Junction Box Terminal Block Penetration for External Wiring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical junction boxes require complex internal wiring connections, making it difficult to connect and disconnect electric wires efficiently, especially when the wiring space is below the housing, which complicates the assembly and replacement of components like battery packs.
Innovation Solution
A connection structure for an electrical junction box that includes a first housing with a through hole and a terminal block with conductors, where the terminal block penetrates the housing and protrudes externally, allowing for external connection and disconnection of electric wires, reducing the need for internal wiring and facilitating easier assembly and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the terminal block is arranged inside the housing with internal wiring, then the electrical connection is secure and protected, but the complexity of wiring increases and the ease of connection deteriorates
Solution Approach 1:
The terminal block is extracted from the internal housing structure and positioned to extend through the housing wall. This allows the terminal block to be accessed from outside the housing, enabling direct connection of electric wires without requiring complex internal wiring routes. The terminal block serves as an external interface component that simplifies connection operations while maintaining secure electrical contact.
2Ease of operation
If the terminal block penetrates the housing externally, then the ease of connection improves, but the sealing and protection of the housing may be compromised
Solution Approach 1:
A sealing member is introduced as an intermediary component between the terminal block and the housing wall. This sealing member fills the gap created by the penetrating terminal block, preventing ingress of moisture, dust, or other contaminants through the penetration point. The sealing member maintains the protective enclosure of the housing while allowing the terminal block to extend externally for convenient wire connection.
3Productivity
If internal wiring is used for battery pack connections, then the electrical connection is stable, but the assembly and replacement time increases
Solution Approach 1:
The electrical connection system is segmented into modular components: the terminal block as a separate accessible interface, the housing as a protective enclosure, and the sealing member as an independent protective element. This segmentation allows the terminal block to be independently positioned and accessed, enabling rapid connection and disconnection of electric wires without requiring disassembly of the entire housing or complex internal wiring manipulation, thus significantly reducing assembly and replacement time.
Data Source
AI summary
A connection structure of an electrical junction box includes: a first housing which is fixed to a vehicle and in which a through hole is formed; and a terminal block that is inserted into the through hole, has a conductor, and is supported by the first housing, wherein the conductor includes a first terminal portion placed on one side of the through hole in a penetrating direction in which the through hole penetrates the first housing, and a second terminal portion that protrudes from the first housing toward the other side in the penetrating direction and that is connected to an electric wire.