Integrated Electrical Connection Box Layout for Compact Terminal Blocks
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Solution Overview
Problem
In vehicles, the increasing number of components requires a reduction in space allocated for electrical connection boxes and terminal blocks to accommodate more components, as conventional setups are cumbersome and inefficient in terms of space utilization.
Innovation Solution
An electrical connection box design that integrates a housing, a holder for electrical components, a terminal block with a busbar, and a relay busbar, allowing for compact configuration by eliminating the need for separate boxes and blocks, with perpendicular connections reducing the size and area of the busbar and terminal block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate electrical connection boxes and terminal blocks are used, then electrical connections can be established, but the arrangement space for other components is reduced
Solution Approach 1:
The patent combines the electrical connection box and terminal block into a single integrated unit. The housing contains both the connection box structure and the terminal block with busbar, eliminating the need for separate components. This merging reduces the total space occupied while maintaining all necessary electrical connection functions.
Solution Approach 2:
The integrated structure serves multiple functions simultaneously: it provides electrical connections through the connection box, houses the terminal block with busbar for wire connections, and contains the relay busbar for additional connectivity. This multi-functionality allows a single component to replace what would traditionally require multiple separate parts.
2Adaptability or versatility
If a terminal block with busbar is added, then electrical connection functionality is improved, but the device size increases
Solution Approach 1:
The terminal block with busbar is nested inside the housing of the electrical connection box. The busbar is positioned within the housing space, and the terminal block structure is integrated into the existing housing volume. This nesting arrangement allows the terminal block functionality to be added without significantly increasing the overall external dimensions of the device.
3Device complexity
If relay busbar is integrated inside housing, then wiring complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The relay busbar is pre-positioned and fixed inside the housing during the assembly process, with its connection surfaces predetermined and aligned before final assembly. The housing structure includes predetermined mounting positions and alignment features that guide the relay busbar into the correct position, reducing the need for high-precision adjustments during final assembly.
Data Source
AI summary
A first electrical connection box includes a housing, a holder (40) that is provided inside the housing, and holds an electrical component (51) to which a first wire (21) is to be electrically connected; and a terminal block (60) attached to the holder (40). The terminal block (60) includes a terminal support base (61) attached to the holder (40), and a busbar (62) supported on the terminal support base (61). The busbar (62) includes a planar first connection surface (84), and a planar second connection surface (86) to which a second wire (22) is to be electrically connected. Also, the first electrical connection box further includes a relay busbar (90) that is provided inside the housing, and includes a third connection surface (97) that is electrically connected to the first connection surface (84), and a fourth connection surface (99) that is electrically connected to the electrical component (51).