Electric Junction Box Common Fastening Members
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Solution Overview
Problem
Conventional electric junction boxes require multiple exclusive fastening members, increasing production costs and reducing the space available for other components due to the need for bolts and nuts to secure bus bars and terminals, which complicates assembly and reduces the number of components that can be accommodated.
Innovation Solution
The electric junction box uses common fastening members for both input and output terminals, allowing for reduced fastening complexity and increased component density by integrating fastening elements within the case, enabling secure and rigid attachment of bus bars and terminals without the need for external bolts and nuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple exclusive fastening members (bolts and nuts) are provided for connecting input and output terminals to bus bars, then reliable electrical connection is achieved, but the number of fastening members increases production costs and occupies space inside the case
Solution Approach 1:
The patent combines the fastening functions for input and output terminals into a single common fastening member. The input-side fastening member simultaneously fastens the input terminal to the input bus bar, while the output-side fastening member simultaneously fastens the output terminal to the output bus bar. This merging reduces the total number of fastening members from four (two bolts with two nuts) to two (one bolt with one nut each), lowering production costs and simplifying the device structure while maintaining reliable electrical connections.
Solution Approach 2:
The common fastening members serve multiple functions: they provide mechanical fastening to prevent dislodgement of terminals and bus bars, ensure reliable electrical connection between terminals and bus bars, and reduce the overall component count. The fastening members are designed to simultaneously perform fastening and electrical connection functions, making them universal components that address multiple requirements with a single element.
2Reliability
If multiple exclusive fastening members are used to secure bus bars and terminals, then secure attachment is achieved, but the space available for accommodating other electric components is reduced
Solution Approach 1:
By merging the fastening functions into common fastening members, the patent reduces the total volume occupied by fastening components inside the case. The reduction from four fastening members to two allows more space to be allocated for accommodating additional electric components while maintaining secure attachment of the fuse and bus bars through the integrated fastening design.
3Strength
If multiple exclusive fastening members are provided, then robust fastening is achieved, but the number of manhours for assembly increases
Solution Approach 1:
The patent merges the fastening operations into fewer steps by using common fastening members. Instead of separately fastening input and output terminals with four different fastening members, the assembly process is simplified to installing two common fastening members. This reduces the number of assembly steps and manhours required while maintaining robust fastening strength through the integrated design of the common fastening members that simultaneously secure both terminals.
Data Source
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AI summary
An electric junction box (1) including a case (2), an input bus bar (3), an output bus bar (4) and a fuse (5) which are accommodated within the case, wherein an input electric wire (W1) and an output electric wire (W2) are electrically connected to the input bus bar and the output bus bar, respectively, the electric junction box further including an input-side fastening member (6,7a,7b) which fastens an input terminal (21) of the fuse and the input bus bar (3) to the case in such a state that the input terminal is laid to overlap the input bus bar, and an output-side fastening member (8,9a,9b) which fastens an output terminal (22) of the fuse and the output bus bar (4) to the case in such a state that the output terminal is laid to overlap the output bus bar, wherein the input-side fastening member and the output-side fastening member are conductive and are passed through the case, and a connecting terminal (T1) of the input electric wire (W1) is fastened to the case (2) at a distal end portion of the input-side fastening member (6,7a,7b) which is exposed from the case, and a connecting terminal (T2) of the output electric wire (W2) is fastened to the case at a distal end portion of the output-side fastening member (8,9a,9b) which is exposed from the case.