Electrical Connection Box Terminal Fastening

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Solution Overview

Problem

Existing electrical connection boxes face challenges in efficiently utilizing limited space to fasten multiple terminals to conductive members, leading to increased size requirements for busbars and blocks due to the need for separate nuts and screw members at both ends of the busbar.

Innovation Solution

The design incorporates a holding portion within the block that accommodates first and second flange portions of nuts, where the second flange portion is thicker or wider, allowing the first flange portion to enter and the second to be restricted, enabling multiple terminals to be fastened using a limited space between terminal portions, reducing the size of the busbar and block.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate nuts and screw members are used at both ends of the busbar, then secure terminal connections are achieved, but the size of the busbar and block must increase

Engineering Contradiction:
Improveterminal connection securityVSAvoidbusbar and block size
Core Design Contradiction:
ReliabilityVSVolume of moving object

Solution Approach 1:

The patent combines multiple nuts and screw members into a single integrated block structure. The block contains multiple through-holes that accommodate screw members, and the nuts are positioned within the block rather than being separate components. This merging reduces the overall number of parts and compactsthe connection assembly, eliminating the need for increased busbar and block dimensions while maintaining secure terminal connections.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent implements nesting by placing nuts inside the block structure. The block serves as a container that houses the nuts and screw members, creating a nested arrangement where smaller components (nuts, screw members) are positioned within the larger block. This nesting approach optimizes space utilization and reduces the external dimensions required for the connection assembly.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Quantity of substance

If multiple terminals are fastened in limited space, then terminal density is improved, but space management becomes more complex

Engineering Contradiction:
Improvenumber of terminals per spaceVSAvoidspace management complexity
Core Design Contradiction:
Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent segments the block into multiple distinct through-holes, each dedicated to a specific terminal connection. This segmentation organizes the limited space into discrete, manageable zones, allowing multiple terminals to be fastened simultaneously without creating complex spatial management issues. Each through-hole provides a defined path for screw members, simplifying the arrangement of multiple terminals within constrained dimensions.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent utilizes the vertical dimension by positioning nuts at different heights within the block and allowing screw members to extend in the vertical direction. This dimensional approach allows multiple terminals to be arranged along the vertical axis, effectively increasing terminal density without requiring increased horizontal space, thereby simplifying space management through three-dimensional utilization.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS10325748B2Electrical connection box
Publication Date: 2019.06.18 YAZAKI CORP
  • US10325748B2 patent drawing
  • US10325748B2 patent drawing
  • US10325748B2 patent drawing

AI summary

An electrical connection box includes a fusible link including a pair of terminal portions, a plate-shaped conductive member, a first nut including a first flange portion and fastened to the conductive member by being screwed with a first screw member, a second nut including a second flange portion and fastened to the conductive member by being screwed with a second screw member, and a block that includes a holding portion holding the first flange portion and the second flange portion and holds the fusible link. The holding portion extends between the pair of terminal portions in a projecting direction of the terminal portions, and includes a first holding portion located on a back side in an insertion direction, a second holding portion located on an entrance side in the insertion direction, and a projecting portion allowing entry of the first flange portion and restricting entry of the second flange portion.