Junction Box Connector Module for Compact Branch Circuit Assembly
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Solution Overview
Problem
The existing electrical junction boxes require multiple steps and components for connecting wires to circuit boards, necessitating significant space and hindering size reduction.
Innovation Solution
An electrical junction box design featuring a board-side connector module with integrated connectors and a branch circuit assembly that allows for simultaneous connection of multiple devices to the circuit board, reducing the number of steps and components through a unified assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors and terminals of wires are individually connected to the circuit board, then reliable electrical connection is achieved, but the number of connection steps and components increases
Solution Approach 1:
The patent combines multiple individual connectors into a single integrated connector assembly that connects to the circuit board as one unit. This reduces the number of separate connection steps while maintaining reliable electrical connections through the integrated design of the connector module.
Solution Approach 2:
The connector assembly is designed as a universal interface that can accommodate multiple wire connections through a single standardized connection mechanism. This multi-functional design allows various electrical connections to be achieved through one unified connector structure, reducing overall component count.
2Ease of operation
If space is allocated for wire connection operations between the circuit board and each device, then connection accessibility is improved, but the overall size of the electrical junction box increases
Solution Approach 1:
The patent repositions the connector assembly to connect with the circuit board from a different spatial dimension or orientation. This dimensional change allows connection operations to be performed in a more compact arrangement, improving accessibility without requiring additional horizontal or vertical space within the junction box.
Solution Approach 2:
The connector assembly is designed to nest within or alongside existing structural elements of the circuit board assembly. This nesting approach allows connection operations to be performed in previously unused spaces, maintaining ease of operation while minimizing the overall volume required for the junction box.
Data Source
AI summary
An electrical junction box includes a circuit board, a branch circuit assembly for distributing power to various devices, a housing that accommodates the circuit board and the branch circuit assembly, and a board-side connector module in which a plurality of board-side connectors mounted on the circuit board are formed as a single body. The branch circuit assembly includes an internal circuit including busbars and an electrical component, a case that accommodates the internal circuit, and a plurality of relay connectors that protrude from the case, are electrically connected to the internal circuit, and are respectively connected to the plurality of board-side connectors, and the board-side connectors are connected to the corresponding relay connectors in a state in which the branch circuit assembly and the circuit board are assembled to the housing.