Junction Box Eyelet Terminal Shielding via Nested Bus Bar
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Solution Overview
Problem
Existing electric junction box assemblies lack protection for eyelet terminals, making them susceptible to damage from environmental factors, which can disrupt the functional operation of the assembly.
Innovation Solution
A junction box assembly design that includes a housing with a first storage compartment for electric components and a second storage compartment for routing power, featuring a first connection housing with a base and female connector housing to connect the eyelet terminal to electric components, and a second connection housing on the bottom housing to engage the second bus bar, effectively shielding the eyelet terminal from the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the eyelet terminal is exposed on the outer edge of the power distribution box, then electrical connection is facilitated, but the eyelet terminal is susceptible to damage from environmental factors
Solution Approach 1:
The eyelet terminal is nested within the first connection housing, which is disposed inside the power distribution box. The first bus bar extends from the first connection housing to the eyelet terminal, allowing electrical connection while the terminal itself remains protected inside the housing structure.
Solution Approach 2:
The first bus bar acts as an intermediary element that transfers electrical connection from the protected eyelet terminal to the external environment. The bus bar extends through the first connection housing, allowing power transmission without exposing the terminal to environmental damage.
2Reliability
If the eyelet terminal is shielded within the housing, then protection from environmental damage is provided, but access for electrical connection may be restricted
Solution Approach 1:
The connection system is segmented into distinct functional parts: the eyelet terminal for secure electrical connection, the first bus bar for power transmission, and the first connection housing for protection. This segmentation allows each component to perform its specific function optimally while working together as an integrated system.
Solution Approach 2:
The first bus bar extends in multiple directions - from the eyelet terminal through the first connection housing to connect with other components. This dimensional arrangement allows electrical connection to be made at different locations without requiring the terminal itself to be exposed.
3Reliability
If multiple connection housings are added to protect the eyelet terminal, then reliability is improved, but device complexity increases
Solution Approach 1:
The first connection housing serves multiple functions simultaneously: it protects the eyelet terminal from environmental damage, provides structural support for the first bus bar, and facilitates electrical connection through its integrated design. This multi-functionality reduces the need for separate protective components.
Solution Approach 2:
The first connection housing merges the protective enclosure with the connection facilitation function. Rather than having separate protective covers and connection structures, the housing integrates both functions into a single component that simplifies the overall assembly.
Data Source
AI summary
A junction box assembly configured to shield the eyelet terminal includes a power distribution box and a bottom housing. A bottom housing is configured to mate with an undersurface of the power distribution box. The eyelet terminal is disposed within the bottom housing. A first connection housing is disposed in the bottom housing. The first connection housing is configured to house a first bus bar having a female connector. The first bus bar is electrically connected to the eyelet terminal. A second connection housing is disposed on an undersurface of the power distribution box. A second bus bar is mounted within an inner space of the power distribution box and a connecting portion of the second bus bar is disposed within the second connection housing. The first connection housing engages the second connection housing within the bottom housing so as provide a shielded.