Busbar Connection Layout for Compact Electrical Connection Boxes
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Solution Overview
Problem
In vehicles with limited space, conventional electrical connection boxes that integrate a terminal block increase in size, making it difficult to accommodate them without compromising the available space for other components.
Innovation Solution
An electrical connection box design featuring a housing, holder, and a terminal block with a busbar that includes perpendicular connection surfaces for wires, allowing for compact sizing by minimizing the area occupied by the busbar and terminal block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a terminal block is integrated with an electrical connection box, then the electrical connection function is improved, but the size of the electrical connection box increases
Solution Approach 1:
The busbar is configured with connection surfaces in different spatial directions (first connection surface in first direction, second connection surface in second direction perpendicular to first direction). This three-dimensional arrangement allows multiple wires to be connected in different directions, providing versatile electrical connection functionality while maintaining a compact overall structure that does not significantly increase the size of the electrical connection box.
2Adaptability or versatility
If the busbar has multiple connection surfaces for different wires, then the electrical connection capability is improved, but the area occupied by the busbar increases
Solution Approach 1:
Instead of arranging multiple connection surfaces in the same plane which would increase the area, the invention uses connection surfaces oriented in different directions (first direction and second direction perpendicular to first direction). This vertical/three-dimensional arrangement of connection surfaces allows multiple wires to be connected without significantly increasing the planar area occupied by the busbar.
Solution Approach 2:
The terminal block is attached to the holder inside the electrical connection box, and the busbar is supported on the terminal support base. This nested arrangement where the terminal block is integrated within the existing electrical connection box structure allows the busbar to provide multiple connection surfaces without requiring additional external space.
Data Source
AI summary
A first electrical connection box includes a housing, a holder (50) that is provided inside the housing and holds an electrical component, and a terminal block (60) attached to the holder (50). The terminal block (60) includes a terminal support base (61) attached to the holder (50), and a busbar (62) supported on the terminal support base (61). The busbar (62) includes a planar first connection surface (84) to which a first wire (21) is to be electrically connected, and a planar second connection surface (86) to which a second wire (22) is to be electrically connected, the second wire (22) being different from the first wire (21). When a direction perpendicular to the first connection surface (84) is defined as a first direction (X11), the second connection surface (86) is perpendicular to a second direction (X12) that intersects with the first direction (X11).