Electric Junction Box Busbar Connector Design
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Solution Overview
Problem
The assembly of electric junction boxes on motor vehicles is challenging due to the need to connect thick electric wires within a narrow space, which complicates the integration of electric power distributing units.
Innovation Solution
The electric junction box design includes a connector section that directly connects the busbar to the electric power inputting section of the power distributing unit, eliminating the need for an electric wire connection and allowing for secure, wire-free assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thick electric wires are used to connect the busbar to the power distributing unit, then reliable electrical connection is achieved, but assembly difficulty increases due to narrow space constraints
Solution Approach 1:
The patent extracts the electric wire from the connection system and replaces it with a direct mechanical and electrical connection structure. The busbar is designed with connection portions that directly engage with the power distributing unit, eliminating the intermediate wire component and its associated bending and routing complexity in narrow spaces.
Solution Approach 2:
The patent merges the electrical connection function and mechanical support function into a single integrated structure. The busbar's connection portions serve both as electrical conductors and as mechanical coupling elements, combining what were previously separate functions (wire for electricity, fasteners for mechanical support) into a unified direct connection system.
2Volume of moving object
If electric wires are bent to fit within the narrow space of the box body, then space utilization is improved, but assembly complexity and time increase
Solution Approach 1:
The busbar is pre-formed with connection portions that are shaped and positioned in advance during manufacturing. These pre-configured connection portions are designed to directly engage with the power distributing unit without requiring any bending or shaping operations during assembly, thus eliminating time-consuming wire routing operations.
Solution Approach 2:
The patent removes the wire bending and routing operation entirely from the assembly process by replacing wires with rigid connection portions that are directly attached to the busbar. This extraction of the intermediate wire component eliminates the need for space-consuming wire bending operations.
3Productivity
If a direct connection structure is used between busbar and power distributing unit, then assembly efficiency is improved, but design complexity of the busbar increases
Solution Approach 1:
The busbar is segmented into distinct functional portions: main body sections for electrical conduction and connection portions for mechanical and electrical coupling. This segmentation allows the connection portions to be designed with specific geometries optimized for direct engagement, while the main body maintains simple electrical conductor characteristics.
Solution Approach 2:
The connection portions of the busbar are designed to perform multiple functions simultaneously: providing electrical connection, mechanical support, and positional alignment. This multi-functionality reduces the need for separate components and simplifies the overall assembly process despite the specialized geometry of the connection portions.
Data Source
AI summary
An electric junction box, which can be easily assembled even if the electric junction box includes an electric power distributing unit, is provided. The electric junction box includes: a box body; a busbar attached to the box body, electric power from a power supply being supplied to the busbar; an electric power distributing unit attached to the box body, the electric power being supplied to the electric power distributing unit through the busbar; and a connector section connecting the busbar to an electric power inputting section of the electric power distributing unit, the box body being provided with the connector section.