Abstract: A method and apparatus for aligning and heat staking a plurality of stackable junction box components having pilot holes normally used only for registration and alignment purposes. A heat stakable element is inserted through the pilot holes and used to secure the stacked components through the pilot holes. This eliminates the need for heat stake and stake hole structure built into the various junction box layers, thereby freeing up valuable junction box layout space for additional bus bar runs and electrical component receptacles. In a preferred form the heat stakable element is formed in the shape of a pilot pin to engage the pilot holes and simultaneously register and heat stake them together.

Abstract: A flat (horizontal) press-fit busbar terminal structure for use in junction boxes, power distribution boxes, and the like at vehicle wiring junctions. Instead of the usual vertical busbar terminal extending through one or more insulation plate layers to be connected to the vertical terminals of a pluggable component, flat press-fit terminals are fastened in horizontal, essentially flush fashion to the surfaces of the flat insulation plates, with horizontally disposed terminal ends for receiving pluggable component terminals therethrough in perpendicular fashion. The flat terminals of the invention greatly reduce the overall height of the junction box, PDB, etc., thereby allowing the vertical component terminals to be used in place of peripheral jumper connections to interconnect one or more layers of busbar terminals.

Abstract: An apparatus for securing wire harness terminal connectors to the underside of an electrical junction block in a blind assembly operation. The apparatus includes a flotation bracket with chambers for receiving the connectors in a mechanical snap-fit in which the connectors are free to float up and down over a limited range within their respective chambers. The connector-containing bracket is next placed in a lower cover, which then fits over the underside of the junction block. Bolts rotatably mounted in the junction block are located to automatically engage captive nuts held in the connectors. As the bolts are subsequently threaded through the captive nuts, the connectors are drawn up in the bracket chambers from a lower rest position to an upper electrical engagement position where the terminals in the connector are placed in electrical engagement with bus bars in the junction block.