Bus Bar Edge Projection for Wire Routing in Junction Boxes
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Solution Overview
Problem
Conventional bus bar attaching structures in electric junction boxes often result in contact between the bus bar edge and electric wires, leading to damage and poor assembly work due to wide spaces between the bus bar and wall portions, and require significant force to insert the bus bar.
Innovation Solution
A bus bar edge structure featuring a projection piece at the opening side of the bus bar-receiving gap that guides the electric wire away from the bus bar edge, functioning as a press-operating portion to facilitate easier assembly and prevent wire contact, with optional features like longitudinal grooves, partition ribs, and U-shaped folded connections for secure insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the bus bar is positioned with a wide space between it and the wall portion to facilitate assembly and connection operations, then the ease of operation is improved, but the risk of contact between the bus bar edge and electric wires increases, worsening the reliability
Solution Approach 1:
A wire guide member is introduced as an intermediary component between the bus bar and the electric wires. This guide member actively directs the electric wires away from the bus bar edge, preventing contact while preserving the wide spacing needed for assembly operations. The wire guide member serves as a mediator that resolves the conflict between operational ease and safety reliability.
2Volume of stationary object
If the bus bar is positioned close to the wall portion to reduce space, then the compactness is improved, but the difficulty of inserting the bus bar increases due to sliding friction resistance, worsening the ease of manufacture
Solution Approach 1:
The wire guide member acts as a mediator that allows the bus bar to be positioned closer to the wall portion while still facilitating easy insertion. By providing a structured path for electric wires, the guide member reduces the sliding friction resistance between the bus bar edge and loose wires, enabling smoother insertion while maintaining compact spacing.
3Ease of operation
If a wide space is provided between the bus bar and the wall portion to accommodate nuts and bolts, then the ease of operation is improved, but the space occupied increases, worsening the volume efficiency
Solution Approach 1:
The wire guide member serves as a space-efficient intermediary that organizes electric wires in a compact manner. This allows connection operations to be performed easily while minimizing the overall space required, as the guide member consolidates wire routing into a structured, space-saving configuration rather than requiring large open spaces.
Data Source
AI summary
A bus bar edge structure of an electric junction box having a junction block main body, a bus bar-receiving gap arranged on the junction block main body, and a space communicating with the bus bar-receiving gap and arranged in a thickness direction of the bus bar includes a projection piece projecting from an edge of the bus bar at an opening side of the space in the thickness direction of the bus bar. An electric wire led from the junction block main body is guided to the projection piece so as to prevent interference with the edge of the bus bar. The projection piece functions as a press-operating portion configured to insert the bus bar into the bus bar-receiving gap. The projection piece is positioned in an opening of a longitudinal groove arranged in the space so as to prevent the electric wire from entering into the opening.