Ancillary Junction Box Mounting to Prevent Rattling
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Solution Overview
Problem
Junction box assemblies in automotive vehicles face packaging constraints, leading to limited space for additional components, which can result in rattling and electrical connection failures when these components are mounted externally or on the bottom surface.
Innovation Solution
An ancillary box with a specific engagement feature that includes a neck member and lip member, orthogonal to the top wall, and rails that engage with a center slot and side slots on the junction box assembly, allowing secure attachment and minimizing surface area requirements, thus preventing rattling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If additional components are mounted on the exterior surface of the junction box assembly, then the number of components that can be accommodated increases, but the surface area required for attachment increases, limiting space for other components
Solution Approach 1:
The ancillary box is nested within the junction box assembly by engaging with a center slot on the bottom surface. This nesting approach allows the additional component housing to be accommodated within the existing structural footprint, maximizing component quantity without proportionally increasing the external surface area required for attachment.
2Quantity of substance
If additional components are mounted on the bottom surface of the junction box assembly, then packaging space is utilized, but the components may rattle against the junction box assembly causing noise and electrical connection failure
Solution Approach 1:
The engagement feature is segmented into multiple functional elements: a neck member that inserts into the center slot, a lip member that provides bearing surface, and rails that engage with side slots. This segmentation distributes the mounting function across multiple contact points, preventing rattling and ensuring stable electrical connections while accommodating the additional component.
Solution Approach 2:
The engagement feature acts as an intermediary mechanism between the ancillary box and the junction box assembly. It mediates the connection by providing a dedicated mounting interface that secures the ancillary box in place, preventing direct contact and rattling between the additional component and the main assembly while ensuring reliable electrical connection.
3Strength
If the engagement feature is positioned away from the open front, then attachment strength increases, but the surface area required for attachment increases
Solution Approach 1:
The engagement feature transitions from a surface-mounted attachment to a three-dimensional engagement by inserting the neck member into the center slot and engaging rails with side slots. This dimensional change allows the attachment to extend below the bottom surface of the junction box assembly, providing enhanced mechanical strength without increasing the external footprint or surface area required for attachment.
Data Source
AI summary
An ancillary box is configured to be mounted to a junction box assembly. The ancillary box is configured to provide housing for an electrical component (e.g., switch assembly). The ancillary box includes a first housing having a first top wall, a first back wall, a pair of first side walls, and a first bottom wall. The first top wall, the first back wall, the pair of first side walls, and the first bottom wall are connected to each other to define an open front. The ancillary box further includes an engagement feature that is disposed on a top surface of the first top wall and centered between the pair of first side walls.