Junction Box Conductive Bar Locking Through Lead Insertion Passages
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Solution Overview
Problem
Conventional junction boxes face issues with the guide plate extending from the lead insertion opening, making it prone to excessive pressure and potential rupture, which can cause the conductive bar to fall off, compromising the structural integrity and electrical connection.
Innovation Solution
The junction box design features a conductive bar with arms that enter a lead insertion space through passage spaces formed by guide plates and positioning plates, providing a stable and secure electrical connection with spring clamps, and allowing the conductive arms to move from a plane into the lead insertion space, enhancing structural support and preventing the conductive bar from dislodging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the guide plate extends from the lead insertion opening to provide fixation for the conductive bar, then the guide plate can be integrally formed with the junction box body and provide guiding, insulating and fixation functions, but the free end portion is easy to withstand excessive pressure and rupture, causing the conductive bar to fall off
Solution Approach 1:
The guide plate is divided into two separate components: a fixed guide plate integrally formed with the box body, and a detachable conductive bar. This segmentation allows the guide plate to provide guiding and insulating functions while the conductive bar can be securely fixed through the passage space without requiring the guide plate's free end to bear excessive pressure.
Solution Approach 2:
A passage space is introduced as an intermediary structure formed by the guide plate and the box body. This passage space serves as a mediator that receives and secures the conductive bar, distributing the pressure and mechanical stress away from the guide plate's free end, thereby preventing rupture while maintaining fixation.
2Ease of operation
If the conductive bar is embedded in a gap formed by the lead guide plate and the box wall for fixation, then the guide plate can provide guiding and insulating functions, but the free end portion is prone to excessive pressure and rupture under load
Solution Approach 1:
The fixation mechanism transitions from a two-dimensional gap embedding to a three-dimensional passage space structure. The passage space, formed by the guide plate and box body, provides a volumetric enclosure that secures the conductive bar more effectively, distributing mechanical stress in multiple directions and preventing the guide plate's free end from bearing excessive concentrated pressure.
3Device complexity
If the guide plate extends from the lead insertion opening with a free end for conductive bar engagement, then the structure can be simplified, but the free end is susceptible to rupture causing the conductive bar to dislodge
Solution Approach 1:
The passage space is designed in advance as a pre-formed structural feature that cushions and absorbs mechanical stress before it can reach the guide plate's free end. This beforehand cushioning prevents excessive pressure from concentrating on the free end, thereby preventing rupture and maintaining stable conductive bar positioning throughout operation.
Data Source
AI summary
A junction box includes a box body and a conductive bar. A guide plate extends from a lead insertion opening, with a laterally extended connection portion at its extended end to connect the box body. First and second support plates and edges of the guiding plate form passages accessible to a lead insert space defined by the guiding plate, the connecting portion, the second support plate and the box body. The conductive bar has a bent conductive arm that moves into the inside of the lead insert space by an elastic force, therefore locked in said space, after it passes the passages.