Bus Bar Mounting Assembly with Projection
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Solution Overview
Problem
Conventional bus bar mounting assemblies for electric junction boxes often damage electrical conduit wires due to burrs created during hole formation and can experience displacement issues with longer bus bars, leading to unreliable connections.
Innovation Solution
A bus bar assembly featuring a hole with a burr and a projection that extends beyond the burr for press-fitting, along with triangular ribs for reduced friction and precise alignment, ensuring accurate positioning and secure mounting without damaging electrical conduits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a hole is punched in the bus bar for mounting, then the bus bar can be positioned and mounted to the body, but a burr is created during the punching process that damages electrical conduit wires
Solution Approach 1:
The patent introduces a projection as an intermediary element between the hole in the bus bar and the mounting hole in the body. The projection fits into the hole and extends beyond the burr, allowing the mounting screw to engage with the projection rather than directly with the burr-containing hole, thus preventing damage to electrical conduits while maintaining positioning accuracy
Solution Approach 2:
The mounting function is segmented into two parts: the hole in the bus bar for positioning, and the separate projection that extends beyond the burr for secure engagement. This segmentation allows the positioning function to be maintained while the harmful burr is isolated from the engagement interface
2Adaptability or versatility
If a relatively long bus bar is employed, then the bus bar can accommodate more terminals, but displacement occurs between each terminal of the bus bar and each terminal-accommodating portion of the body
Solution Approach 1:
The projection is pre-formed on the bus bar at the correct position and orientation before assembly. This preliminary positioning feature ensures that when the bus bar is installed, the terminals are automatically aligned with the terminal-accommodating portions of the body, preventing displacement issues even with longer bus bars that have more terminals
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
The solution prevents damage to electrical conduits from burrs and ensures accurate alignment and secure connections, enhancing the reliability of electric connections within the junction box.
Implementation Method 1
a pair of the holes may be spaced apart from each other in a longitudinal direction of the bus bar, and a pair of the projections may be correspondingly formed in the body so as to be press-fit into the holes
Implementation Method 2
the projection may have a plurality of press-fit ribs extending outwardly from a peripheral surface thereof and being approximately triangular in traverse cross-section. In this configuration, the rib formed on the peripheral surface of the projection can be smoothly press-fit into the inner space of the hole with ease. In this case, friction resistance is greatly decreased
Data Source
AI summary
The present invention is intended to provide a novel assembly for properly or accurately mounting the terminal portion of the bus bar on the terminal-accommodating portion of a body for an electric junction box without doing any harm to an electrical conduit(s) which is disposed within the electric junction box. An assembly for mounting a bus bar (1) to a body (12) for an electric junction box, comprises a hole (9) disposed in the bus bar (1), and having a burr (31) created during the hole punching process; and a projection (21) formed in the body (12), and suited for being press-fit into the hole (9), wherein the projection (21) extends beyond the burr after being press-fit into the hole (9). In this configuration, the hole (9) may serve as a basis for position determination of each terminal portion (3, 4) of the bus bar (1), and the projection (21) may serve as a basis for position determination of each terminal-accommodating portion (25) of the body (12). A pair of the holes (9) may be spaced apart from each other in a longitudinal direction of the bus bar (1), and a pair of the projections (21) may be correspondingly formed in the body (12) so as to be press-fit into the holes (9). The projection (21) may have a plurality of press-fit ribs (29) extending outwardly from a peripheral surface thereof, and being approximately triangular in traverse cross-section.