Electrical Connection Box Bus Bar Positioning Without Screws

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Solution Overview

Problem

Existing electrical connection boxes require screws for fixing the bus bar-embedded substrate to the heat sink member, increasing component count and necessitating screw hole processing.

Innovation Solution

The bus bar is positioned relative to the case using protrusions and recesses or holes, eliminating the need for screws and allowing heat dissipation through metal members connected to ground potential.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If screws are used to fix the bus bar-embedded substrate to the heat sink member, then the connection strength is improved, but the number of components and processing complexity increases

Engineering Contradiction:

Improveconnection strengthVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The fixing function and positioning function are merged into a single integrated structure. The case includes positioning protrusions that simultaneously serve as fixing elements and positioning elements, eliminating the need for separate screws and reducing component count while maintaining connection strength

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The screw fixing mechanism is extracted and replaced with an integrated positioning protrusion structure built into the case. This extraction removes the need for separate fastening components while maintaining the necessary mechanical connection and positioning functionality

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If screws are used to fix the bus bar-embedded substrate to the heat sink member, then the connection strength is improved, but the manufacturing complexity increases due to screw hole processing

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mechanical screw fixing system is replaced with an integrated positioning protrusion structure. This substitution eliminates the need for screw hole processing and assembly operations, simplifying manufacturing while maintaining secure mechanical connection

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If the bus bar is positioned using protrusions inserted into holes or recesses, then the device complexity is reduced, but the positioning precision may be affected

Engineering Contradiction:

Improvedevice complexityVSAvoidpositioning precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The positioning protrusions are designed with specific local geometric features that ensure precise positioning. The protrusions have predetermined shapes and dimensions that mate with corresponding features in the case, providing accurate positioning without requiring high-precision machining of multiple components

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Inventive Principle:

Principle #5Merging (Combining)

4Temperature

If the distal end of the bus bar is exposed outside the case, then heat dissipation is improved, but the risk of external contact and potential short circuits increases

Engineering Contradiction:

Improveheat dissipationVSAvoidrisk of short circuits

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The bus bar is segmented into different functional zones: the distal end is exposed for heat dissipation, while the connection portion is protected within the case. This segmentation allows simultaneous achievement of heat dissipation and electrical protection by separating the thermal management function from the electrical connection function

Inventive Principle:

Principle #1Segmentation

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

Screwless positioning and enhanced heat dissipation are achieved, stabilizing the bus bar potential and preventing excessive heating at critical points.

Implementation Method 1

The bus bar may comprise a first protrusion that protrudes toward the case at a position where the bus bar is accommodated in the case. The case may comprise a first member constituted of resin facing the bus bar and a first hole or a first recess defined in the first member and into which the first protrusion is inserted. The bus bar may be positioned relative to the case by the first protrusion being inserted into the first hole or the first recess.

Methodology Applied

Scientific EffectMechanical insertion and positioning: Mechanical Fastener

Implementation Method 2

The case may comprise a second member constituted of metal located on an opposite side from the bus bar via the first member. The first protrusion may be inserted into the first hole defined in the first member, and a distal end of the first protrusion may come into contact with the second member. According to this configuration, heat of the bus bar can be transferred to the second member constituted of metal. Due to this, the heat of the bus bar can be dissipated via the second member.

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

the second member may be electrically connected to a ground potential. According to this configuration, the potential at the bus bar can be stabilized.

Methodology Applied

Scientific EffectElectrical grounding: Earthing

Implementation Method 4

the first protrusion may be inserted into the first hole defined in the first member, and a distal end of the first protrusion may be exposed outside the case. According to this configuration, the heat of the bus bar can be dissipated outside the case via the first protrusion of the bus bar.

Methodology Applied

Scientific EffectThermal radiation and convection: Thermal Radiation

Data Source

PatentUS12620792B2Electrical connection box

Publication Date: 2026.05.05 AISAN IND CO LTD

AI summary

An electrical connection box may include: a bus bar constituted of metal; and a case accommodating at least a part of the bus bar. The bus bar may include a first protrusion that protrudes toward the case at a position where the bus bar is accommodated in the case. The case may include a first member constituted of resin facing the bus bar and a first hole or a first recess defined in the first member and into which the first protrusion is inserted. The bus bar may be positioned relative to the case by the first protrusion being inserted into the first hole or the first recess.