Electrical Junction Box Reinforcement Plate Alignment
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Solution Overview
Problem
Conventional electrical junction boxes face challenges in ensuring the strength and accurate positioning of printed circuit boards, particularly where bus bar structural plates are not stacked, due to deformation risks from heat and difficulty in reinforcement.
Innovation Solution
Incorporating a reinforcement plate with a through hole for screw passage and an engagement portion that aligns with the heat-dissipating member's screw hole, allowing easy positioning and reinforcement of the insulating substrate, while preventing deformation from heat soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcement plate is added to reinforce the insulating substrate, then the strength is improved, but the device complexity increases
Solution Approach 1:
The reinforcement plate is merged with the insulating substrate by bonding them together, creating a composite structure that reinforces the substrate without requiring separate support mechanisms. This combining approach improves strength while minimizing additional complexity.
Solution Approach 2:
The patent uses a composite structure combining the insulating substrate with the reinforcement plate to create a stronger assembly. This composite approach allows the insulating substrate to gain enhanced mechanical strength through the bonded reinforcement plate.
2Strength
If the insulating substrate is reinforced by stacking a reinforcement plate, then the strength is improved, but the positioning accuracy with respect to the heat-dissipating member deteriorates
Solution Approach 1:
Positioning holes are formed in advance in the reinforcement plate at precise locations that correspond to the screw holes in the heat-dissipating member. This preliminary positioning action ensures accurate alignment is achieved before the actual assembly process, maintaining manufacturing precision while providing reinforcement.
Solution Approach 2:
The reinforcement plate provides localized reinforcement at specific areas of the insulating substrate where needed, with positioning holes strategically placed to ensure accurate alignment with the heat-dissipating member. This localized approach maintains precision while providing targeted strength enhancement.
3Device complexity
If the insulating substrate is reinforced without a reinforcement plate, then the device complexity is reduced, but the positioning accuracy with respect to the heat-dissipating member deteriorates
Solution Approach 1:
Positioning holes are pre-formed in the reinforcement plate at exact locations that match the screw holes in the heat-dissipating member. This preliminary positioning ensures that when the assembly is constructed, accurate alignment is automatically achieved without requiring complex positioning mechanisms during assembly.
4Strength
If the insulating substrate is reinforced by stacking a reinforcement plate, then the strength is improved, but the ease of manufacture deteriorates
Solution Approach 1:
Positioning holes are formed in advance in the reinforcement plate at precise locations corresponding to the screw holes in the heat-dissipating member. This preliminary positioning action simplifies the assembly process by ensuring automatic alignment, making the manufacturing process easier despite the additional reinforcement plate.
Solution Approach 2:
The reinforcement plate provides localized reinforcement with strategically positioned holes that align with the heat-dissipating member's screw holes. This localized design with pre-positioned alignment features simplifies the assembly process by reducing the need for complex positioning procedures.
Data Source
AI summary
An electrical junction box includes an insulating substrate, a bus bar that is bonded to the insulating substrate, and a reinforcement plate that is bonded to a region of the insulating substrate to which the bus bar is not bonded. The reinforcement plate includes a through hole that allows passage of a shaft portion of a screw. A heat-dissipating member is stacked on a surface of the reinforcement plate opposite to the insulating substrate, and includes a screw hole into which the screw is screwed. A retaining member retains the respective positions of the insulating substrate, the bus bar, and the reinforcement plate, and the reinforcement plate includes an engagement portion that aligns the through hole and the screw hole by engaging with the retaining member.