter.

### Claim 19 (depends on 18)

The method of claim 18, further comprising individually routing each of the at least two power distribution wires within a channel of the at least two channels formed in the wire tray.

### Claim 20 (depends on 18)

The method of claim 18, further comprising disconnecting the at least two power distribution wires from the inverter by removing a cover from the housing.