Electric Distribution Box Terminal Alignment and Insulation
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Solution Overview
Problem
In electric distribution boxes handling high voltages, misregistration of external connection terminals with female-female terminals leads to insertion issues and reduced insulating performance due to flat surfaces and insufficient creeping distance between terminals and bus bars.
Innovation Solution
The design includes first and second recess portions on the cases to securely hold female-female terminals, with convex portions and inserting direction-limiting features to prevent misalignment and ensure proper orientation, and projecting portions to maintain a sufficient distance between terminals and bus bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the upper case is fitted on the lower case with female-female terminals completely received in recess portions, then the structure is compact and space is saved, but the external connection terminal-inserting hole and the corresponding female-female terminal may be displaced out of registry
Solution Approach 1:
The patent applies preliminary action by providing guiding protrusions on the lower case that correspond to guiding recesses in the upper case. These guiding structures are pre-positioned to ensure that when the upper case is fitted onto the lower case, the external connection terminal-inserting holes and the female-female terminals are automatically aligned correctly, preventing displacement before the fitting operation is complete.
Solution Approach 2:
The patent uses guiding protrusions and guiding recesses as intermediary structures that mediate between the upper case and lower case. These intermediary elements facilitate proper alignment during the fitting operation, ensuring that the external connection terminal-inserting holes and female-female terminals register correctly without requiring high precision in the main fitting surfaces.
2Device complexity
If the upper case strikes against a working table, then the external connection terminal-inserting hole and the corresponding female-female terminal are displaced out of registry, but the case structure remains simple
Solution Approach 1:
The guiding protrusions and recesses are pre-positioned on the cases to create a self-aligning mechanism. If displacement occurs due to impact, the guiding structures enable the operator to realign the cases by inserting the external connection terminals into the female-female terminals, which will guide the cases back into correct registry without requiring complex adjustment mechanisms.
Solution Approach 2:
The patent applies self-service by designing the guiding protrusions and recesses such that the external connection terminals themselves serve as alignment tools. When displacement occurs, the operator simply inserts the external connection terminals into the female-female terminals, and the guiding structures automatically realign the cases, making the connection process self-correcting without requiring additional alignment tools or complex procedures.
3Device complexity
If the female-female terminal has flat side surfaces, then the terminal structure is simple, but the terminal may be inserted in a wrongly-oriented manner
Solution Approach 1:
The patent applies asymmetry by providing guiding protrusions on the lower case and corresponding guiding recesses in the upper case. These asymmetric guiding structures ensure that the female-female terminals can only be inserted in the correct orientation, as the protrusions and recesses are shaped to prevent insertion in wrong orientations. This maintains simple terminal structures while ensuring precise orientation through the asymmetric guiding mechanism.
4Ease of manufacture
If the upper surface of the lower case is flat to install multiple bus bars, then the installation is simple, but the creeping distance between female-to-female terminals and bus bars becomes insufficient
Solution Approach 1:
The patent applies segmentation by dividing the lower case surface into distinct functional zones: a flat bus bar installation surface for easy mounting, and elevated terminal mounting portions where the female-female terminals are positioned. This segmentation allows the bus bars to be installed on the flat surface while the terminals are elevated above it, maintaining sufficient creeping distance for insulating performance while preserving ease of bus bar installation.
Solution Approach 2:
The patent applies dimensionality change by transitioning from a two-dimensional flat surface to a three-dimensional structure with elevated terminal mounting portions. The terminals are positioned at a higher elevation than the bus bar installation surface, creating vertical separation that ensures sufficient creeping distance while maintaining the flat surface for easy bus bar installation. This vertical dimensionality resolves the contradiction between ease of installation and insulating performance.
Data Source
AI summary
An electric distribution box for containing a distribution parts includes a first case, a second case that is attached to the first case, and a female-female terminal that has holding portions for holding and electrically connecting mating terminals. A first recess portion is provided on one of the first and second cases, and receives a part of the female-female terminal. A second recess portion is provided on the other of the first and second cases, and receives a remaining part of the female-female terminal. An inserting hole for inserting one of the mating terminal to contact with the female-female terminal is formed in at least one of the first and second recess portions.