Electric Junction Box Bus Bar Positioning Mechanism
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Solution Overview
Problem
The existing electric junction boxes face difficulties in proper positioning and assembly due to the terminal portion being arranged perpendicular to the direction of case overlap, leading to increased manufacturing costs and the need for additional components.
Innovation Solution
The electric junction box design includes a positioning plate and mount portion on the bus bar, along with a pushing piece and inclined face on one case member, allowing for easy alignment and attachment without increasing the number of components or costs, even when the terminal portion is perpendicular to the case overlap direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the terminal portion is arranged perpendicular to the case overlap direction, then the connector can be engaged with the connector engagement portion, but it becomes difficult to position the bus bar at a proper position on the lower case
Solution Approach 1:
The bus bar is pre-positioned on the lower case before the upper case is attached. The positioning structure on the lower case prepares the bus bar in advance at the correct location, so that when the upper case is attached, the bus bar is already in the proper position without requiring additional adjustment or complex fixation during assembly.
Solution Approach 2:
A positioning structure (such as positioning protrusions or positioning holes) is introduced as an intermediary element between the bus bar and the lower case. This positioning structure facilitates the alignment and positioning of the bus bar, making it easier to achieve proper positioning even when the terminal portion is arranged perpendicular to the case overlap direction.
2Ease of operation
If the bus bar is divided into separate pieces to make positioning easier, then positioning becomes simpler, but the number of components and manufacturing cost increase
Solution Approach 1:
The positioning function is segmented from the bus bar itself and transferred to a separate positioning structure on the lower case. This allows the bus bar to remain as a single piece while the positioning capability is provided by distinct positioning elements (protrusions or holes) on the lower case, thus avoiding the need to divide the bus bar into multiple pieces.
Solution Approach 2:
The positioning function is extracted from the bus bar and implemented through a separate positioning structure on the lower case. This separation allows the bus bar to maintain its integrity as a single component while the positioning capability is provided by dedicated positioning elements on the lower case, reducing overall system complexity.
3Manufacturing precision
If additional components or complex fixation methods are used to position the bus bar, then proper positioning can be achieved, but manufacturing cost increases
Solution Approach 1:
The positioning structure is merged with the lower case as an integrated feature rather than a separate component. The positioning protrusions or holes are formed directly on the lower case during its manufacturing process, combining the positioning function with the existing lower case structure and eliminating the need for additional separate positioning components or complex fixation methods.
Solution Approach 2:
The lower case is designed to serve multiple functions: it provides structural support, houses the bus bar, and incorporates positioning structures for alignment. By making the lower case multi-functional, the patent eliminates the need for separate dedicated positioning components, thereby reducing manufacturing cost while maintaining positioning precision.
Data Source
AI summary
An electric junction box, having a terminal portion positioned in the connector engagement portion and arranged perpendicular to a direction along which case members attach each other, which can be assembled easily without increasing the number of components and manufacturing cost is provided. Also, a power supply device having the above-described electric junction box is provided. The electric junction box includes: a box main body having a connector engagement portion and an upper case attached to a lower case in an overlapping relationship; and a bus bar received in the box main body. The lower case includes a bottom wall portion, a positioning wall and peripheral walls. The bus bar includes the terminal portion positioned in the connector engagement portion, a positioning plate portion and a mount portion. The peripheral wall includes a cutout portion allowing the positioning plate portion to move into and out from the lower case.