Junction Box Terminal Support via Insulation Plate Pins
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical junction boxes for motor vehicles face challenges in supporting terminals without increasing costs or complexity, as insert-molding or press-inserting methods require additional equipment and steps, leading to potential terminal deformation and unreliable connections.
Innovation Solution
The electrical junction box employs support pins projecting from an insulation plate that engage with recesses or protrusions on the terminals, eliminating the need for a terminal holder and allowing for flexible terminal arrangement and secure positioning without retraction during coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If terminals are insert-molded in the fuse terminal holder, then terminal support strength is improved, but manufacturing cost increases greatly and flexibility of terminal arrangement decreases
Solution Approach 1:
The invention extracts the terminal holder from the system and replaces it with support pins that project directly from the insulation plate. This eliminates the need for insert-molding terminals into a separate holder component, thereby reducing manufacturing cost while maintaining terminal support functionality. The support pins are simply inserted into holes in the insulation plate, providing adequate support without the complexity and cost of insert-molding processes.
Solution Approach 2:
The invention segments the terminal support function from the terminal holder body by using separate support pins that project from the insulation plate. Each support pin independently supports individual terminals or groups of terminals, allowing for flexible arrangement and reducing the need for a complex integrated holder structure. This segmentation simplifies manufacturing while maintaining support strength.
2Strength
If terminals are press-inserted into terminal holes in the fuse terminal holder, then terminal support strength is improved, but manufacturing complexity and cost increase due to required equipment
Solution Approach 1:
The invention removes the terminal holder component entirely and integrates the support function directly into the insulation plate through support pins. This eliminates the need for press-insertion equipment and complex multi-step manufacturing processes. The support pins are simply inserted into holes in the insulation plate, providing a straightforward manufacturing process while maintaining terminal support capability.
3Adaptability or versatility
If terminals are bent from bus bar without support, then manufacturing flexibility is improved, but terminal deformation occurs during coupling reducing connection reliability
Solution Approach 1:
The invention applies preliminary support action by positioning support pins before terminal coupling occurs. The support pins project from the insulation plate and provide pre-positioning and support for terminals, preventing deformation during the coupling process. This preliminary support ensures that terminals maintain their correct position and shape when external terminals are connected, thereby ensuring connection reliability while allowing manufacturing flexibility.
Data Source
AI summary
To provide an electrical junction box wherein terminals juxtaposed in the box can be supported, when fuses or the like are fitted in the terminals. An electrical junction box is provided on an outer surface with electrical component containing sections. Terminals are juxtaposed in the containing sections. The terminals are connected to an internal circuit member. Each terminal is provided on opposite side edges in a width direction with recesses or protrusions. Support pins project from the electrical junction box or an insulation plate contained in the box so that each support pin is disposed between the adjacent terminals to extend in a direction perpendicular to the terminals and is fitted in the recesses or protrusions.