Junction Box Busbar Fastener Assembly for Automotive Power Distribution
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Solution Overview
Problem
Existing electrical junction boxes in automotive electronics require multiple power feed wire assemblies and fastener assemblies, leading to increased weight, size, and manufacturing complexity, which hinders fuel efficiency and cost-effectiveness.
Innovation Solution
A power interface is designed with a conductive busbar assembly that uses a single fastener assembly to connect two junction boxes, sharing a power feed wire assembly, thereby eliminating redundant connections and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple power feed wire assemblies and fastener assemblies are used to connect junction boxes, then reliable electrical connections are achieved, but weight and size of the electrical system increase
Solution Approach 1:
The patent combines multiple separate power feed wire assemblies and fastener assemblies into a single integrated fastener assembly that simultaneously connects multiple junction boxes. This merging eliminates redundant components while maintaining reliable electrical connections between all junction boxes through a shared power feed arrangement.
Solution Approach 2:
The single fastener assembly is designed to perform multiple functions: it mechanically connects multiple junction boxes while also serving as a common power feed connection point. The assembly universally interfaces with multiple junction boxes, eliminating the need for separate dedicated connections for each box.
2Reliability
If multiple power feed wire assemblies and fastener assemblies are used to connect junction boxes, then reliable electrical connections are achieved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent merges multiple separate assemblies into one integrated fastener assembly that handles multiple connections simultaneously. This reduces the total number of components that need to be manufactured, inventoried, and assembled, thereby reducing device complexity and manufacturing complexity while maintaining connection reliability.
Solution Approach 2:
The universal fastener assembly design allows a single component type to serve multiple junction boxes, simplifying manufacturing processes by reducing the variety of unique parts that must be produced and assembled. This multi-functional approach maintains reliable connections while lowering complexity.
3Power
If multiple power feed wire assemblies are used to connect junction boxes, then adequate power distribution is achieved, but cost of components increases
Solution Approach 1:
The patent merges multiple power feed wire assemblies into a single shared power feed arrangement where one power feed wire assembly serves multiple junction boxes simultaneously. This eliminates redundant wire assemblies and fasteners, reducing component quantity and cost while maintaining adequate power distribution to all connected junction boxes.
Solution Approach 2:
The single power feed wire assembly is designed with universal connectivity to distribute power to multiple junction boxes through the shared fastener assembly. This multi-functional power distribution approach reduces the total number of power feed components needed while ensuring adequate power delivery to all connected devices.
Data Source
AI summary
A junction box assembly is provided with a conductive boss having a first contact surface and a second contact surface spaced apart from the first contact surface. A pair of threaded conductive studs each extends from one of the contact surfaces. A housing is overmolded onto the boss so that the first contact surface, the second contact surface, and the pair of studs are exposed. A printed circuit board (PCB) is oriented in the housing. A busbar is oriented in the housing in electrical communication with the PCB. The busbar has a conductive tab with an aperture formed therethrough. One of the pair of studs is received within the aperture and the contact tab is in electrical communication with one of the first contact surface and the second contact surface.