Relay Terminal Side Protrusion for Junction Box Assembly
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Solution Overview
Problem
The existing electronic component assembly structures for vehicles, such as relay modules in electrical junction boxes, face challenges in workability due to inclination issues and difficulty in positioning relay terminals during assembly, leading to poor assembly efficiency and increased complexity.
Innovation Solution
An electronic component assembly structure that includes a main body section with a terminal portion fitted to a terminal fitting, where the terminal portion extends along a side surface of the main body section with a gap, allowing guided insertion into a housing chamber to prevent inclination and facilitate easy assembly, and includes interference portions to regulate posture and prevent excessive inclination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If relay terminals protrude from the bottom surface of the relay body, then the relay can be assembled into the holding member, but the relay is likely to be inclined and positioning becomes difficult
Solution Approach 1:
The patent inverts the traditional protrusion direction of the terminal portion. Instead of protruding from the bottom surface, the terminal portion now protrudes from the side surface of the relay body. This inversion allows the terminal portion to be positioned and fitted before the relay body is inserted into the holding member, enabling visual confirmation of fitting status and improving positioning accuracy while maintaining assembly workability.
2Ease of operation
If terminal fittings are smaller than the relay body, then the relay can be held by the holding member, but it is difficult to position the relay in the appropriate insertion direction
Solution Approach 1:
The patent applies preliminary action by having the terminal portion protrude from the side surface and be fitted to the terminal fitting before the relay body is inserted into the holding member. This preliminary fitting action establishes the correct insertion direction and position, making subsequent assembly easier and more precise. The terminal portion serves as a guide that pre-positions the relay correctly.
3Reliability
If relay terminals are fitted into spring portions, then electrical connection is achieved, but the terminals are covered and it is difficult to visually check the fitting state
Solution Approach 1:
The patent uses the terminal portion as an intermediary element that extends from the relay body to the terminal fitting. This intermediary structure allows the fitting state to be visually confirmed from the outside, while still achieving reliable electrical connection through the spring portion. The terminal portion acts as a mediator that provides both electrical connectivity and visual feedback on fitting status.
4Manufacturing precision
If the fitting portion extends along the side surface with a gap, then guided insertion is enabled and inclination is prevented, but the structure becomes more complex
Solution Approach 1:
The patent segments the relay structure into distinct functional parts: the relay body, the terminal portion protruding from the side surface, and the fitting portion extending with a gap from the side surface. This segmentation allows each part to perform its specific function independently - the fitting portion provides guidance and prevents inclination, while the terminal portion provides electrical connection and visual feedback, achieving high alignment precision without excessive overall complexity.
Data Source
AI summary
An electronic component includes a main body section having a plurality of surfaces and a terminal portion that is disposed in the main body section and that is fitted to a terminal fitting. A housing member includes a first housing chamber that guides and accommodates the main body section and a second housing chamber that accommodates and holds the terminal fitting. The terminal portion includes a base end and a fitting portion that extends from a protruding tip of the base end and that is fitted to the terminal fitting. The fitting portion extends from the protruding tip of the base end, along a side surface of the main body section with a gap from the side surface, without causing an extending tip to protrude beyond the deep surface.