Electrical Junction Box Busbar Overlap Assembly
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Solution Overview
Problem
Existing electrical junction boxes require increased space and additional connectors as the number of FL holders to be connected increases, leading to inefficiencies in power supply and component arrangement.
Innovation Solution
The electrical junction box design incorporates a bolt holding portion with a stud bolt and busbars, allowing the first and second busbars to be overlapped and connected through a nut, eliminating the need for additional electric wires between FL holders and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple FL holders are connected using separate electric wires, then each holder can be supplied with power, but the space required increases and the number of connectors increases
Solution Approach 1:
The patent merges multiple power supply paths into a single integrated busbar structure. The first and second busbars are connected through a common connection terminal and stud bolt, creating a shared power distribution network that eliminates the need for separate electric wires between FL holders, thereby reducing space while maintaining power supply capability
Solution Approach 2:
The connection terminal and stud bolt assembly serve multiple functions simultaneously: they provide mechanical support for both busbars, establish electrical connection between power supply and FL holders, and enable modular assembly. This multi-functional design reduces the number of separate components needed, reducing overall space requirements
2Adaptability or versatility
If multiple FL holders are connected using separate electric wires, then each holder can be supplied with power, but the number of connectors increases
Solution Approach 1:
The patent combines multiple connection functions into a single connector assembly. The first connection terminal and second connection terminal are integrated into the same structural unit, allowing both busbars to be connected to the stud bolt simultaneously. This reduces the number of separate connectors from two (one for each wire) to one integrated assembly
Solution Approach 2:
The stud bolt and connection terminal assembly performs multiple functions: it serves as the mounting point for both busbars, provides the electrical connection path for power supply to multiple FL holders, and enables modular assembly and disassembly. This multi-functional design eliminates the need for multiple dedicated connectors
3Stability of the object's composition
If a nut is fastened to the stud bolt to assemble holding portions, then the structure becomes stable, but the assembly process requires precise positioning
Solution Approach 1:
The busbars are pre-positioned and overlapped before the final nut fastening step. The connection terminals are designed with predetermined positions that guide the busbars into correct alignment during assembly, so that when the nut is fastened to the stud bolt, the components are already in their proper positions, reducing the precision required during the actual fastening operation
Data Source
AI summary
There is provided an electrical junction box including: a bolt holding portion that includes a stud bolt and a bolt holding portion body configured to hold the stud bolt; a first holding portion that includes a first busbar provided with a first connection terminal and a first holding portion body configured to hold the first busbar and a first electronic component; and a second holding portion that includes a second busbar provided with a second connection terminal and a second holding portion body configured to hold the second busbar and a second electronic component. The bolt holding portion, the first holding portion, and the second holding portion are assembled with a nut in a connection state in that the stud bolt is passed through the first connection terminal and the second connection terminal, and in that the first busbar and the second busbar are overlapped with each other.